ce 3220 13-1 aggregate production.pdf
TRANSCRIPT
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Aggregate Production
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AGGREGATE
PRODUCTION
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AGGREGATE
PRODUCTION
Four basic functions:
Size reduction - crushing Size separation - screening
Elimination of undesirablematerial - washing
Movement and storage
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Crushers
Crusher Production
Screening
Screen sizing
AGGREGATE
PRODUCTION
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CRUSHERS
Jaw
Gyratory
Cone
Roll
Impact Specialty
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JAW CRUSHERS
Rock flows into the space between
two vertical jaws. One jaw is
stationary. The other jaw movesin an elliptical-downward motion
toward the stationary jaw while
crushing, and upward and awayfrom the stationary jaw allowing
the crushed material to exit.
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JAW CRUSHERS
Moves in anelliptical-
downwardmotiontoward the
stationary jaw whilecrushing
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JAW CRUSHERS
Table 14.3 gives representativecapacities.
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JAW CRUSHERS
Jawcrushers areprimaryunits, thatreceivematerialdirectlyfrom thequarry.
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GYRATORY CRUSHER
Has a gyrating mantle mounted
within
a deepbowl.
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Table 14.4 givesrepresentativecapacities.
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GYRATORY
CRUSHER
Gyratories are
used as primary orsecondary units.
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CONE CRUSHER
Works like a gyratory with aneccentric rotating cone around a
vertical shaft to cause a gyrating
movement of the head.
Differs from a gyratory:
Ø A shorter head
Ø Smaller receiving opening
Ø Higher rotation speed
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GYRATORY CONE
CRUSHERS
Cone shorter head
Gyratory
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GYRATORY CONE
CRUSHERS
Gyratory
Cone smaller
receiving opening
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GYRATORY CONE
CRUSHERSCone higherrotation speed
Gyratory
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ROLL
CRUSHERS
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ROLL CRUSHERS
Roll crushers are used forintermediate stages ofreduction.
Very limited reductioncapability, see Table 14.2,page 411.
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ROLL CRUSHERS
The maximum size stone that may
be fed a roll crusher is directly
proportional to the diameter of therolls. If the stones are too large,
they will not grip the material and
pull it through the crusher.See Figure 14.10, page 421.
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IMPACT
CRUSHERS
Impact breakers
provide acubical product
even with slabby
material.
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IMPACT CRUSHERS
Speed of
rotation is
importantto the
effective
operationof these
crushers.
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SPECIALTY CRUSHERS
Ball Mill
Ball mills use steel
balls to produce fine
material.
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BALL MILL
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PRODUCTION EXAMPLE
A 42X48-in jaw crusher w/ a closedsetting of 3 in. will produce what
tonnage per hr in the following sizeranges of a stone having a unit
weight of 110 lb/cf crushed:
- 2½ in.+
- Between 2½ and 1½ in.
- 1½ in. -
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CRUSHER
PRODUCTION
Table 14.3 gives capacities for
Blake-type jaw crushers.
Table 14.4 for gyratory
crushers.Table 14.5 for cone crushers.
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STEP 1. CAPACITY
OF CRUSHER
42- by 48-in jaw crusher
Closed setting of 3 in.
Capacity of crusher ?
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STEP 1. CAPACITY
OF CRUSHER
42- by 48-in jaw crusher
Closed setting of 3 in.
Capacity of crusherTable 14.3, p. 413
190 tph
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CRUSHER
PRODUCTION
Read the fine print .
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STEP 2. CAPACITY
ADJUSTED
Capacity of crusher 190 tph
Stone unit weight of 110 lb/cf
Unit weight adjustment =
or 1.1
cf lb100
cf lb110
/
/
190 tph 1.1 = 209 tph
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Jaw closed setting, 3 in.
Refer to Figure 14.5, page 415
Horizontal scale is the crusher
setting: Read down the 3 in.line and find the % passing a
2 1/2 and 1 1/2 inches.
STEP 3. SIZE
DISTRIBUTION
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Fig. 14.5, read down the 3” line to the size.
STEP 3 SIZE DISTRIBUTION
Percent
passing
is on
the left
side ofthe
figure.
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Figure 14.5, page 415
Horizontal scale is the crusher
setting: Read down the 3 in.
line and find the % passing at
2 1/2 and 1 1/2 inches.2½ in. 73 % passing
1½ in. 46 % passing
STEP 3 SIZE
DISTRIBUTION
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STEP 4. QUANTITY
Output of crusher, 209 tph
Size,
in.
%
assin
% in
ran e
Total
out ut
Produced
tph
Over 2½ 100-73 27 209 56.4
2½- 1½ 73-46 27 209 56.4
1½- 0 46-0 46 209 96.2
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STEP 4. QUANTITY
Output of crusher, 209 tph
Size,
in.
%
assin
% in
ran e
Total
out ut
Produced
tph
Over 2½ 100-73 27 209 56.4
2½- 1½ 73-46 27 209 56.41½- 0 46-0 46 209 96.2
Total 100 209
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STEP 5. CHECK
Check your work, always total
Percent must come to 100%
Output must equal quantityOutput of crusher, 209 tph
2½ - 1½ 73-46 27 209 56.41½- 0 46-0 46 209 96.2
Total 100 209
OKOK
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ROCK TYPE EFFECT
Is there data availableconcerning rock type?
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ROCK TYPE EFFECT
Adjustment factors for rock type,limestone as a production base
Rock Factor
Limestone 1.00
Dolomite 1.00
Gneiss 0.95Slate 0.90
Granite 0.90 coursed rained
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ROCK TYPE EFFECT
Rock Factor
Chert 0.80
Quartzite 0.80Rhyilite 0.80
Granite 0.80 fine grained
Diorite 0.80
Basalt 0.75
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ROCK TYPE EFFECT
tph20911tph190 .
If the rock in the previous example
was limestone the 209 tph is correct.
However, consider that it is a diorite.
What would be the production?tph16780tph209 .
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EXAMPLE No. 2
Select a jaw crusher for
primary crushing and a roll
crusher for secondarycrushing to produce 110 tons
per hour of limestone rock.
The maximum-size stone from
the quarry will be 16 in.
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EXAMPLE No. 2
The stone is to be crushed tothe following specifications:
Passing Retained on Percent
2½ 100
2½ 1¼ 40-60
1¼ ¾ 18-30
¾ ¼ 15-25
¼ 0 10-20
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STEP 1 Select a Jaw
Crusher
The maximum-size stone from
the quarry will be 16 in. Minimum top width (opening)
of the jaw crusher:
16 in. + 2 in. = 18 inches
Text page 412
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Produce 110 tons per hour
of limestone rock. Try a 24 X 36 in. crusher
with a 3 in. closed setting,
114 tph
Table 14. 3
STEP 1 Select a Jaw
Crusher
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Fig. 14.5, read down the 3” line to thesize. Percent passing is on the left
side of the figure.
STEP 2 Size Distribution
Size % passingOver 2½ 100-73
2½-1¼ 73-39
1¼-¾ 39-26
¾-¼ 26-11
¼-0 11-0
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STEP 2 Size Distribution
Size % assin % in ran e
Over 2½ 100-73 27
2½-1¼ 73-39 34
1¼-¾ 39-26 13
¾-¼ 26-11 15
¼-0 11-0 11
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STEP 3 Output Ranges
Size % ran e Feed t h Size t h
Over 2½ 27 110 29.72½-1¼ 34 110 37.4
1¼-¾ 13 110 14.3
¾-¼ 15 110 16.5
¼-0 11 110 12.1
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Size % ran e Feed t h Size t h
Over 2½ 27 110 29.7
2½-1¼ 34 110 37.4
1¼-¾ 13 110 14.3
¾-¼ 15 110 16.5¼-0 11 110 12.1
100% 110 tph
STEP 3 Output Ranges
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STEP 4 Select a Roll
Crusher Size % ran e Feed t h Size t h
Over 2½ 27 110 29.7
2½-1¼ 34 110 37.4
The roll crusher must handle
29.7 plus its own return feed.
See discussion page 430.
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STEP 4 Select a Roll
Crusher The roll crusher must handle
29.7 plus its own return feed.
tph34.90.85
tph29.7
Maximum size from the
jaw crusher 3 in.
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STEP 5 Roll Diameter
Try a 2 in roll crusher setting.
Radius (R) of the rolls = ?
C, roll setting = 2 in.A, maximum feed-size feed = 3 in.
Equation 14.1in.11.8
0.085
1R
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STEP 5 Roll Diameter
The roll diameter must be atleast 23.5 in. and the crusher
must handle 34.9 tph.Table 14.6Try a 24 X 16 crusher with a 2 in.
closed setting -- 115 tph.The first number indicates the
diameter of the rolls.
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STEP 6 Roll CrusherSize Distribution
Size % assin % in ran e
2½-1¼ 100-56 44
1¼-¾ 56-36 20
¾-¼ 36-16 20
¼-0 16-0 16
Fig. 14.5, read down the 2” line to the size.
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STEP 7 Roll Crusher
Output Ranges
Size % ran e Feed t h Size t h
2½-1¼ 44 29.7 13.11¼-¾ 20 29.7 5.9
¾-¼ 20 29.7 5.9¼-0 16 29.7 4.8
100% 29.7 tph
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STEP 8 Combined Output
Size Jaw t h Roll t h Total
tph
% in
range
2½-1¼ 37.4 13.1 50.5 461¼-¾ 14.3 5.9 20.2 19
¾-¼ 16.5 5.9 22.4 20
¼-0 12.1 4.8 16.9 15
110 tph 100%
S 9 C
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STEP 9 Check
Requirement
Size Require
ment
% in
range2½-1¼ 40-60 46
1¼-¾ 18-30 19
¾-¼ 15-25 20
ok
okok