WELCOME

TO
TRAINING PROGRAMME
ON
‘MATERIAL HANDLING’
DURING 
17TH – 18TH DECEMBER, 2013 
AT
SAIL / CET , RANCHI
ON

BY
B.K.BISOYI
MANAGER (MECH.)
SAIL/CET, RANCHI 1
INTRODUCTION

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 THE TECHNOLOGY OF CRUSHING

Crushing is the reduction of large rocks into smaller rocks by

Impact
Attrition
Shear
Compression

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 THE TECHNOLOGY OF CRUSHING

Weakest zones

When a material is compressed/sheared/attrition, it will break from the

weakest zone.

What is a Crusher ?
A crusher is a machine designed to reduce large rocks into smaller rocks
by compression/attrition/shear/impact.
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 CLASSIFICATION OF CRUSHERS
(BASED ON TYPE OF CRUSHING)
CRUSHERS

COMPRESSIVE CRUSHERS IMPACT CRUSHERS

(Compress the material until it breaks) (Principle of quick impact to crush
the material)

JAW CRUSHERS IMPACTORS

CONE CRUSHERS HAMMER MILLS

GYRATORY CRUSHERS

ROLLER CRUSHERS

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CLASSIFICATION OF CRUSHERS
(BASED ON SIZE OF CRUSHING)

CRUSHERS
TERTIARY/ FINE QUATERNARY /
CRUSHERS FINE
CRUSHERS

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 JAW CRUSHERS

 Mainly used as primary

crushers
 Produce materials that can
be transported by belt
conveyors to the next
crushing stage.
 Capacity: Upto 1600 tph
Principle of operation:
The crushing process takes
place between a fixed jaw and a
moving jaw
Intermittent process
Hydraulic setting adjustment
Liner plates JAW CRUSHER IS A RELIABLE, ROBUST
Manganese steel, EQUIPMENT AND IS QUITE POPULAR IN
Ni-cr alloyed CI PRIMARY CRUSHING APPLICATIONS. 7
BETTER RETURN ON INVESTMENT.
MAJOR COMPONENTS OF JAW CRUSHERS

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 TYPES OF JAW CRUSHERS

SINGLE TOGGLE JAW CRUSHER DOUBLE TOGGLE JAW CRUSHER

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JAW CRUSHER AT KIOM

Capacity : 600 tph

Feed opening : 1520 mm
Plate Width : 2130
mm
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 CONE CRUSHERS
BOWL
Mainly used as intermediate or fine crushing MANTLE WITH
WITH
to obtain a product with good uniform shape LINER
LINER

Capacity: Upto 1200 tph

CSS
Principle of operation: OSS

The material is crushed in a crushing cavity

between an external fixed element(bowl liner)
and internal moving element (mantle) mounted
on the oscillating shaft assembly.
An eccentric shaft rotated by a gear and pinion
produces the oscillating movement of the main
shaft.
The fragmentation of materials results from the
continuous compression that takes place
between the mantle liners and bowl liners in the
chamber.
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 CONE CRUSHERS Contd…
Principle of operation:
The eccentricity causes the cone head to
oscillate between OSS and CSS discharge
opening.
The eccentricity is one of the major factors
which determine the capacity of the cone
crushers.
Adjustment of OSS/CSS:
The settings can be adjusted by
 Rotating the bowl against the threads so that
the vertical position of the outer wear part is
changed.
•Time consuming but uniform wear & tear of
liners Higher capacity in
By lifting and lowering the main shaft secondary crushing with
low operating cost
•Adjustment can be done continuously under 12
load.
CONE CRUSHERS - MAJOR COMPONENETS

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TERTIARY CONE CRUSHER OF M/s HEC FOR MIOM – VARIOUS
COMPONENTS UNDER MFG.
Capacity 500 tph
Feed Size: (+)30 to (-)75 mm
Output: 30 mm

MAIN FRAME DRIVE SHAFT

PINION
RING GEAR 14
TERTIARY CONE CRUSHERS OF M/s HEC FOR MIOM – VARIOUS
COMPONENTS UNDER MFG.

ECCENTRIC SHAFT
GEAR ASSEMBLY HOUSING MAIN SHAFT

CONE CONE
ADJUSTMENT RING
ASSEMBLY 15
CROSS SECTION OF A CONE CRUSHER

Metso Cone Crusher H P VXKI.mpg

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 GYRATORY CRUSHERS

 Efficient primary crushing in mining

application.
 Crushing chamber designed to accept feed
materials of relatively larger size.
 Capacity: 100 tph-9000tph
Principle of operation:
Same as cone crusher.
Provides much larger feed area than a jaw
crusher
Taller, heavier with massive foundation
Adjustment of closed side settings(CSS):
Equipped with a hydraulic setting adjustment,
which adjust CSS and thus have better
productivity.
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GYRATORY CRUSHERS - MAJOR COMPONENTS

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GYRATORY CRUSHING STATION

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GYRATORY CRUSHER STATIONS

Mobile Primary Gyratory Station

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 CRUSHER - SUPPLIERS

METSO FL SMITH SANDVIK THYSSENKRUP

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 ROLLER CRUSHERS
Purpose:
Mainly for crushing easily fractured
materials such as soft limestone, chalk
and clay.

Reduction ratio - 3:1 to 5:1

Principle of operation:
The roller crushers consists of two
rollers. One of the roller shafts is
adjustable while the other has a fixed
position and is provided with a flywheel.

The gap between the two rollers can be

varied depending upon the degree of
crushing required.

Rollers have scrapers to remove any

material sticking to the surface. 22
 IMPACT CRUSHERS
Purpose
Generation of fine materials e.g.
Sand.
Liberate hard minerals from
waste materials
High reduction ratio and cube
shaped product.
Capacity: Upto 1800tph
Principle of operation
The feed material is crushed in the
quick rotational movement of
hammers/bars fixed to the rotor .
HAMMERS
/ BARS

The particles produced are then

further crushed inside the crusher
HIGHER CAPACITY, CUBICAL
as they collide against crusher parts
PRODUCT & GENERATION OF
and against each other, producing a FINES IS NOT A PROBLEM
finer, better-shaped product.
NOT RECOMMENDED FOR CRUSHING TOO FINES MATERIALS 23
IMPACT CRUSHERS - MAJOR COMPONENTS

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 IMPACT CRUSHERS - TYPES

HORIZONTAL SHAFT VERTICAL SHAFT TWIN ROTOR

IMPACTOR IMPACTOR IMPACTOR

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 VERTICAL SHAFT IMPACT CRUSHER

Vertical shaft impactor

The vertical shaft impactor is like a
“stone pump” which operates like a
centrifugal pump.
The material is fed through the center
of the rotor, where it is accelerated
to high speed before being discharged
through the openings in the rotor
periphery.
The material is crushed as it hits on
the outer body and also due to the
rock-on-rock action.
Used for generation of fines e.g.
Sand, gravel etc. VERTICAL SHAFT
IMPACTOR

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 HAMMER MILLS

Purpose
To grind and pulverise materials that are not too hard or abrasive.

Principle of operation:
Similar to impactors
The hammer mill rotor has many pivoted hammers attached to it and the
discharge opening consists of a grate through which the material has to
pass, thus contributing to the reduction process.
The rotor speed and the grate spacing can be optimised to suit different
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applications.
REDUCTION RATIO OF CRUSHERS - TYPICAL CALCULATION

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REDUCTION RATIO OF CRUSHERS - GRAPHICAL REPRESENTATION

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How to select a Crusher?

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 FACTORS AFFECTING THE SELECTION OF CRUSHERS

 Purpose of crushing (Primary / Secondary / Tertiary / Quaternary)

 Location (Fixed /Mobile)
 Type of material (Hard /Soft/Medium)
 Abrasiveness (Abrasive/Non Abrasive)
 Feed size of materials (Larger/Smaller/Medium)
 Capacity of crusher (Higher /Medium / Lower)
 Reduction ratio (Higher /Medium / Lower)
 Product Size (Fines /Coarse)
 Operation & Maintenance aspects
 Other Economic aspects

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SELECTION OF CRUSHERS (Based on Capacity)

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 SELECTION OF CRUSHERS
(Based on Capacity, Feed Size & End product)

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 SELECTION OF CRUSHERS

Typical
Typical Amount
Crusher Typical Feed Size maximum Reduction Hardness Abrasiv
Capacity of Fines Moisture content Application
type Process Stage upto (mm) End Product Ratio of material eness
(tph) Produced
size (mm)
Jaw Primary 1400 200-300 3:1 to 5:1 Upto 1600 Low Soft to Dry to slightly
High Heavy mining
crushers very hard wet, not sticky

Primary 1500 200-300 4:1 to 7:1 > 1200 Low

Gyratory Soft to Dry to slightly
High Heavy mining
crushers very hard wet, not sticky

Secondary 450 60-80 3:1 to 5:1 Upto 1200 Low

Mining,
Medium
Cone Low Dry or wet, not Quarried
Tertiary / 300 0-30 3:1 to 5:1 Upto 1000 Low / hard to
crushers /High sticky materials, Sand
Quaternary Medium very hard
& gravel

Primary / 1300 200-300 10:1 to Upto 1800 Medium Quarried

Horizontal secondary 25:1 / High Soft to
Dry or wet, not materials, sand
shaft medium Low
sticky & gravel,
impactors hard
recycling
Tertiary 40 0-30 6:1 to 8:1 Upto 600 High
Vertical Medium
Dry or wet, not Sand & gravel,
shaft hard to Low
sticky recycling
impactors very hard

Primary Fines Fines 3:1 to 5:1 Upto 500 High crushing of

Roller
Soft Low Dry or wet easily fractured
Crusher
materials

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 COMPARISION OF TYPES OF CRUSHERS

Characteristics Jaw crusher Gyratory crusher Cone Crusher

Secondary / Tertiary /
Type Primary Crushing Primary Crushing
Quaternary
Capacity Lesser Higher Medium

(≤ 1600 tph) (1000-9000 tph) (≤ 1200 tph)

Work Intermittently Continuously Continuously

3:1 to 5:1
Reduction Ratio 3:1 to 5:1 4:1 to 7:1

Weight of Equipment Medium Heavy Medium

crushing surface flares in crushing surface flares in

Crushing Surface Jaw Plates
from top to bottom from bottom to top

Larger /Medium feed

Feed Opening Larger feed opening Smaller feed opening
opening
Principle of
Compression Gyration Gyration
operation

Operating Cost Medium High Economical

Chances of passage of
Relative No chance of passage of No chance of passage
35of
material without
merits/demerits material without crushing material without crushing
crushing
CRUSHER – SPECIFIC POWER CONSUMPTION (TYPICAL)

Type of crusher Specific Power Consumption

(kWhr/t)
Gyratory Crusher 0.1 to 0.2

Jaw Crusher 0.4 to 0.6

Cone Crusher 0.4 to 0.6

Impactor Crusher 1 to 1.2

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 CRUSHER - SPECIFICATION
Sl. No. Description Specification

1 TYPE OF CRUSHER JAW / GYRATORY /CONE

2 Quantity (No.) 1

3 Rated Capacity (tph) 1000

4 Design Capacity (tph) 1300

5 ROM Dimensions(mm x mm x 1200x1000x1000

mm)
6 Material to be handled Direct Ore and Beneficiable ore
7 Crusher Feed F100 (mm) 1000

8 Crusher Feed F80 (mm) 600

9 Crusher Product P100 (mm) 288

10 Crusher Product P80 (mm) 134

11 Bulk Density (t/m3) 2.2

12 Crushing Work Index (kWh/t) 11 37

 CRUSHER - PERFORMANCE
The performance of a crusher depends upon the right choice & correct
operation of associated equipments such as feeders, conveyors, screens, drives,
silos etc.

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CLOSED LOOP CRUSHER CIRCUIT

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OPEN LOOP CRUSHER CIRCUIT

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THANK YOU

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