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Mark Krause

General Manager

Aggregate Division McLanahan Corp

Crushing 101-

“Let’s not make this more

complicated than it really is”

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I am changing from:

We’re all

Ambassadors of

Aggregates……

To:

We are all

Ambassadors for

Safety

• When we are truly committed to safety, we demonstrate safe behaviors in all aspects of our lives 24/7. Safety isn’t something we “turn on and off” at work.

• 2014 was worse than 2013 and 2013 was worse than 2012!

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The best and easiest way to help your company’s bottom line is to be safe!

Workplace injuries, illnesses and fatalities cost more than $170 billion per year in the U.S. Beyond the immediate financial impact, more than one million injuries and 2.3 million cases of ill-health are experienced by workers in an average year, contributing to a loss of about 40 million working days. Overall, nearly 50 workers are injured every minute of every work week, and 17 will die on the job every day.

Fatalities from 10/13 thru 4/1418 Total

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Fatalities from 10/13 thru 4/14

Fatalities from 10/13 thru 4/14

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Making the right choice…..

“Making little ones out of big ones”

Our Challenge

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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

Crushing 101- Factors to be considered

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Crushing 101- Factors to be considered

Crushing 101- Factors to be considered

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• 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

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•Jaw Crusher

•Gyratory

•Cone Crusher

Standard Head

Short Head

•Roll Crusher

Dual and Triple

Crushing 101-Types of compression crushing

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.

Crushing 101-Three types of crushing

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•Horizontal Shaft Impact

•New Holland

•Andreas

•Vertical Shaft Impact

•Hammermill

•CageMill

Crushing 101-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.

Crushing 101-Three types of crushing

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Crushing 101-

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.

Crushing 101-Product Specifications

Size #4(11/2) ASTM Requested Size #56 (1) ASTM Requested Size #6 (3/4) ASTM Requested

Percent Used Material Spec Band Control Material Spec Band Control Material Spec Band Control

Sieve Gradation #4 Band Gradation #56 Band Gradation #6 Band

1-1/2" 100 90-100 100

1" 40 20-55 35-45 100 90-100 100 100 100 100

3/4" 10 0-15 10-15 60 40-85 55-65 100 90-100 100

1/2" 15 10-40 10-15 35 20-55 30-40

3/8" 3 0-5 0-5 4 0-15 2-6 8 0-15 5-11

No. 4 2 0-5 0-5 2 0-5 0-4

No. 8 2

No. 16 2

No. 30 2

No. 50 2

No. 100 2

No. 200 1.0 0-2 1.0 0-2 1.3 0-2

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Crushing 101-Calculating Reduction RatioUsing the P80 (80% passing) method

Feed Output

6” 100%

5” 97%

4” 88%

3” 70%

2” 36% 100%

1-1/2” 10% 98%

1” 5% 90%

¾” 81%

½” 68%

3/8” 58%

Using in/out method =

6” ÷ 2” = 3 to 1 reduction

Using P80 method =

3.5” ÷ .75” = 4.7 to 1 reduction

Crushing 101-Basic Crusher Guide

Crusher Type Maximum Feed Size Product Size

Jaw Crusher 80% of opening generally

24”

6-12” x 0

Gyratory Feed opening reliant upon

size of crusher

10-12”x 0

Standard Head Cone 14” ¾” to 4”

Horizontal Shaft Impactor 40” (primary)

16”(secondary)

6”

¾” to 4”

Hammermill 8” 4M to 1-1/2”

Short Head Cone 8” ¼” to 5”

Vertical Shaft Impactor 6” 4M to 1-1/2”

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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

Feed

Opening

Large total feed area

(both sides of spider)Primary Gyratory Crusher

Basic Gyratory

Head and

mantle

Hydroset System

Concave Liners

Spherical Spider

Bushing Eccentric 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

Gyratory Video

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Jaw Crusher

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Basic Jaw CrusherGENERAL

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)

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Basic Jaw Crusher

Toggle

plate

Toggle

seatMoving jawStationary 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

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

Toggle plate

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Jaw Crusher Video

Jaw Crusher Video

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Horizontal Shaft Impact Crushers

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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Impact Video

Impact Video

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HSI Basics

Blow Bar Condition must be checked

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Houston we have a problem !

Cone Crusher Review

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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)

Cone Crusher Video

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Cone Crusher Video

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 fresh feed

Fine recirculation feed

Correct Feed Distribution

A segregated feed distribution

will lead to :

ring bounce

poor liners wear

more oversized products

poor particle shape

Coarse fresh feed

Fine recirculation feed

Correct Feed Distribution

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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.

Proactive Maintenance1560 OmniconeBushing 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.

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VSI Crushers

HOW IT WORKS

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Vertical Shaft Impact CrushersShoe 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.

Shoe Table and Anvil Ring

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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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Factors Affecting Cone PerformanceVSI Video

• Speed

• Setting

• Stroke

Factors Affecting Cone PerformanceFactors affecting a compression crusher’s performance

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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.

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

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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

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Affect of Setting on Compression Performance:

•A closer setting will yield a finer

output gradation with a lower

throughput capacity

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.

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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.

• Speed

• Setting

Factors Affecting Cone PerformanceFactors affecting a HSI crusher’s performance

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• Speed

Factors Affecting Cone PerformanceFactors affecting an Impact crusher’s performance845

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%

• 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:

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• Setting

Factors Affecting Cone PerformanceFactors 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

• Ten things I know about you.

1.You are reading this.

2.You are human.

3.You cannot say the letter ''P'' without separating your lips.

4.You just attempted to do it.

5.You are laughing at yourself.

6.You have a smile on your face and you skipped No. 5.

7.You just checked to see if there is a No. 5.

8.You laugh at this because you are a fun loving person &everyone does it too.

9.You will have fun showing this column to someone else.