SANDVIK ROCK
PROCESSING
THE ART OF CRUSHING
Quarry Academy 2005
What is a C&S system ?
Feed
Machines
&
Processes
Products
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Super Quarries & Mines
Medium Quarries
Small Quarries & Mobiles
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600-2000 tph
300-600 tph
150-300 tph
THE ART OF CRUSHING
Raw
material?
How big? (Size of rawmaterial)
How much? (Capacity)
Final products?
Contamination?
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THE ART OF CRUSHING
Feedcurves
Max
Topsize
Impact Work index (Wi)
Abrasion index (Ai)
Type of rock / geology
Density
Wi measured x B.D./1.6 = Wi real
Moisture
Contamination
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THE ART OF CRUSHING
Crushing Rock
Crushing Gravel
Crushing Ore
9 Limited reduction
9 Maximum reduction
9 Cubical shape
9 Cubical shape
9 Shape of no importance
9 Over- and undersize
is important
9 Over- and undersize
is important
9 Over- and undersize of no
importance
9 Flexibility
9 Flexibility
9 Flexibility of minor importance
9 Crushing and
screening
9 More screening than
Crushing
9 More crushing -less screening
9 Range of products
9 Contamination?
Limited reduction
9 One or two products
9 Range of products
9 Sellable Products !
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9 Sellable Products !
9 Product to further processing !
THE ART OF CRUSHING
Final Products - Specifications
Asphalt / Concrete
9 Shape of material
9 Over and undersize
9 No contamination
Railway ballast
9
9
9
9
Curve limitations
Shape of material
Over and undersize
No contaminations
Base course / Sub base
9 Curve limitations
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Different in all countries
Product properties
British norms
German norms
NORMS
French norms
Slots
US norms
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L
3
Reduction Ratio (1)
F80
Reduction Ratio =
P80
F80 = (80 % of feed mtrl)
P80 = (80 % of the product)
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Reduction Ratio (2)
Normal reduction:
100
Jaw crusher
2-3
90
Gyratory crusher
3-4
80
Cone crusher
3-5
70
Impact crusher (VSI)
4-6
60
Impact crusher (HSI)
7-10
50
40
HSI
H-Cone
S-Cone
Jaw
Feed
30
20
10
0
1
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10
100
1000
Reduction Ratio (3)
Using reduction ratio to predict required no. of crushing stages
2-stage Impact Plant:
10x7=70
P80 Feed: 400 mm
P80 Products: 16 mm
OK, Only for Ai <0.15
2-stage Jaw/cone Plant
3x4=12
Min. required plant
reduction ratio:
400
= 25
16
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NOT OK
3- stage Jaw/cone Plant
3x3x4=36
OK
Reduction Ratio 3
Impactors VS Compresive crushers
Imp
Total cost
(Investment + Wear)
act
cr u
she
r
/
w
a
ne
o
C
he
s
c ru
9
9
9
9
High reduction ratio
Low investment
High wear cost
Max Ai= 0.15
Jaw / Cone crusher
9 Low reduction ratio
9 Big investment
9 Low wear cost
Production (tons)
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Impact crusher
Primary Crusher station
Continuous process
Conveyable product
Remove Contaminations
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Primary Crusher station
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Primary Crusher station
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Primary Crusher station
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Intermediate storage
Quality producing part of plant
independent of Primary crushing
and loading operation
Even out variations in the material
distribution. Uneven load gives
problems in all machines coming
after.
Better total availability for the Plant
Recommended stockpile volume
for 2 shifts operation
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Intermediate Storage (2)
1 feeder
1 feeder
2 feeders
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3 feeders
4 feeders
Secondary Circuit
Big feed opening
High capacity
Controlled feed
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Secondary Crushers
Hydrocone H / S
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Secondary Impactor
Production of railway ballast
Hydrocone
S4800 C
Alt.
Hydrocone
H6800 CXD
C.S.S: 150-175 mm
0-18
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0-35
Railway
flakes Ballast
Screening
Open / Closed circuit
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Open Circuit
Screening ahead of a crusher
avoids packing.
Less wear in the crusher.
Higher total capacity.
The product is controlled by the
screening cloth and the setting of
the crusher.
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Open Circuit Examples
Splitting of
crusher feed
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By-passing fine
material
Scalping
Closed Circuit
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Calibrated product
Higher reduction ratio.
Better cubical shape
More machines
Lower capacity
Closed Circuit
4/5
Closed circuit ~ 1/5 of screen
feed circulating recommended
Smaller or same setting (CSS)
as separation.
5/5
Higher wear
1/5
Cubical shape
Big screen
discrepancy:
4/5
Short jobs
Prod of sand
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Closed Circuit Examples
Screening after
crusher
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Screening ahead of
crusher
Screening ahead of
and after crusher
SCREENNING SUMMARY
A
Screen duties
A = Scalping screening
B = Close circuit screening
C = Final products screening
D = Natural fines screening
D
C
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Final Crusher
Demands:
Optimised feed
Capacity
Product shape
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FINAL CRUSHER - Hydrocone
100
90
Feed
H3800 F
80
70
%-Passing
60
50
40
30
20
10
0
Aperture (mm)
0,1
10
100
Good shape product area
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Good Flexibility
Higher crushing forces
Limited good shape range
Uniform reduction ratio
FINAL CRUSHER- Merlin VSI
100
90
Feed
RP108
80
70
%-Passing
60
50
40
30
20
10
0
Aperture (mm)
0,1
10
100
Good shape product area
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Better shape
Uneven Reduction
Limited topsize capacity
High fines production
HYDROCONE MERLIN RP
100
Feed
H3800 F
RP108
90
80
70
60
%-Passing
Hydrocone H3800
F
Ecc: 29 mm
C.S.S: 16 mm
ASR Plus
50
40
30
20
10
0
Aperture (mm)
0,1
Merlin RP 107
Tip speed: 60 m/s
Bi-flow: 0 %
150 kW
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10
Curves show Hydrocone H3800 F and
Merlin RP 107 in a medium hard granite
(Wi=16)
in open circuit
operation
100
Storage at Crusher
Choke fed Crusher;
Higher Reduction
Better shape
(cubical)
Better utilization of
mantle and liners
Bin volume; 5-10
min operation
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Crusher feed
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Process Control
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Stationary / Mobile
Stationary
Mobile
Long term Contracts
Valuable products
Range of products
Production on demand
Flexibility with many
stages
High Production control
Contract crushing
Crushing at construction
site
Low product demands
Few products
Flexibility with Fleet
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Mobile Units (1)
Mobility selection chart
Portable
Wheel-mounted
25
Track-mounted
100
Movements/Year
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Mobile Units (2)
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Mobile Units (3)
Dismounting time
Portable
Wheel-mounted
Track-mounted
10
50
Hours
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Mobile Units (4)
Nom. loading Capacity (m/h)
300
250
200
150
100
10
20
30
40
50
60
Machine Weight (Tonnes)
Wheel Loader
Excavator
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Application
Example
2-Stage Plant
Capacity:200 tph
Feed station
Hydrocone
H-4800 EC
Jawmaster
JM 1108 HD
Screen
CS 86-IV
0-4
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Bin with
Feeder
4-8
8-16
16-32
Application
Example
3-Stage Plant
Capacity: 200 tph
Bin with
Feeder
Hydrocone
S-3800 EC
Feed station
Hydrocone
H-3800 M
Jawmaster
JM 1108 HD
Screen
CS 86-II
Screen
CS 86-II
0-4
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4-8
8-16
16-32
Application
Example
4-Stage Plant, Cone
Capacity: 200 tph
Screen
CS 86-II
Hydrocone
S-3800 EC
Feed station
Jawmaster
JM 1108 HD
Screen
CS 86-II
Bin with
Feeder
16-32
Hydrocone
H-3800 MF
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Hydrocone
H-3800 M
8-16
4-8
0-4
4-Stage Plant, VSI
Application
Example
Capacity: 200 tph
Hydrocone
S-3800 EC
Screen
CS 126-II
Feed station
Bin with
Feeder
Jawmaster
JM 1108 HD
16-32
VSI
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Hydrocone
H-3800 M
8-16
4-8
0-4
Application examples
SUMMARY
Product distribution
Product
2-stage
3-stage
4-stage
4-stage, VSI
0-4 mm
33 t/h
43 t/h
61 t/h
88 t/h
4-8 mm
19 t/h
29 t/h
35 t/h *
38 t/h *
8-16 mm
41 t/h
66 t/h (*)
54 t/h *
44 t/h *
16-32 mm
107 t/h (*)
62 t/h *
50 t/h *
30 t/h *
* Good shape
2-stage
3-stage
4-stage
Cheap
Easy to move
Bad shape
Low flexibility
Medium expensive
Could be moved
Medium shape
Good flexibility
Expensive
Difficult to move
Very good shape
Very good flexibility
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Application
Example
Mining Plant
Hydrocone
S-4800 C
Jawmaster
JM 1312 HD
Hydrocone
H-4800 M
EFC
EFC
0-10
2x Hydrocone
H-4800 EF
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