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Quarry Academy 2005
SANDVIK ROCK PROCESSING
THE ART OF CRUSHING
Quarry Academy 2005
Feed
MachinesMachines&&
ProcessesProcesses
Products
What is a C&S system ?
Quarry Academy 2005
Super Quarries & Mines 600-2000 tphMedium Quarries 300-600 tphSmall Quarries & Mobiles 150-300 tph
Quarry Academy 2005
THE ART OF CRUSHING
Raw material?How big? (Size of rawmaterial)How much? (Capacity)Final products?Contamination?
Quarry Academy 2005
THE ART OF CRUSHING
FeedcurvesMax TopsizeImpact Work index (Wi)Abrasion index (Ai)Type of rock / geologyDensity
– Wi measured x B.D./1.6 = Wi real
MoistureContamination
Quarry Academy 2005
THE ART OF CRUSHINGCrushing Rock
Limited reduction
Cubical shape
Over- and undersize is important
Flexibility
Crushing and screening
Range of products
Sellable Products !
Crushing Gravel
Limited reduction
Cubical shape
Over- and undersize is important
Flexibility
More screening than Crushing
Contamination?
Range of products
Sellable Products !
Crushing Ore
Maximum reduction
Shape of no importance
Over- and undersize of no importance
Flexibility of minor importance
More crushing -less screening
One or two products
Product to further processing !
Quarry Academy 2005
THE ART OF CRUSHING
Final Products - Specifications
Asphalt / ConcreteShape of materialOver and undersizeNo contamination
Railway ballastCurve limitationsShape of materialOver and undersizeNo contaminations
Base course / Sub baseCurve limitations
Different in all countries
Quarry Academy 2005
Product properties
NORMSBritish norms
Slots
L
L3German norms
“US” norms
French norms
Quarry Academy 2005
Reduction Ratio (1)
F80 = (80 % of feed mtrl) P80 = (80 % of the product)
80
80
PF
=Reduction Ratio
Quarry Academy 2005
0102030405060708090
100
1 10 100 1000
HSIH-ConeS-ConeJawFeed
Reduction Ratio (2)Normal reduction:
Jaw crusher 2-3Gyratory crusher 3-4Cone crusher 3-5Impact crusher (VSI) 4-6Impact crusher (HSI) 7-10
Quarry Academy 2005
Reduction Ratio (3)
P80 Feed: 400 mmP80 Products: 16 mm
Min. required plant reduction ratio:
2-stage Impact Plant:
10x7=70OK, Only for Ai <0.15
2-stage Jaw/cone Plant3x4=12NOT OK
3- stage Jaw/cone Plant3x3x4=36OK
Using reduction ratio to predict required no. of crushing stages
2516400
=
Quarry Academy 2005
Reduction Ratio 3Impactors VS Compresive crushers
Impact crusher High reduction ratioLow investmentHigh wear costMax Ai= 0.15
Jaw / Cone crusherLow reduction ratioBig investmentLow wear cost
Production (tons)
Tota
l cos
t(In
vest
men
t + W
ear)
Jaw / Cone crusher
Impa
ct c
rush
er
Quarry Academy 2005
Primary Crusher station
Continuous processConveyable productRemove Contaminations
Quarry Academy 2005
Primary Crusher station
Quarry Academy 2005
Primary Crusher station
Quarry Academy 2005
Primary Crusher station
Quarry Academy 2005
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
Quarry Academy 2005
Intermediate Storage (2)
1 feeder
2 feeders
3 feeders
4 feeders
1 feeder
Quarry Academy 2005
Secondary Circuit
Big feed opening
High capacity
Controlled feed
Quarry Academy 2005
Secondary Crushers
Hydrocone H / S Secondary Impactor
Quarry Academy 2005
Production of railway ballast
C.S.S: 150-175 mm
HydroconeS4800 C
HydroconeH6800 CXD
Alt.
0-18 0-35 flakesRailwayBallast
Quarry Academy 2005
ScreeningOpen / Closed circuit
Quarry Academy 2005
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.
Quarry Academy 2005
Open Circuit – Examples
Splitting of crusher feed
By-passing fine material
Scalping
Quarry Academy 2005
Closed Circuit
Calibrated productHigher reduction ratio.Better cubical shapeMore machinesLower capacity
Quarry Academy 2005
Closed Circuit
Closed circuit ~ 1/5 of screen feed circulating recommendedSmaller or same setting (CSS) as separation.Higher wearCubical shapeBig screen
discrepancy:– Short jobs– Prod of sand
4/5
1/5
4/5
5/5
Quarry Academy 2005
Closed Circuit – Examples
Screening after crusher
Screening ahead of crusher
Screening ahead of and after crusher
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A
B
C
D
Screen dutiesA = Scalping screeningB = Close circuit screeningC = Final products screeningD = Natural fines screening
SCREENNING SUMMARY
Quarry Academy 2005
Final Crusher
Demands:
Optimised feed
Capacity
Product shape
Quarry Academy 2005
FINAL CRUSHER - Hydrocone
Good FlexibilityHigher crushing forcesLimited good shape rangeUniform reduction ratio
0
10
20
30
40
50
60
70
80
90
100
0,1 1 10 100Aperture (mm)
%-P
assi
ng
FeedH3800 F
Good shape product area
Quarry Academy 2005
FINAL CRUSHER- Merlin VSI
Better shapeUneven ReductionLimited topsize capacityHigh fines production
0
10
20
30
40
50
60
70
80
90
100
0,1 1 10 100Aperture (mm)
%-P
assi
ng
FeedRP108
Good shape product area
Quarry Academy 2005
HYDROCONE – MERLIN RP
Curves show Hydrocone H3800 F and Merlin RP 107 in a medium hard granite (Wi=16) in open circuit operation
0
10
20
30
40
50
60
70
80
90
100
0,1 1 10 100Aperture (mm)
%-P
assi
ng
FeedH3800 FRP108
Hydrocone H3800 F
Ecc: 29 mmC.S.S: 16 mmASR Plus
Merlin RP 107Tip speed: 60 m/sBi-flow: 0 %150 kW
Quarry Academy 2005
Storage at Crusher
Choke fed Crusher;Higher ReductionBetter shape (cubical)Better utilization of mantle and linersBin volume; 5-10 min operation
Quarry Academy 2005
Crusher feed
Quarry Academy 2005
Process Control
Quarry Academy 2005
Stationary / MobileStationary
Long term ContractsValuable productsRange of productsProduction on demandFlexibility with manystagesHigh Production control
MobileContract crushingCrushing at constructionsiteLow product demandsFew productsFlexibility with Fleet
Quarry Academy 2005
Mobile Units (1)
Portable Track-mountedWheel-mounted
1 5 25 100Movements/Year
Mobility selection chart
Quarry Academy 2005
Mobile Units (2)
Quarry Academy 2005
Mobile Units (3)
Portable
Track-mounted
Wheel-mounted
1 10 50
Hours
Dismounting time
Quarry Academy 2005
Mobile Units (4)
10 30 40 5020
100
150
200
250
300
60
Machine Weight (Tonnes)
Nom. loading Capacity (m³/h)
Wheel LoaderExcavator
Quarry Academy 2005
2-Stage Plant ApplicationExample
Capacity:200 tph
Feed station
JawmasterJM 1108 HD
Bin withFeederHydrocone
H-4800 EC
ScreenCS 86-IV
0-4 4-8 8-16 16-32
Quarry Academy 2005
3-Stage Plant ApplicationExample
Capacity: 200 tph
Feed station
JawmasterJM 1108 HD
Bin withFeederHydrocone
S-3800 EC
ScreenCS 86-II
0-4 4-8 8-16 16-32
HydroconeH-3800 M
ScreenCS 86-II
Quarry Academy 2005
4-Stage Plant, Cone ApplicationExample
Capacity: 200 tph
Feed station
JawmasterJM 1108 HD
Bin withFeeder
HydroconeS-3800 EC
ScreenCS 86-II
HydroconeH-3800 M
ScreenCS 86-II
HydroconeH-3800 MF
16-32 8-16 4-8 0-4
Quarry Academy 2005
4-Stage Plant, VSI ApplicationExample
Capacity: 200 tph
Feed station
JawmasterJM 1108 HD
Bin withFeeder
HydroconeS-3800 EC
ScreenCS 126-II
HydroconeH-3800 M
VSI
16-32 8-16 4-8 0-4
Quarry Academy 2005
Application examplesSUMMARY
Product distributionProduct 0-4 mm 4-8 mm 8-16 mm 16-32 mm2-stage 33 t/h 19 t/h 41 t/h 107 t/h (*)3-stage 43 t/h 29 t/h 66 t/h (*) 62 t/h *4-stage 61 t/h 35 t/h * 54 t/h * 50 t/h *4-stage, VSI 88 t/h 38 t/h * 44 t/h * 30 t/h *
* Good shape
2-stageCheapEasy to moveBad shapeLow flexibility
3-stageMedium expensiveCould be movedMedium shapeGood flexibility
4-stageExpensiveDifficult to moveVery good shapeVery good flexibility
Quarry Academy 2005
Mining Plant ApplicationExample
EFCEFC
JawmasterJM 1312 HD
HydroconeS-4800 C
2x HydroconeH-4800 EF
0-10
HydroconeH-4800 M
Quarry Academy 2005
Quarry Academy 2005