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65 views53 pagesCAK 160 Crushing Practice Theory
The document provides a historical overview of crushing practices and the evolution of various types of crushers, including jaw and gyratory crushers, from their inception in the 19th century to modern developments. It discusses the performance characteristics, operational principles, and the impact of technological advancements on the efficiency of crushing operations. Additionally, it highlights key figures and milestones in the development of crushing machinery within the mining and quarrying industries.
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0% found this document useful (0 votes)
65 views53 pagesCAK 160 Crushing Practice Theory
The document provides a historical overview of crushing practices and the evolution of various types of crushers, including jaw and gyratory crushers, from their inception in the 19th century to modern developments. It discusses the performance characteristics, operational principles, and the impact of technological advancements on the efficiency of crushing operations. Additionally, it highlights key figures and milestones in the development of crushing machinery within the mining and quarrying industries.
Uploaded by
Manuel NavarroCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
/ 53
CRUSHING PRACTICE
anne
Reprinted from ROCK PRODUCTS
: A ALLIS-CHALMERS
(Copyright 1930, 1951, 1952, 1958 by Maclean-#uaer Publishing Co, Port
Part
Port It
Port IV
Part V
Part VI
Port Vil
Part vith
Port IX
Part X
Part XI
Post Xil
Port Xilt
Part XIV
Part XV
Part XVI
INDEX
Historical summary
Definitions used in crusher operation.
Operating cheracterstics of various types of eruthers
Gyrotory crusher concaves
Gyretory reduction crushers — types ond characteristics.
Some factors which influence crusher performance.
Jaw erushers, types end special uses.
Crushing rolls end their use.
Special types of roll crushers.
Characteristics ond performance of hammernils.....-
Crusher product curves and tables.
Selecting the primary crusher.
19 of quarry equipment for efficient crushing practice
Selec!
‘Comparison of ayratory and jaw erushers os primaries...
Selection of secondary ond reduction crushers...
Crother operation in open ond closed cireut compared,
‘Advantages of surge bins ond storage bins.
un
13
8
2
26
30
34
38
a
46
49 Crushing
Tie EAT SS patent on 8
rushing machine wae issued. in
1880. Te covered a device which, in
a crude way, incorporated the drop-
hammer principle later used in the
famous stamp mill, whose history is
59 intimately Tinked with that of the
golden age of American mining. Ten
Years later another patent was sued,
Shieh comprised a ‘wooden box, cor
taining © cylindrical drum—appar
‘ently of Wood also—on which a mum
ber of iron knobs, or hammers, were
fastened; the expectation was that
this drum, when revolved at about
350 rpm, would shatter the rock
fed into the top of the box, This de
vee, although it was conceived as an
impact crusher and thus would rate
fas a forerunner of the hammermill,
Dore a somewhat closer resemblance ¢0
the single slodging-roll erusher. There
‘no evidence. that either ‘of these
early inventors carried their work
through to frultion.
"Eli Whitney Blake invented the fist
‘successful mechanical vodk breaker —
‘the Blake jew erusher patented in
3858. Blake adopted a mechanical
Principle familiar to all students of
Imechanies, the powerful toggle link-
age. That his iden was good Seat
tested to by the fact that the Blake-
type jaw crusher fs taday the stant
ard by whieh all jaw crushers are
Judged, and the leading machine of
thew class. for heavy-duty primary
crushing service,
Early Designs
The gyratory principle was the
basis of several rudimentary designs,
patented between 1860 and 1878, none
Practice and Theory
By BROWNELL McGREW*
Part I, Historical summary
‘of which embodied practical mechan-
Teal detais—at least, not in the Tight
of our presentday Knowledge of the
fart, Then, in 1881, Philetus W. Gates
Was granted @ patent on a machine
‘hich included in its design all of the
fsvential features of the modern gy=
ratory erusher. ‘The fixet sale of Tee
ford antedates the patent by. several
months, a No. 2 erusher, sold to the
Boffalo Cement Co. in 1850. That was
‘the first of several thousand gyratory
crushers which earried the name of
Gates to the far corners of the earth.
"An interesting sidelight_ of these
‘early days occurred in 1883 at Meri-
‘den, Conn, where a contest was staged
betccen a Blake jaw crusher and a
Gates gyratory crusher. “Each ma.
chine was required ta crush 9 eu. yd.
of stone, the feed-size and discharge
Settings’ being similar. The Gates
rusher finished its quota in 20!
minutes, the Blake crusher in 64%
‘minutes, hich must have been a and
Gisappointment, to the proponent. of
the Blake machine, who happened
de the challenger.
Hend-Loaded Stone
For some years after these pioneer
machines were developed, require:
ments, viewed in the light of present
practice, were very simple. All maining
nd quarrying, whether underground
or open-pit, was done by hand; tan-
hnages generally were small, and prod-
‘uct specifications simple and Hberal.
In the milling of precious metal
foxes, stamp sills were popular as the
final reduction machine, These were
generally fed with an ore size that
ould be produced handily by one break
through ‘the small gyratory and jaw
‘crushers “Which served a8, primary
‘breakers. Even in large underground
mining operations there wat no de-
mand for large crushers; increased
Tonnage requirements were met. by
duplicating the small units. For ex
‘ample, at the huge Homestake opera.
on in 1915 there were no Ieee than
22" small Gates gyratory crushers
sizes Nos. 5 and 6 to prepare the ore
for the batteries of some 2500 stamps.
Most commercial. crushed-stone
plants were small, and demand’ for
Small product sizes practically non-
existent. Many: plants Iimited output
to two or three’ products. Generally
the top size was about 28+ of Sin.
ringsize: an intermediate. size of
about 1% ing or thereabouts, might
dermade, and the dust, or screenings,
removed through openings of about
Heim. In ballast plants the job was
even’ more simple, one split and an
‘oversize reerush being all that was
needed
Many small plants consisted of one
crusher, either jaw or gyzatory, one
‘lovato® and one screen. Recrushing,
if done, was taken care of by the
same machine handling the primary
Deak. ‘The single crusher, when of
the gyratory tye, might be any size
from the Ne. 2 (Bin. opening) to che
No. 6 with i2-in. opening.
Plants Grow in Output
‘When demand grew beyond the ca:
pabilites of one eruaher, was genet
Ally a simple matter to’ add a second
machine to take care of the recrushe
ing oF secondary crushing work. A
popular combination, for example,
onsisted of No. 6 primary and a
No, 4 secondary, or_possibly a 20- x
WOvin, or 24 x 12in. primary jay,
followed by one of the small gyra:
tories, When the business outgrew the
fapacity of thie sore of plant, it was
‘ot unusual to double up, either in the
same building, or by erecting an en
tirely separate plant adjacent to the
original one.
Grusher manufacturers were not
standing stl during these early
years. In the gyratory line, for ex-
ample, the No. 2 was the first popular
‘ize, and larger machines were
oped from time to time up to the No.
then the No. 7 (later redesigned
and called No. 734). Power-Shovel Leading
‘The steam shovel began to change
the entire picture of open-pit work
ing. ‘With the steam shovel came the
really “huge” No. 8 erucher, with ste
ing opening. “Up to this
s crusher had kept pace
with the” gyratory, bath from the
standpoint ‘of receiving opening_and
cepaciy. but pow the gyratory ter
ped into the leading position, which
‘theld for some 15 years. Once the ice
twat broken, larger and larger sizes
of the gyratory type were develored
rapidly, relegating the once huge No.
8 machine to the status of a second:
ary evusher. This tar toward really
large primary erushers started Just
few years before the turn of the
ontury, and in 1010 erushere with
Bin. Teceiving openings were being:
Dail
“Wik Alle Chalars ayratoy devlaped
inane.
Along about this time the jax
crusher suddenly came back to life
‘and stepped out in front with a great
‘contribution to the line of mammoth:
size primary crushers: the 84. 60-n.
machine built by the Power & Blin:
ing Machinery Co. for trap rock
quarry in eastern Pennaylvania, This
Big erusher was followed by a No. 10
(Zin. opening) gyratory crusher for
the secondary break. Interest created
Dy this installation reawakened the
Industry to the possibilities of the
jave crusher as a primary breaker,
and lines were brought up-to-date to
parallel the already developed gyra-
tory lines.
Tom Edison's Contribution
Although his machines never came
Into general use in the industry,
‘Thomas A. Edison ranke ag & pio:
reer in the development of the large
primary treaker; in fact, Edison 3s
credited with the promulgation of a
very interesting and constructive bit
of Feasoning, which was the baste of
his. development. Coneerned atthe
time’ with the development of a Se.
posit of Jean magnetic iron ore at
Edigon, N.d., he was using a number
of the small jaw erushers then avail-
ble for his initial reduction. ‘Realls-
ing that to concentrate this ore at a
cost to permit marketing it compet
tively meant cutting every possible
‘omer, he studied the problem of mine
ing and erushing the ore as one of the
Steps susceptible of Improvement.
In approaching the problem, Edi-
son’ veatoned. that the recoverable
‘energy in a pound of coal was appro
‘ately equal to the available energy
in-one pound of 50 pereent dynamite;
‘but the’eost per pound of the dynamite
was about 100 times that of the coal
Furthermore, a large part of the dy”
namite used in hie mining operation
‘was consumed in secondary breaking
to reduce the ote to sizes that the
sinall_ primary ‘crushers would. ane
dle, ‘The obvious conclusion was that
Si would be much cheaper to break the
lange pieces of ore by mechanical
rather than by explosive energy.
With that thesis as a starting point,
hie set out to develop a large primary
60 in, x 86 In Faimeun single roll ober,
breaker, development which cule
inated several years Inter in the
hhuge and spectacular 8: Tt Baie
son rolls. A description of the action
of this machine vill be found ina
later section of this series. During
the early yeare of the present century
these giant machines ereated ‘onside
erable interest, and ‘several were in.
stalled in this country. | However,
they never became popular, and inter”
cat swung back othe te versie
gyratory and jaw types. Edicon rolls
Were also developed in smaller sives
for use as secondary and reduction
crushers. In his own ‘cement plant
Edison used four sete of rolls operat:
ing in series to reduee the quarry-ran
ook to a size suitable for grinding.
Other Types of Primaries
During the same years wherein the
industry was concerned with develop-
ment of larger and still larger 93
mary crushers, another member of the
family was born: the single, sledging-
roll erucher. The Aulis-Chelmers Co,
entered this feld in 191%, building 20
sets of 26-in. dia, 60-in, face single:
roll erushers for the Fairmount, IIL,
flux limestone plant of the Caspari
Stone Co. Taking the name of it
proving ground, this machine w
christened the “Fairmount erusher
‘The machine quickly achieved a high
degree of popularity, and although ie
field of application is relatively lin:
ited, quite a number of them were in-
stalled for primary erushing service
‘The line was expanded to include
smaller sizes, as well as the big 60-
x 84-in, machine,
Development of concentration and
eyanidation in the mining. industry
failed “for Sner_ crushing than wat
feasible in the gyratory of jase erash~
fers then available. This requirement
was met for a number of years By the
Gouble. smoath-face crushing rolls,
originally known as “Cornish” rolls.
‘AS the mining industry uring the
© Separioe Mecly eushar with man-cheking
Seperor Mei tne eduction crusher with
period we are discussing was a very
Active one, the development. inthis
type of crusher had reached 2 fairly
Iigh stage before the end of the sem
tury, and some excellent heavy-duty
rolls were available at that time, That
‘this machine was not used to any cone
siderable extent Inthe commercial
crushing plants of that period was due
simply to the fact that there was no
demand for the smaller sizes of eruch=
cd stone, at least not any more than
could be taken eare of by the crushing,
‘methods then in vogue in ach plants
‘This brings us to the rather sig-
nificant fact that, while all of the
teresting and rather remarkable de-
velopment re have outlined was going
on, very litle, if anything, vas being
ono to develop special crushers for
Secondary and. fne-redvetion work,
other than the work on erushing rolls
Just deseribed
Secondary Crushers
‘The use of large primary breakers
made secondary crushing. necessary,
but this depariment was taken cars
of nicely by the existing’ lines of
Standard gyratory machines. In com
Iereial crushed ‘stone plants, there
Was gradual increase in’ the number
of products, but generally a sufficient
demand existed fr the coarser grades
for ballast ard macadam roads to ab=
sorb the output. So for a time every.
thing went along quite comfortably
in this respect, and the operator cor
cerned himself with the problem of
getting out increased tonnage, selling
his produet a it-was made, or stocks
Ing Tt during of-seasons for any paw
teular grades,
‘Then came reinforced conerete, and
with it @ rapidly increasing demand
for small sizes of crushed store an
gravel. (tis hard to say when this
‘demand Began 0 assumo sizable pr
portions, but shortly after 1910 com-
mmarcial plants began to fect the effects
of it, and to lock for a remedy. For
Some time, ag was quite logiesl, the
remedy consisted of installing, more
small secondary crushers, generally
small gyratories. This procedure am
sumed rather startling proportions sn
Some large plants. For example the
array of erushore in the plant of the
Brownell Improvement Co, Thornton,
Hl (built in 1918) ‘comprised one 48:
fn. primary, four No. 713 secondaries
anda batiery of finishing erushors
that included four No. 6 and twelve
No, 4. All were gyratories, although
later, wo eats of rushing rolls were
added to augment the production of
‘mall stone.
Short-Head Gyratories
Probably the earliest attempt to
adapt the standard. gyratory for
eduction crushing service was the
shortchead arrangement, which con-
sisted "simply. of an’ abbreviated
crushing head, installed in the
standard machine, with concaves to
match. This device did not prove 0
be very successful; rushing’ stresset
‘were concentrated’ at a point where
the top shell wae il fitted to withstand
them, and the throw at the point of
discharge was too smalt to take full
2 opening. Chronologically,
this adaption isa rather venerable
fone; it antedates. by a_mimber of
years the more serious efforts to de-
Yelop special Bne-reduction crushers,
a development whieh did not gather
headway until shortly after the end of
‘World War I,
Te would be a dificult matter to aa.
certain just where this’ development
hhad its ‘inception; probably a great
deal of parallel work was being done
te 62-inch Soper Mealy cutare bil for rething capper ee in 1926, 1 ayraery of cocant ds
Superior primary ersher
“hipmant fo Aiea:
fat the time by the various crusher
Duilders, "One of our own early ex:
periments along these ines was the
Installation of special concaves in sov-
eral of the No. 4 crushers in the
‘Thorston plant mentioned above to
reduce the crashing angle. ‘The re:
sults) were ‘encouraging. enough to
start a more thorough investigation
into the design of erushing chambers.
‘The dise crusher was one of the
first special machines brought out for
fine crushing, and for several years
this new type enjoyed a wide popu-
larity. ‘The single toggle Saw erusher
was developed im larger sizes, and ber
cause it eguld be operated at closer
Settings than similar sizes of the
‘Blake type, found quite field of serv-
fce in emall plants as @ reduction
crusher.
Fine Crushing
‘The first important development in
the move to adapt the gyratory erush-
er to fine crushing was the debut of
the Superior McCully" ne-reduction
crusher, which was brought out by
the Power & Mining Machinery aivi-
jon of the Worthington Co, 2 few
years before the AilisChaimers Co.
ook over there crushers. This mae
chine vas designed slong lines iden-
tleal to those of the standard Superior
MeCully crusher with one important
exception: instead of the orthodox tae
ppered top shell of the standard om
‘chine, the new crusher was fited with
4 eylindrially. bored shell, the con-
caves being vertical and reversible
‘The crushing head was flared cor
respondingly, this additional flare re-
sulting, for & given size of receiving
‘opening, in a head of much larger di
ameter, For example, whereas. the
Standard erusher with 10-in. Peeeiv=
ing opening has a head diameter of
about 27 in. at the bottom, the cor-
Fesponding dimension for the 10-in,
reduction erusher i about 40 in, Ee:
centric speeds were increased, and
throwe were adjusted for operation
At close Settings. Originally these ma.
things were fitted with straight-face
oncaves: later the eoncaves were fa:
ered at both endo to distribute the
‘wear betters eventually non-choking
Concaves became standard equipment
Te would be dificult for wey ad te
ious for the reader, were we to at
tempt to chronicle al of the develop.
rent ork, some of stsucsessful and
{ome not, which went on inthe decade
following the end of the Brat World
War. One important contribution &o
‘the art wae the high-speed, directcon-
nected. Newhouse. crusher, which in
roduced «new principle of ashing
for’ cleanness nd. ‘uniformity of
Product.
Some 20 years ago the principle of
the widely Sared rushing head a8
ombined with some other new and
Fadieal departores fom current prac
tice, and the cone crusher entered the
eduction ‘ervehing:Beld. Two inter-
{sting innovations incorporated in tia
machine were (3) an unswaly large
throw and (2) a spring Toaded and ad
Jostable erashing bow
Special Gyratory Concaves
‘About the same time that the cone
rusher appeared, at least three dif-
ferent builders applied the principle
of curved-profle rushing chambers,
certainly the most important and fare
Feaching improvement in crusher de-
Sign that had been made for many
yyears—possibly the greatest since the
inception of the gyratory type. In our
own case this development took the
form of "non-choking” concave,
‘which could be installed in any of the
existing models of gyratory crusher
‘without any change.in the shape of
the crushing head. The type quickly
‘became standard equipment in our re-
duction crushers, the Newhouse and
Superior MeCully fine reduction ma-
chines. But of equal importance was
the fact that the efficieney of many
hundreds of existing standard."mar
chines, of all ages’ and styles, was
Imarkedly improved at a-very ‘nominal
cost by substituting these new curved
foneaves for the old straightface
All crushers developed up to this
time, exeopt the very large machines
of the gyratory type, were provided
‘with ‘some means of adjustment. 9
compensate for wear or t9 adjust for
jons in product size. The range
istmont in most machines was
justments in most eases Te
aquired shutting down the machine. In
the gyratory types, after a esrtain
amount of adjustment was made, st
was necessary to reset the concaves
‘This did not constitute any. serious
drawback in primary and secondary
feruching service, because wear was
Slow generally and the exact setting
‘of discharge opening was not critical
matter. With the increase in demand
for fine erashing the situation alter-
‘ed; it was necessary to sot crushers
lorer and to. maintain the setting
within ‘closer limite. Te was imme:
Giately apparent that a crusher with
a large range of adjustment, without
AUECHALE
branes oss
tictientens the necesuity of resetting the wearing
parts, would be very desirable: aa 6
fatter of fact, the first cone crushers
‘brought out incorporated such a fee:
ture, which proved to be very popular.
Special Setting Adjustment
Gur own engineers studied this
problem along the lines of combining
Wide range with speed of adjustment.
‘The result of this study was the ine
troduction of the idea of supporting
the mainshatt on an oiloperated hy:
‘eaulie jack, This fden was Arst ine
corporated in a special model of the
Newhouse crusher, designated as the
“Oil-Adjasted” crusher. “A. few of
these machines were built and tested
under "severe operating conditions,
fand the line would undoubtedly have
been, developed extensively had not
the “gulet” period through the early
1900's effectively checked the demand
{for new crushers.
‘We had not lost sight of the pos-
sibilities of this method of adjustment,
however, and when-conditions showed
signs of improvement we were ready
to incorporate the oil adjustment fea.
ture into an entirely new machine, a
machine which was to be designed in
All ite proportions specifically for re-
Guetion crushing, with a selentifial.
ly. proportioned crushing chamber,
“quiek-eet” adjustment, safety release
for trampriron protection, and. high
speed operation for maximum capacity
close settings. This machine, the
"Type R,” was brought out early in
1938.
Giant Gyratories
We lett the big primary gyratories
back among the misty memories of the
first World War. A&.a matter of £0c%,
there is not a great deal more to tell
0 far ae these machines are concern
8, except for one more big jump in
top ‘size. Tho machine, whieh hed
reached a 48-in. receiving opening bY
1910. and S4:in. shortly thereafter,
‘was developed a few years later int
the G0sin. is,
‘Our ovin first 60-in, machines were
built in 1926-21, and these erushers—
{vo of ‘which "were installed ina
South American copper mine-—set
world record in weight and. propor
tions which still stands. Thess giant
Iiichinee, weighing about 500 tons
each, and rearing their sto frames to
the height of a tworstory building, are
Indeed e long step forward from, the
first tiny No. 2 Gates erusher that
came out of the litle shop on Rane
dolph Stieet in Chicago some 6i-o8d
years ago.
Part Il, Definitions Used in Crusher Operation
DS 5 288 £298 in every toe of ne
usteial activity, a number of ex-
‘ressiont, peculiar 'to operation of
eek erushing plants, have come into
‘common usage among crusher design-
fers and operators. Inasmuch as these
terme are used rather loosely, and
‘with a considerable degree of freedom
ag to their exact meaning, itis desir-
able to define a few of the more im-
portant ones to make clear the sense
In which they” will be used inthis
work.
Definitions
Blocking means the blockading of
the crusher recsiving opening By a
pices of rock or ore thet fe too large
foventer the crushing chamber in any
position.
Bridging means. the blockading of
the receiving opening by one oF more
ploces, any of which are emell enough
tov enter the crushing. chamber, but
‘Which ave prevented from doing. 50,
either because they fail 30 a8 to span
the opening, or so that they mutually
block each other from entrance.
Choking means a complete, oF pra
tically complete. stoppage of the down-
‘ward flow of material in the crashing
chamber. Tt may be the result of an
fexternal condition, euch as a “back-
1up” of material occasioned by an ob-
struction in the discharge chute, in
hich ‘case choking. is followed’ by
Dacking in the crushing chamber. OF
Choking may be the result of a con-
dition existing within the
‘chamber, such os too close a
Setting, oo many fines in the feed, oF
Sticky material. When eo caused, pack=
ing. precedes—and brings sbout™—the
chokeop
“The choke-point in a crushing cham.
oer la that level in the chamber where
‘the capacity of the crusher is a minis
Yoon; that i, itis the bottle neck of
fhe crushing chamber. fe follows that
{tli the point where choking fe mott
fly to ovcar-—particelatly.20 tf the
choke fs promoted by a condition exe
ing miln the crashes. Note that
the existence of a choke-point does
"ot imply that choking wil necessarily
fecury in fac, as. will be explained
Inter all compreasion-type‘ersshers
tive’ cholespont at some level ithe
inthe cronhing chamber~
Chakevfeed implies’ a completely
filed erching chamber for fall 23
the design wii permit) with a sufi-
lent heal of materia above the tecae=
Ing opening to keep the crusher fal
otinuoualy. ‘hin contrasta with rege
ated-eed which implies thatthe fon
ot material to the crusher fs thrttid
to a point omewhat below the apc
45 of the machine, 20 that the cruther
18 never completely filed
Packing refers to a compacted or
sompretsed condition of the material
Inthe crusher, characterized by a com.
plete’ or neary complete abzence of
folds. Any condition which tends £0
Tetard the free movement of mate:
Hal downward through the erssking
Caner tends ‘kewise to. promote
packing
aching also f wed to deeribe the
tullding tp of fine, sticky material on
the diaphragm of a eyratory crusher,
fr'in the discharge chute below any
{ope of crashes
Ratioctreduction. Precisely, thie
term refers to the size of the largest
ube thatthe crusher, will receive,
divided hy the sizeof the largent cube
the it wil dacharge.Accnliy, we
fre not dealing with exact cubes hen
‘We crash rock or oxer therefore itis
more convenient, at feast when dle
gvtsing crushers of the compression
family, to base the ratjo-of-reduction
‘upon the dimensiong of the crushing
chamber.
"Tn crushers of the jaw and gyratory
types the atio-of-reduction is taken to
mean the ratio of the receiving apen=
Ing” (measured from the top of the
movable member to the top of the sta
tlonary member), to the discharge
‘opening, which may be “open side” oF
“close side," depending upon the type
of crusher, ax will be explained later
For eruching roll, either single oF
double, the Tatio-of-reduetion ie the
ratio of the greatest dlmension that
the machine wil nip, to the dimension
ofithe discharge setting.
‘The hammermill is’ not quite so
‘easily gauged, because of the wide di
parity in the size of product possible
“with any one grate-bar spacing. The
only fair basis of comparison with
‘other types, therefore, is to hase the
ratio upon the size of the largest cube
‘that the mill will reeeive, divided bY
the size of the product, this product to
bbe gauged by the same standards of
sereen analysis that are commonly
used to judge the produets of the other
types.
Crusher Clossifications
Crushers may be divided into three
‘general classes, with respect to the
Tanner in which they do their work:
G1) Preseuze Crushers. This category
embraces the several types of g9r%
tory crushers and jaw crushers, as
well the double crushing vols, with
fither smooth or corrugated shells.
{@) Impact Crushers: This division is
represented chiefly ‘by the various
styles of Hammermill; aso by the cage
type disintegzator. (3)" Combination
Impact and Sledging Crushers. In this clats_we have the single or double
ledging roll crushers. An example of
the former is the Fairmount crusher,
of the latter, the Edicon rell erssher
Some further subdividing and quali
Seation might be applied to theae gen-
feral clagsiheations, but these, Zor the
ost part are not of particular impor
tance! Presaure crushers, for example
tay be divided Into two subsclasses
the reciprocating, and the continuous
prescure, types. The gyzatory and jawe
‘rushers come under the first category.
the crushing rolls under the second.
Stricly speaking, the gyratory motion
Is not a reciprocating one, but it isso
‘with respect to any vertical radial
plane through the erushing. chamber;
therefore it is convenient to view it
Inv that light. “Some roll crushers,
notably the Tight coal crushing tyr
ave more of & tearing action, a8 c
tracted. tothe heavy sledging. pe
Tormance of such machines as the
Fairmount crusher
Part 111, Operating characteristies of various types of crushers
x ouR mscrsnoxs of the operating
‘characteriaties of the various erush:
cer types wee shall av0i3, as far a8 pos
iil, burdening the reader with me:
chanical details, which are covered
quite thoroughly in catalogues and
Dulleting printed for chat purpose. A
brief general description of the es
sential features of each type will
serve to clarify the action, for these
‘who are not farailiar with eroshing
equipment,
Fig. 1 thows a sectional view of a
typical gyratory. crusher. This type
of machine Js, by virtue of chrono:
logical priority, known as the "stard-
‘ard gyratory’ crusher. Although it
incorporates many refinements in de-
sign, it is fundamentally. the same
rusher that first bore the name of
“gyratory”y ite crushing chamber is
very much the same shape; the motion
is identically the same, ané the meth-
‘od of transmitting power from belt 0
trashing head ig similar. Its an ine
teresting fact that the same similarity
in easential features of design exists
Jn “the ease of the “standard,” oF
Blake type, jaw crusher, which is
Something in the way of a tribute te
the inspiration and mechanical abiits
of the mien who originated these me
Essentially, the gyratory crusher
‘consists of a heavy castiron, or steel,
frame which includes tm its lower part
an actuating mechanism (eccentric
fand driving gears), and Jn 185 upper
part a cone-shaped crushing chamber,
Fined with wear-reeisting plates (con
caves). Spanning the crushing cham
ber across ite top isa steady-rest
Gpider), containing a machined jour
nal which fixes the position of the
Upper end of the mainshaft. The ae-
tive erushing member consists of the
Imuinshaft and its crushing head, or
head-center and. mantle. ‘This assem
bly is suspended in the spider journal
bby means of a heavy mut-whieh, in all
but the very large machines, is ar-
ranged for a certain amount of vert
‘al adjustinent of the shaft and head,
‘At its lower end the mainshate passes
through the babbitted ecent
hate with respect to the centerline of
the erusher, Thus, when the eccentric
ig rotated by its gear train, the lower
fend of the mainshaft is caused to gy-
rate (oscillate ina small circular
bath), and the erushing head, ikewiee,
spvratee within the erushing chamber,
progressively approaching, and reeed
tng. from, each element of the cone
shaped inner surface
‘The action of the gyratory erusher,
and of the other member of the re.
siprocating pressure family, the jove
crusher, ie fundamentally ‘a sieple
fone, ut as will be seen a great deal
of thought and some very progressive
engineering has been expended upon
the design of crushing chambers to
increase capacities and to permit the
Lise of lover discharge sittings for
secondary and fne-reduction crushing.
Referring to the table, always
available from the manufacturer,
it wil be noted that standard gy
ratory crushers are manufsetured in
‘commercial see ranging from 8 in.
60 in. receiving openings. Capacities
are listed for minimum and maxinrom
open-side’ discharge settings, in short
tons per hoor, and the horsepower re-
fquirements for aoft and hard mate-
Bila are listed for each size. The ca-
pacities, and the minimum settings,
fre based upon the use of standard
(traight-faee) concave.
Rigidity Prime Essential
‘To stand up under the extremely
rugged work of reducing hard and
tough rock and ore, and in doing sto
maintain reasonably trae alignment
of ite running parts, the crusher
must necessarily be of massive and
Aigid proportions, rigidity being. of
equal importance fo ultimate strength.
Regardless of the tensile strength of
the metal used in the main frame, top
shell, and spider, these parts must be
‘made with walls and ribs thick enough
to provide this rigidity. Therefore it
is practicable to use clove-grained cast iron, and special high-test, mixtures
‘of cast iron, for these parts, if the
machine is intended for crushing: sott
cot medium materials. When very hard
and tough materials are to be crushed,
the ma ‘usually strengehened
by substituting east. steel in one ar
more of its parts.
Wearing parts in the gyratory
crusher may be either chilled ast iron
or manganese steel, depending on the
character of the material to be crushed
land the nareicular clas of service for
‘which the machine ie intended, Stand-
ard crushers, in the aml and medium
sizes, are customarily fitted with ehil
fedsiron head and eoncaves for crush
‘ng sofe ‘and ‘mediam limestone and
Iaterials of similar. hardness. and
abrasiveness, because its relatively
low first cost and exesllent swesring
‘qualities make it the most economical
Imaterial to use when the service fe not
foo ‘severe, Manganese steel, which
combines extreme toughness sith ‘un-
surpassed wear-resistance, is the i
versal choice for erushing hard, tough
tock regardless of the case of service
‘or type of rusher, Even though the
fodk be quite soft and notrabrasive,
itis general practice to se. man-
fanese. steel concaves in the larger
sizes of primary crushers because of
the shocks attendant upon handling
large and heavy pieces of rock.
Straight-Face Concaves
When used for primary or coarse
secondary crushing service, the type
‘of crusher we have been ‘describing
is usually Atted with the style of con
‘cave shovn in Fig. 2 These
type of liner ever since the gyratory
crusher came into popular use. ‘The
distinguishing features of this’ type
fof concave are
(1) The receiving opening, for any
given size of crusher, is at
(2) The choke-point (point of min
sum capacity) is at the discharge
opening.
(8) The ratio of reduction varies for
different sizes, ranging trom
about 5.85 to 76, and averaging
about 63 for ail'szes from 6 in.
to 42 in, inclusive. These ratios
are based upon the use of atand-
ard-theow eeoentrice
Usually the primary erusher ig se.
lected on the basis of (1) size of re
‘ceiving opening and (2). capacity.
More often than mot, the gyratory
ther th satiety
Ing opening will have ampl
tor ‘the job. Furthermore, the per-
tissible ‘inimom discharge setting
for the standard gyratory 18 usually
small enough to make an acceptable
stcondary feed, For these xeagons the
Standard erusher is, as stated before,
savally supplied with straightface
‘eoneaves for primary erushing service.
‘There are some secondary crushing,
applications Where maxiiaum receiv.
ing opening, for “any” given size. of
‘machine, is desirable. For such appii-
cations straight-face concaves are In.
dicated, provided of course that the
crusher 20 feted will have suflclent
‘capacity for the job in hands On the
other hand, most geeondary—and some
primary—erushing jobs require maxic
‘mum capacity and maximum ratio of
feduction, rather than maxinrom ve
ceiving opening. ‘The. standard” gy.
ratory erusher has been adapted for
such applications by the introduction
of an interesting and. important
change in the shape of its cfushing
chamber, regarding which. ve shall
hhave more to say under the subject of
“non-choking coneaves.”
aibere atlof course certain limiting
factors which govern the proportions
‘of the ‘crushing chamber in, these
standard gyratory machines. One of
these, the ratio of reduction which
‘can safely be made in any piven me
chine, has already been mentioned. As
the ratio of reduction i simply” the
atio of receiving opening to. di
charge opening, Tt follows that this
limitation is “directly related to the
safe minimum discharge setting, All
crusher manufacturers eetablish what
fare considered to be safe minimum
settings forthe different sizes. of
crushers of their manufacture, Pabe
lished ‘capacity tables for gyratory
‘and jaw crushers generally list ca:
pacities at settings down to and ine
‘luding these minimum openings, The
practice for gyratory crushers Ig to
predicate these minimum settings upon
the use of atandard-throw escentries?
lity throws which experience hag
proven te be right for each particu
lar size of crusher
Crusher Settings
‘The setual minimum safe setting
will Vary sometchat, for any given
machine, depending upon the charac:
fer of the material. the amount of fines
inthe feed, and whether the erushe? is
being operated ‘under choke-feed oF
Fegulated feed conditions. Tt is possi
bile, when all conditions are favorable,
to ‘operate gyratory crushers, ‘with
standard throw eccentrics, at smaller
Aischarge settings than are indicated
by the published ‘tables. Generally
speaking, however, it cannot be sort
sidered ‘food practice to do 60) and
Any experimentation along these lines
should "be accompanied "bya close
check on the power consumption, to
rmalce sure that the erusher is not being
overloaded,
When it is necessary, or desirable,
to operate a gyratory erusher at dis:
charge settings below the minimum
standard, the safe procedure is to ft
fhe machine with a reduced throw eo
centric. The crusher manufacturer
‘seme 7]
usin Hen
ren Se
sll ne able to advise the operator
About these special throws fr mas
chines of
Lf" reduced throw eacentie is ine
stalled, the capacity at any given set-
ting will drop off approximately in di-
rect proportion te the reduction ‘in
‘throw. Th some cates it is possible to
compensate, partially at least, £08 this
drop-off by' speeding up the machine.
Here, again, the manufacturer will be
able to advise the operator as to the
maximum safe speed for any particu
tar crusher of We tne
‘Another factor which governs the
proportions of the eruthing chamber
{s the maximom permissible angle be-
tween th two crushing, faces, This
aleo is subject to a certain amount of
‘ariation, depending upon the char-
acter of ‘the ‘material, and upon the
size of the machine. Crushing angles
may ‘vary. between’ the approximate
lms of and $0 eg, line of
Standard gyratory crushers, It is pos:
sible to use larger angles in the later
Sizes of erashere beratse the greater
weight of the Individnal pieces of mar
terial tends to minimize slipping. Far:
thermore, in these large machines, 8
difference of afew degrees in the
crushing angle makes 2 considerable
ifference in the height, weight, and
‘ost of the crusher.
Tt is obvious that the cocffcient-of-
frietion of the material to be crushed
has a very direct bearing upon the
‘maximum permissible erushing angle.
Some slippery materials, even though
Guite ‘soft, require. special reduced
angle crushing chambers. Inthe stand
lard gyratory crusher this is accom:
plished very simply by ineressing the
‘Thickness of the coneaves at the top,
and tapering them down toward ‘he
Aischarge: in the. jaw erusher the
‘change is generally made by inserting
‘8 wedge-shaped filler behind the linet plates on the movable jaw.
For given cooficient of friction
the harder the material is, the smaller
‘wil “be the maximum "permissible
‘rushing angle. Extremely hard, tough
‘materials even though their coeficient
Of frieton be fairly high may require
Special reduced crushing angles te
prevent ‘excessive slipping. Anyone
‘who has seen hard granite boulders
shoot out of a gyratory or jaw erush-
tor has watched a wide-angle
rusher at work on hard granite oF
trap rock, has hada visual demon
stration of this physical fact.
‘A certain amount of slippage oc-
cours in all pressure type erushers, re-
kardlese” of how small the erushiog
angle may be (that is, within prac:
tHeabie design limita), expecially in
the lower part of the crushing cham-
ber shere the pleces are smaller and
Tighter. Under normal operating con-
ditions this tendeney ig counteracted
by the weight of material in the upper
part of the chamber. Another method
Sf compensation Is. to “break” the
langle of the lower tier of coneaves to
provide a more favorable crushing
[Bnele in this zone.
Crushing Action
Fig. 2, showing the “standard gyra-
tory with straight concaves,” is a see-
tion through any vertical, radial plane
In the crushing chamber of one of the
Intermediate sizes of the crusher. In
‘order to understand the crushing ace
tion in such x chamber it is helpfal
to consider the process as though
‘each step took place in am orderly, and
“ideal” fashion. It is hardly neces-
sary to add that the action never does
take place in just that fashion; never-
theless the concept is fundamentally a
correct one, and the average perform:
fanee of the erusher follows the pat-
tern s0 closely that it is possible to
predict, within surprisingly close lime
Ite, what any particular design of
crusher will do.
We start out by visualizing the
crushing chember filed with a tract
fable material which will act Just the
war we want ib to, with a head of mae
ferial (choke-feed) above the recelv=
ing opening so that no up-sorce. of
Toad ‘will occur during. the. closing
stroke of the crusher head. Now, cone
sider any horizontal. plane through
this bedy of material a5, for exam
‘ile, the plane atthe reeeiving opening,
Tepvesented by line "O” in the dis
fgram. The crusher head iat the mo-
rent in the close-side position.
“As the head recedes on its opening
stroke, the body of material moves
Sownward until, at the end of the
stroke, the plane has moved t0 posi:
tion "i." Note that the length of line
"1" from concave to openside head
potition, is the same as that of line
'0." from concave to elose-side head
On the next closing stroke line “4
is compressed by the amount of the
head movement at that level, and on
the next opening stroke it moves down
0. position "2"—and 30 on down
through the chamber, until it becomes
short. enough to pase through the
open-side discharge setting.
‘We can just as readily vicualize the
process as being the moversent of the
trapezoidal areas enclosed by each ade
jacent pair of horizontal lines and the
two crushing facos, Better stl, we can
consider jt as the movement of annt=
Jar volumes whose eroseseetions are
the areas just mentioned. This latter
conception is essential In vievallzing
the action of non-choking eoncaves
snd flared erushing chambers.
Tn the diagram, the” broken line
through ‘the center of the erushing
chamber is the lne-of-mean-dlameters
fof the compacted areas, When the
profiles of beth crushing faces are
Straight lines, as in the case under
consideration, this meandiameter line
is also straight, and its slone depends
‘upon the relative tapers of the head
and concaves. When the line approx!=
mately parallels the centerline of the
‘rusher, which is also the case for the
diagram we are examining, the theo:
retical” action closely approximates
that of ‘the jaw rusher of similar
fross-seetional proportions. Practical:
Jy, however, the eyratory will have
‘some advantage over the jaw, a# Te-
ards freedom from choking, because
tthe spider arms of the gyratory pre-
‘vent a complete filling of the crush-
ing chamber at the top. When the line
slopes away from the erusher center=
Sine at ite lower end the character
tes change quite definitely in favor of
the gyratory, ss will be seen.
Preventing Choker
Itis apparent that although the dis-
tance. batwoen successive ‘horizontal
planes increases gradually as there
planes move dowmeard. (due to in
‘reaced throw of the head), the aves,
fand hence the volumes, successively
‘eerease. If we conceive the vohume
O-1 as consisting of a mixture of rock
‘and air—that fp, containing a certain
Percentage of voids-—then i is evident
that when this volume has moved
position 18-19, the percentage of these
voids will bo considerably diminished,
If it should happen thatthe voids have
reached auch a low proportion sehen
the material drops from 17-18 to 18-19,
that the closing’ stroke on 18-19 com:
pletely eliminates all voids, we have
4 choked eondition at that point, a eon
ition “which ie. untenable beeauce
downward movement of the material
teases, and the erusher either stalls or
falls at some point.
Clearly, there must be a maximom
safe ratlo between the volumes 0-1
and 18-19, a vatio which must depend
"upon the Shape of the crushing cham
10
Suction through ershing
Mcculycrnkes with nomhoking toncaves
ber, the amount of head-movement,
the’ pereentage of voids in the feed,
fand ‘upon the character of the feed,
with particular reference fo the man
ner in whieh it shatters in the erush=
er. The more fines there are in the
feed, theless will be the pereentage of
voids, and the greater will be the
chance of building up to a choked cone
ition. This is especlally true for Aigh
reduction atios and. close discharge
Settings; itis the reason “why the
farefal crusher builder always, cate
Bons against feeding vnsereened ‘ma
terial to ine-reduction crushers. tis
also understandable why it is advise
able to use reduced throw eccent
for settings below the manufactur
recommended minimums, Tf a condic
ton of near-choke should exist just
above the discharge level, a. large
movement of the head may be sufie
Cent to complete the choke; whereas
{2 smaller throw would not be o likely
{to "Tollow through” to that extent,
eis apparent that the choke-point
in the crushing chamber we have been
discussing is at the discharge level
for immediately above it. It is equally
lear that the unit pressures in such a
chamber inerease progressively from
the top, down, reaching thelr mas
rum valve at the choke-point, where
the voids are at a minimum. It fol-
lows that the amount of "wear on
Tend and eoncaves must increase prow
gressively toward the lover part of
the chamber. As a matter of fact,
when the crusher setting and other
tonditions are such that the machine
is operating. at anything approaching,
2 choke condition, wear ts very rapid
Jn the rogion of the discharge point,
2s compared to the rest of the chamber.
eo much 90 that “belling” of the
head, and “dishing” of the concaves ia
Tikely “fo. progress to a troubieaome
degree Part IV. Gyratory crusher concaves
BIG 2 in port 01 Mustrated the cross
section of a typieal gyratory erusher
ig. illustrates the same crushing
chamber we have. been considering,
‘except that, in place of the straight
face concave, the non-choking type has
been Substituted. For the sake of aie
rest comparison we have shown the
Same discharge setting in both. dia-
rams. although 4 closer setting would
Ee permisaibe for the non-choking a=
rangement.
Inasmuch as the eecentre-throv is
the same, and the concaves in the upe
per part of the chamber parallel those
of the standard type, it follows that
the successive drops of the material
in thie gone would be similar. This is
true down to line 15. Then we note a
Gifference in the new diagram; the
Grop per stroke increases much more
rapidly than in the former case until,
at stroke 16, the line hes arrived at
the discharge level.
“The choke-point hat been raised to
goint 18-14, nctead of being atthe dis~
harge level. From the choke-point, on
‘down to the discharge level each suc-
‘cessive volume is greater than volume
{ord and greater than the volume
immediately preceding. Therefore, the
shape of the crushing chamber in the
zone below the choke-point is favorable
to choke-free operation, Under certain
conditions choking cam occur in this
gone, however, as will be pointed out
tater,
‘The ratiof-volume-reduction be
tween volumes Ot and 16-19 in the Sige
ure previously discussed is obviously
greater than the ratio between vol-
‘Umes 0-1 and 12-14 in the non-cheking
‘diagram; actually the ratio in the for-
imer case is about 4:1, and in the lat
ter. aboot 1.76:1. Therefore, if we
‘asrume an equal percentage of voids
in the feed for both cases, it is ap-
arent that the non-choking arrange
tment will not, when the choke-pomnt
fs reached, have compacted the mates
ial to as low a percentage of voids
fs the straight-face chamber. Also,
the actual volume of 18-19, in the
standard. chamber, ia substantially
smaller than that of 18-14 in the nome
choking chamber. Tnasmuch as these
volumes pass the choke-point in the
sume time-period, the capacity through
the 19-14 zone is obviously the greater
ofthe two.
‘These tio facts account for the su-
perlor performance ef the standard
gyratory--and the standard jaw—
rusher when fitted with non-choking
Timers. As compared with the straight:
ace coneaves, the salient features of
the nonschoking variety
(G1) ‘They permit the use of smaller
discharge settings in any given size
of crusher.
(2) Capacities axe considerably
higher, particularly so in the Tange
of finer settings
(3) Were of rushing head and con-
caves Is more evenly. distributed in
fhe lower part of the crushing cham:
ber,
(i) The receiving opening is re
duced, the amount of this reduction
‘lepending pon the. cfusher setting,
fnd upon the degree of curvature of
the concave faces.
(5) The ratio-of-edaction in. the
different sien. of standard crushers
aries from about 6 to 9) aver
ging about 79 for the snes mon:
ened previously. ‘This fg aieo based
tpon the use of standard-throw exeon-
thee,
(G) ‘he crusher product is mare
wniforen, andi generally ‘contain
lees fine material.
(i) Power requirements are vers
detnitely in favor of the nom-ehok
ing eoncaves.
eis obvious that this type of con-
cave has some very desirable features
‘As'a matter of fact the development
of seientfally designed, ved pro:
fle crushing surfacer is probably’ the
most. important single’ Improvernent
ver made in pressuretype crushers
‘The relative pecformancs of non-chok
ing concaves in the standard gyrators
rushers 1s graphically ‘ilstrated in
‘Table f. THe table containe a com
plete ist of capacity ratings for Se
Berior MeCully crushers, from 8 to
42 in, inclotve, for stralghtfaco, and
ron-choking, eoncaves.
"This table also lists “Modifies
Straight’ Concaves.” These ate con:
saves having a lessor curve atthe bot
ig. 3: Stonderd grater, wih non-eolins
n
ieny Nydas ayoiery cwiher wih
tom partly approaching the nonchoke
tng soncaver but having the choke
abst 2 the tottom of the chamber
Hy areata whet he opens
‘ing is lage enoagh to permit the woe
Bf trnight coneaves, bot where some
‘of the advantages of ron-ahoking con
aves are dented. These ieloee i
teased capacity, more aniform sing
Shd the dstrbttion of wear to pre
‘ent “balling” of the head.
TE should Be made clear at this
that these concaves, although they
tear the ble of "noeshokingy do not
fed absohte Insurance’ apainet
Shaking: In thet reaper the ttle is
ferhape a trite misleading, THe very
Tact that a chokepont existe a0 all
‘within the erushing chamber makes it
vide that choklog ean ocest On
fe other handy they do minimize tee
danger of choking, ad their genera)
‘haractaratica are such that Ut de-
‘Striptive title i not to far afield.
Character of Product
Among the salient festures of the
nonchoking ‘concave, we mentioned
the character of the product. So fi
wwe have been dealing with crushers
‘whose cecentrie speeds are low enough
{%» permit the material 20 fall, with
each receding ‘stroke of the active
ferushing member, the ful distance al
Towed by the close, and openside phys
{cal proportions of the eruching chare-
ber, Pegardless of the shape ofthe con-
caves. In uch crushers, the maximam
fene-way dimension of product par
eles is governed by the open-side
discharge setting; therefore It ia eve. tomary to predicate both product and
capacity upon that setting. Actually,
‘the sizing fe done by the closing stroke
of the erusher on the material in the
ove jost above the discharge opening:
in other words, upon that material
which will be discharged during the
Text opening. stroke Jt follows: that
the shape of the chamber immediately
above the discharge opening must have
ome influence upon the product gra-
ation, and. we. should ‘expect. that
non-choking coneaves, by virtue of the
Smaller angle they” afford. between
head and concaves in. the discharge
zone, would make a wore uniform
‘and’ somewhat finer-—produet than
straight concaves. This is true, and it
nam important and favorable feature
‘of these, concaves, particolariy #0 as
‘applied to the production of commer-
cal crushed stone.
‘One more stord about the character
‘of product. As the percentage of voids
‘Gecreases in the crushing chamber,
the amount of very fine material pro-
duced at exch stroke ic apt to increase,
‘due to the crushing of particles
fagainst each other as they become
‘more and more closely packed. There-
fore the ratio-of-volume-reduelion has
4 definite Infiuenee upon the amount
‘of fines in the erusher product. This
{s especially true of friable materials,
On such materials the substitution of
non-choking concaves for those of the
‘conventional type vill usually result
fn marked decrease in the percentage
‘of ‘extremely fine material in the
crusher product.
From the standpoint of power con-
‘sumption, the best machine fe the one
‘that doee the Teast amount of unnec-
‘essary work. A certain amount of n0n-
productive work ie expended by any
pressuretype crusher in “pushing
‘Eround” material ‘which is siresdy
‘small engugh to pass the discharge
‘opening but which ie prevented from
‘Going £0 Eeeause the particles are
trapped in the surrounding body of
material
As the percentage of voids decreases
the number of such trapped particles
increases, the amount of non-preduc-
tive work likewise inereases, and the
‘material becomes harder to! move at
4 becomes more compacted. Actually,
there is some work being accomplished
fon this small material which. might
Droperly ‘be classed us productive
‘works but, from the viewpoint of the
commercial crushed stone producer at
Teast, ie fo undesirable work: the at-
feltional production of fines, men
Honed”in’ the preceding paragraph,
‘The clean-breaking crusher Is the eco.
nomical erusher, both from the stand-
point of power consumption, and gen-
feral wear and texr. Ang, because the
hor-choking concaves make for clean
er breaking, they benefit the crusher
Jn both of these respecte. At com
parable discharge settings the power
‘saving may run aa high 28 20 percent
econ vw of epi gp came ®
Superior gyratory crusher capacities—
fons 2000Ibs per Hour
2 Port V. Gyratory reduction crushers—types and characteristics
N THE PRECEDING pages we cov.
fered. briefly the. developmont of
various types of reduction crushers of
the gyratory family. Pig 4 shows 3
rindern gytatory fedoction erusher,
hich introduced the
