• Author / Uploaded
• Jairo Gonzaga

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SANDVIK ROCK PROCESSING THE ART OF CRUSHING

Quarry Academy 2005

What is a C&S system ? Feed

Machines & Processes

Products

Quarry Academy 2005

¾Super Quarries & Mines ¾Medium Quarries ¾Small Quarries & Mobiles

Quarry Academy 2005

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?

Quarry Academy 2005

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 Quarry Academy 2005

THE ART OF CRUSHING Crushing Rock

Crushing Gravel

Crushing Ore

9

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 !

Quarry Academy 2005

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 •

Quarry Academy 2005

Different in all countries

Product properties British norms German norms NORMS

L

French norms Slots

“US” norms

Quarry Academy 2005

L 3

Reduction Ratio (1) F80 Reduction Ratio = P80

F80 = (80 % of feed mtrl) P80 = (80 % of the product)

Quarry Academy 2005

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

Quarry Academy 2005

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