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Crushing 101-

Let’s not make this more

complicated than it is.Mark Krause

Making the right choice…..

“Making little ones out of big ones”

Our Challenge

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Terminology:

Open Circuit

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Closed Circuit

Know what you need to make

Primary gyratory’s up to 5 to 1 Jaws up to 6 to 1Cones up to 8 to 1 HSI’s up to 10 to 1

Walk through the Agg Flow the more reduction the more work there is to be done

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The Goal is to Produce Required Aggregate Sizes at the Lowest Cost per Ton!

1) Maximize the Tons per Man Hour that can be produced within the existing processing circuit

2) Consistently operate all equipment at it’s maximum design capacity

3) Make the sizes that you need within the production circuit

4) Avoid re-handling finished sized aggregates

Plant Optimization

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Quick review of crusher types• Compression Crushing – Material is squeezed between

two surfaces

– Gyratory crusher

– Jaw crusher

– Cone crusher

• Impact Crushing – Material is hit or thrown

– Horizontal Shaft Impactor

– Vertical Shaft impactor

– Hammermill

• Attrition – Material is worn down via a rubbing action

– Rod Mill

– Ball Mill

– Autogenous Mill

Compression- reduces material

as it advances downward through

the chamber by means of

squeezing (compression) the

material between a moving piece of

steel and a stationary. Output is

changed by adjusting the gap

setting at the discharge point of the

crusher.

Crushing 101-Three types of crushing

•Jaw Crusher

•Gyratory

•Cone Crusher

Standard Head

Short Head

•Roll Crusher

Dual and Triple

Types of compression crushing

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Impacting- uses the theory of

mass and velocity to reduce the

feed material. Generally speaking

the faster the speed of the crusher,

the finer the output. The first break

of the feed will occur along the

natural fracture line of the material

while the second break will be

perpendicular to the first break.

•Horizontal Shaft Impact

•New Holland

•Andreas

•Vertical Shaft Impact

•Hammermill

•CageMill

Types of impact crushing

Milling- uses the theory of

mass and velocity combined

with a milling or grinding action

to reduce the feed material.

Usually used in softer and less

abrasive materials. Also thought

to create a higher quantity of

fines. Provides high reduction

ratio.

Three types of crushing

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As the topic suggests our focus today

is on crushing. We cannot properly

look at crushing 101 without including

screening. Screening is so important

it gets a session unto itself.

Calculating Reduction Ratio

Using the P80 (80% passing) methodFeed Output

6” 100%

5” 97%

4” 80%

3” 70%

2” 36% 100%

1-1/2” 10% 98%

1” 5% 90%

¾” 80%

½” 68%

3/8” 58%

Using in/out method =

6” ÷ 2” = 3 to 1 reduction

Using P80 method =

4” ÷ .75” = 5.3 to 1 reduction

Crushing 101-Reduction Ratio

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• 500 HP to 1400 HP

• 263,000 lbs.. To 1,297,000 lbs..

• Naming = Feed Opening x Head Diameter

Models

42x65

50x65

54x75

62x75

60x89

60x110

Primary Gyratory Crusher

Models

42x65

50x65

54x75

62x75

60x89

60x110

Feed

Opening

Large total feed area

(both sides of spider)

Primary Gyratory Crusher

Basic Gyratory

Head and

mantle

Hydroset System

Concave Liners

Spherical Spider

BushingEccentric causes the main

shaft with the head and

mantle attached to move

back and forth towards

stationary concave liners.

Rock is

compressed/crushed

between mantle and

concaves

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Gradation is controlled by adjusting the spacing between the mantle and the concaves at their closest point

Main shaft is supported by a hydraulic system that provides adjustment and release when uncrushables enter the chamber.

Gyratory Operating Principles

Jaw Crusher

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Basic Jaw Crusher

GENERAL

The Size of a Jaw Crusher is defined by Feed opening IE: 42x54 = 54” wide by 42” depth

Maximum feed size in R.O.Q. feed : 80% of depth

IE : 42 x 54 Jaw CrusherDepth 42” - 1067mm x 80%Maximum Lump = 34” (854 mm)

Toggle

plate

Toggle

seat

Moving jaw

Stationary jaw

Eccentric main-shaft causes

the pitman to move back

and forth towards stationary

jaw die.

Rock is

compressed/crushed

between stationary and

moving jaw dies

Basic Jaw Crusher

Gradation is controlled by adjusting the spacing between the dies at their closest point

Toggle-Plate is held in place by spring and supports lower portion of the pitman

Toggle plate will bend/break first to protect crusher from damage

Jaw Crusher Operating Principles

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Sizer or Toothed Roll Video

Horizontal Shaft Impact Crushers

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Basic Impacting

Blow Bars

Rotor

Breaker Plates

Feed material is reduced by :

•Initial impact with hammer ( 40-60 %)

•Impact with breaker plates ( 30-40%)

•Inter-particle collisions

•Attrition

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Cone Crusher Review

Basic Cone Crusher

Compression Crusher

Drive turns horizontal-countershaft

Pinion-gear on countershaft rotates eccentric-gear

Eccentric rotation causes the main-shaft and the head

to “wobble”

Rock is compressed/crushed between mantle and

concaves

Gradation is controlled by adjusting the spacing

between the mantle and concave at their closest point

ie: closed side setting (css)

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Cone Crusher Review

Cone Crusher Review

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Cone Crusher Review

90% - 100%

40% - 60%

0% - 10%

Cone Crusher Review

Cone Crusher Review

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A segregated feed distribution

will lead to :

➢ ring bounce

➢ poor liners wear

➢ more oversized products

➢ poor particle shape

Coarse freshfeed

Fine recirculation feed

Correct Feed Distribution

An off centered feed distribution

will lead to :

➢ ring bounce

➢ poor liners wear

➢ poor particle shape

Correct Feed Distribution

Reactive MaintenanceHP400 Bushing Failure

Discovered after crusher “locked

down”during production shift.

Safety interlock failed and operator attempted

to manually bypass the control.

Major parts damage. (bushings, eccentric,

mainshaft)

Extensive downtime, lost production of

critical product. (40hrs at 100 tph@ $20/ton)

Non-budgeted failure.

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Proactive Maintenance1560 Omnicone Bushing Failure

Discovered during scheduled PM Service.

Temperature Monitor trending higher.

Damage not severe.

Only bushing was damaged. No other

parts were damaged.

No production lost.

No significant overage of budgeted costs

by discovering failure early.

• Speed

• Setting

• Stroke

Factors affecting a

compression crusher’s

performance

Affect of Speed on

Compression Performance:

•Within the first 10% of slow down we will

actually see an increase in the overall

throughput of the machine.

•It is a balancing act of change in reduction

and output gradation and throughput of the

machine.

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Low speed : Secondary applications, after a jaw crusher

Medium speed : Gravel applications with coarse feed

Standard speed : Tertiary applications (0 x ½” …)

High speed : Sand applications (4M or less ...)

Speed ranges :

Smaller Head Diameters : 750-1200 RPM

Larger Head DIameters : 700-950 RPM

•Speed choice

Cone Crusher Review

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

1 1/2"

1 1/4"

1"3/4"9/16"

1/2"7/16"

3/8"# 4

# 16

size

% P

assi

ng

RPM = 950, 32mm

RPM = 850, 32mm

Speed Change

Affect of Setting on

Compression Performance:

•A closer setting will yield a finer output

gradation with a lower throughput capacity

13mm

(1/2")

16mm

(5/8")

19mm

(3/4")

22mm

(7/8")

25mm

(1")

32mm (1

1/4")

38mm (1

1/2")

45mm

(1-3/4")

51mm

(2")

90mm 3-1/2" 100 100

75mm 3" 100 100 94 88

50mm 2" 100 100 93 84 80 71

38mm 1-1/2" 100 95 87 84 73 67 58

32mm 1-1/4" 100 93 87 80 73 64 53 49

25mm 1" 100 95 84 75 71 64 53 45 40

19mm 3/4" 86 81 72 64 59 53 44 38 32

16mm 5/8" 78 68 60 53 49 44 35 32 27

13mm 1/2" 67 59 53 45 41 35 31 27 22

10mm 3/8" 53 46 43 37 34 26 23 19 18

6mm 1/4" 36 30 25 20 18 17 15 13 9

Discharge gradation (percent passing)

Closed Discharge Setting (mm and inches)Mesh Size

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Affect of Setting on

Compression Performance:

•A closer setting will yield a finer output

gradation with a lower throughput capacity

Model MAX Feed Size* HP LBS 3/8" 1/2" 5/8" 3/4" 7/8" 1" 1 1/4" 1 1/2" 1-3/4" 2"

MSP100 C 5-3/8" 100 14,990 75 85 90 95 105 125

MSP 100 M 4-1/8" 100 14,990 65 75 85 90 95 105 125

MSP 200 C 7-1/4" 200 26,455 180 190 200 225 240

MSP 200 M 5-3/4" 200 26,455 140 170 180 190 200 225 240

MSP 200 F 2-3/4" 200 26,455 140 170 180 190 200 225 240

MSP 300 C 7" 300 41,225 230 250 270 300 355 410

MSP 300 M 5-3/8" 300 41,225 210 230 250 270 300 355 410

MSP 300 F 4" 300 41,225 175 210 230 250 270 300 355

MSP 400 C 7- 1/4" 400 62,610 350 395 445 510 575

MSP 400 M 6-3/4" 400 62,610 325 350 395 445 510

MSP 400 F 5-5/8" 400 62,610 265 300 325 350 395

STPH

Closed Side Setting (Capacities may vary +/- 15%)**

Affect of Stroke on

Cone Performance:

•As we decrease the stroke of the cone crusher, we will see a

reduction in fines production. Or “a reduction in the reduction”.

•It is a balancing act of change in reduction and output gradation and

throughput of the machine. Lowering the stroke, lowers the

throughput, but lowering the stroke can increase the mechanical

advantage of the crusher.

Affect of Stroke on

Compression Performance:

• Higher stroke means higher nominal capacity :

– the relation is linear : i.e. roughly double stroke means double

nominal capacity

• Higher stroke also means higher minimum possible setting

• The motor size selection depends on the stroke

– with higher stroke your need more power

• Stroke's effect on output curve is minimal and difficult to perceive.

• Choke fed cavity, cavity design and speed affect the output curve

much more than stroke.

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VSI Crushers

Vertical Shaft Impact Crushers

Shoe Anvil (Steel on Steel)– Indicates that the crusher is for large feed sizes

and/or coarse products. The crusher will utilize an impeller table that typically

incorporates three to six impellers. The top size to these machines will be

reduced to control the reduction ratio.

ROR (Rock on Rock)– This machine will be using an enclosed rotor with a rock

shelf. This configuration is typically used in abrasive or shaping applications with

a feed size less than 75mm.

ROS (Rock on Steel) – This machine will be using an enclosed rotor and anvils.

This configuration is typically used in abrasive applications with a feed size less

than 75mm, requiring maximum reduction.

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Shoe Table and Anvil Ring

Closed Rotor (Autogenous)

• Feed size up to 50mm

• Lower wear costs

Rock on Rock

VSI – Rotor Configurations

Rock Box

• Lower reduction

Shaping

• Lower wear costs

Rock on Rock

• Higher power draw

VSI – Configurations

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• Speed

• Setting

Factors affecting a HSI

crusher’s performance

• Speed

Factors affecting an

Impact crusher’s

performance

845

RPM

1056

RPM

1268

RPM

1” 100% 100% 100%

¾” 97.0% 98.0% 99.0%

5/8” 86.0% 90.0% 94.0%

½” 70.0% 76.0% 84.0%

3/8” 44.0% 55.0% 66.0%

¼” 30.0% 38.0% 48.0%

4M 19.0% 27.0% 35.0%

8M 11.0% 15.0% 20.0%

16M 8.0% 10.0% 13.0%

30M 6.0% 8.0% 10.0%

50M 5.0% 6.0% 8.0%

100M 4.0% 5.0% 7.0%

200M 3.0% 3.5% 5.0%

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• Speed – Increase

• Will make the discharge finer (when speed is to high, penetration decrease and limits the increase in reduction;

• Will not change the discharge volume;

• Will decrease the circulating load (as % of new feed rate);

• Will increase the reduction ratio;

• Will increase the specific horsepower (per TPH)

Affect of Speed on

Impact Performance:

• Setting

Factors affecting an Impact

crusher’s performance

8 6 4 3 2 1.5 1 ¾ ½ 3/8 ¼ 1/8

100 98 95 88 70 55 45 30 25 20 18 13

100 96 90 75 60 50 35 30 25 20 15

100 98 92 80 65 55 40 34 28 22 17

100 95 85 70 60 45 38 32 25 20

GAP SETTING (inches)

F=10 / R=5

F=8 / R=4

F=6 / R=3

F=4 / R=2

PERCENT PASSING EACH SIZE (Inches)

Affect of # of Bars on

Impact Performance:

Rotor RPM Crusher output Return Product (1 1/2")44" 4 bar 500 124 9 115

44" 4 x 2 500 250 34 216

44" 3 bar 500 148 23 125

Rotor RPM Crusher output Return Product (1 1/2")49" 4 x 2 500 444 92 352

49" 3 bar 500 474 56 418

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• Maintaining Crusher Performance– Understand the crusher design limits ie: volume, power, force

– Keep a daily operator’s log sheet (production, amp draw, issues, sounds)

– Maintain a proper blended feed to the center of the crusher

– Minimize feed segregation

– Select the proper crusher liner

– Change liners when a 10% decrease in productivity is noticed

– Maintain proper feed top size to the crusher

– Check the crusher closed side setting regularly

– Maintain proper drive belt tension

– Maintain crusher lubrication system

Creating A “Rock Solid” Maintenance Program

• Difference Between Re-Active & Pro-Active Maintenance Programs– Reactive Maintenance consists of repairing equipment after it has

broken down. • This will be considered the exception rather than the norm.

– Pro-active Maintenance will drive our maintenance program and will consist of activities used to identify and repair equipment before it breaks down.

• Performing equipment maintenance according to the manufacturer’s schedule or best practices will be a priority.

• What a “Pro-active” Maintenance Program Achieves– More Effective Maintenance Spending

– Improved Operating Performance

– Increased Uptime and Reduction in Lost Tonnage

– Lower Total Operating Costs

– Extend Equipment Life

– Increased Safety – Environmental Stewardship

Creating A “Rock Solid” Maintenance Program