2/28/2018 - mapyourshow.com
TRANSCRIPT
2/28/2018
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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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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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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
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