CRUSHERS
Loading & Unloading…
[Link]
Giant Crushers…
[Link]
/watch?v=IQ41yP7LMII
[Link]
watch?app=desktop&v=6W
GXLU1UOp0
PRIMARY CRUSHERS
• Primary crushers are heavy-duty machines, used to reduce
the run-of-mine ore down to a size suitable for transport and
for feeding the secondary crushers or AG/SAG mills.
• They are always operated in open circuit, with or without
heavy-duty scalping screens (grizzlies).
• There are two main types of primary crusher in metalliferous
operations –jaw and gyratory crushers- although the impact
crusher has limited use as a primary crusher and will be
considered separately
JAW CRUSHERS
• The jaws are set at an acute angle to each other, and one jaw is pivoted so
that it swings relative to the other fixed jaw.
• Material fed into the jaws is alternately nipped and released to fall further
into the crushing chamber. Eventually it falls from the discharge aperture.
• Size reduction ratio of jaw crushers is between 3-6. Their capacities is
below 1600 t/h.
• Jaw crushers are classified by the method of pivoting the swing jaw:
Blake, Dodge and Universal.
The most common jaw crusher used in mineral processing applications is
blake type jaw crusher. There are two forms of the Blake crusher; double
toggle and single toggle.
The single-toggle machine has a somewhat higher capacity than the
double-toggle machine of the same gape. Because its elliptical jaw
motion assists in pushing rock through the crushing chamber.
Throw is the maximum amplitude of swing of the jaw. Throw can be adjusted. It
is is determined by the type of material being crushed. It varies from 1 to 7 cm.
and is highest for tough, plastic material and lowest for hard, brittle ore.
• The angle between the jaws is usually less than 26 ° as the use of a larger angle
than this causes slipping, which reduces capacity and increases wear.
• The speed of jaw crushers varies inversely with the size, and usually lies in the
range of 100-350 rev/min.
• The jaws are usually constructed from cast steel and are fitted with replaceable
liners, made from manganese steel, or "Ni-hard", a Ni-Cr alloyed cast iron.
• Apart from reducing wear, hard liners are essential in that they minimise
crushing energy consumption, reducing the deformation of the surface at each
contact point.
• In order to overcome problems of choking near the discharge of the crusher,
which is possible if fines are present in the feed, curved plates are sometimes
used.
With
Gape
The angle of
nip
Discharge Set
All jaw crushers are rated according to their width and gape, i.e. the width of the
plates and the gape, which is the distance between the jaws at the feed opening.
For example, an 1830 X 1220mm crusher has a width of 1830 mm and a gape
of 1220 mm.
JAW crusher ile ilgili görsel sonucu
GYRATORY crusher ANİMATİON ile ilgili görsel sonucu
GYRATORY crusher ANİMATİON ile ilgili görsel sonucu
jaw crusher ile ilgili görsel sonucu
jaw crusher ile ilgili görsel sonucu
jaw crusher ile ilgili görsel sonucu
GYRATORY CRUSHER
• The gyratory crusher consists essentially of a long spindle, carrying a hard steel
conical grinding element, the head, seated in an eccentric sleeve. The spindle is
suspended from a "spider" and, as it rotates, it sweeps out a conical path within the
fixed crushing chamber, or shell, due to the gyratory action of the eccentric.
GYRATORYcrusher ile ilgili görsel sonucu
GYRATORY crusher ANİMATİON ile ilgili görsel sonucu
• In fact, the gyratory crusher can be regarded as an infinitely large
number of jaw crushers each of infinitely small width. Since the
gyratory, unlike the jaw crusher, crushes on full cycle, it has a much
higher capacity than a jaw crusher of the same gape, and is usually
favoured in plants handling very large throughputs.
• Crushers range in size up to gapes of 1830 mm and can crush ores with
top size of 1370 mm at a rate of up to 5000t h -1 with a 200 mm set.
• Gyratory crushers can be fed from trucks.
• The outer shell of the crusher is constructed from heavy steel casting or
welded steel plate, cast-iron (Ni-hard) liners or concaves are bolted to
the shell. The head is one of the steel forgings which make up the
spindle. The head is protected by a manganese steel mantle
• Gyratory crushers are rated according to their the gape with and bottom
diameter of head., which is the distance between the jaws at the feed opening.
For example, an 1070x1800 mm crusher has a gate width of 1070 mm (A) and
head diameter of 1800 mm (B).
GYRATORY crusher ile ilgili görsel sonucu
GYRATORY crusher ile ilgili görsel sonucu
GYRATORY crusher ile ilgili görsel sonucu
GYRATORY crusher ile ilgili görsel sonucu
GYRATORY crusher ile ilgili görsel sonucu
GYRATORY crusher ile ilgili görsel sonucu
gyratory crusher ile ilgili görsel sonucu
COMPARISION OF JAW CRUSHER AND GYRATORY CRUSHER
• Gyratory crushers are, in general, used where high capacity is required. Since they
crush on full cycle, they are more efficient than jaw crushers, provided that the
chamber can be kept full. Jaw crushers tend to be used where the crusher gape is more
important than the capacity. If high capacity is required, then a gyratory is the answer.
If, however, a large gape is needed but not capacity, then the jaw crusher will probably
be more economical, as it is a smaller machine and the gyratory would be running idle
most of the time.
• If feed t/h < 161.7 (gape in metres)2, a jaw crusher is used. Conversely, if the tonnage is
greater than this value, use a gyratory crusher.
• In gyratory crusher, feeding can be applied from trucks. For feeding to jaw crushers,
heavy duty feeders are needed.
• Jaw crushers perform better than gyratories on clayey, sticky and plastic material, due
to their greater throw. Gyratories have been found to be particularly suitable for hard,
abrasive material.
• Gyratory crusher tends to give a more cubic product than jaw crushers if the feed is
laminated or "slabby".
• The capital and maintenance costs of a jaw crusher are slightly less than those of the
gyratory, but installation costs are lower with the gyratory, since it occupies about two-
thirds the volume and has about two-thirds the weight of a jaw crusher of the same
capacity.
• The jaw crusher can be sectionalised easily. Thus, because of the need for
transportation to remote locations and for underground use, it may be advantageous to
install jaw crushers.
SECONDARY CRUSHERS
• Secondary crushers take the primary crushed ore as feed, the
maximum feed size will normally be less than 15 cm in
diameter.
• Their purpose is to reduce the ore to a size suitable for grinding.
• The bulk of secondary crushing of metalliferous ores is
performed by cone crushers, although crushing rolls and
hammer mills are used for some applications.
• There may be a tertiary stage before the material is passed to
the grinding mills. Tertiary crushers are, to all intents and
purposes, of the same design as secondaries, except that they
have a closer set.
CONE CRUSHER
• The cone crusher is a modified gyratory crusher. The essential difference is that
the shorter spindle of the cone crusher is not suspended, as in the gyratory, but is
supported in a curved, universal bearing below the gyratory head or cone.
CONE crusher ile ilgili görsel sonucu
[Belgeden bir alıntı
[Belgeden
veya ilginç birbir
alıntı veya
noktanın özetini yazın.
ilginç
Metin bir
kutusunu belge
noktanın
içinde herhangi bir
özetini yazın.
yere
Metin
konumlandırabilirsiniz
kutusunu
. Kısa alıntı metin
belge içinde
kutusunun
herhangi bir
biçimlendirmesini
yere
değiştirmek için Metin
konumlandır
Kutusu Araçları
abilirsiniz.
sekmesini kullanın.]
Kısa alıntı
metin
kutusunun
biçimlendirm
esini
değiştirmek
için Metin
Kutusu
Araçları
cone crusher animation ile ilgili görsel sonucu
• Since a large gape is not required, the crushing shell flares outwards which allows for
the swell of broken ore by providing an increasing cross-sectional area towards the
discharge end.
• The flare of the shell allows a much greater head angle than in the gyratory crusher,
while retaining the same angle between the crushing members. This gives the cone
crusher a high capacity, since the capacity of gyratory crushers is roughly proportional
to the diameter of the head.
• Cone crusher is rated by the diameter of the cone.
• The fast discharge and non-choking characteristics of the cone crusher
allow a reduction ratio in the range 3-7 but this can be higher in some
cases.
• Cone crushers have range in size from 559mm to 3.1 m
• Two 3.1 m Symons cone crushers, each with capacities of 3000t h -1, have
been installed in a South African iron-ore plant.
• The throw of cone crushers can be up to five times that of primary
crushers, which must withstand heavier working stresses. They are also
operated at much higher speeds. The material passing through the crusher
is subjected to a series of hammer-like blows rather than being gradually
compressed as by the slowly moving head of the gyratory.
• The Symons cone crusher is the most widely used type of cone crusher. It
is produced in two forms: the Standard for normal secondary crushing and
the Short-head for fine, or tertiary duty. They differ mainly in the shape of
their crushing chambers.
• The Standard cone has "stepped" liners which allow a coarser feed than in
the Short-head. They deliver a product varying from 0.5 to 6cm. The
Short-head has a steeper head angle than the Standard, which helps to
prevent choking from the much finer material being handled. It also has a
narrower feed opening and a longer parallel section at the discharge, and
delivers a product of 0.3-2.0 cm.
symons cone crusher SHORT HEAD ile ilgili görsel sonucu
ROLL CRUSHER
Roll crushers, or crushing rolls, are still used in some mills, although they have been
replaced in most installations by cone crushers. They still have a useful application in
handling friable, sticky, frozen, and less abrasive feeds, such as limestone, coal, chalk,
gypsum, phosphate, and soft iron ores. The mode of operation of roll crushers is
extremely simple, the standard spring rolls consisting of two horizontal cylinders
which revolve towards each other. Roll crushers are also manufactured with only one
rotating cylinder, which revolves towards a fixed plate. Other roll crushers use three,
four, or six cylinders.
The great disadvantage of roll crushers is that, in order for reasonable reduction ratios
to be achieved, very large rolls are required in relation to the size of the feed particles.
They therefore have the highest capital cost of all crushers. Reduction ratios greater
than 4:1 are rarely used.
Feeding
GYRATORY crusher ANİMATİON ile ilgili görsel sonucu
Product
Feeding
Productc
t
Feeeding
Product
• Toothed Roll Crusher
roll crusher working principle ile ilgili görsel sonucu
IMPACT CRUSHER
In this class of crusher, comminution is by impact rather than compression, by sharp blows
applied at high speed to free falling rock. There is an important difference between the
states of materials crushed by pressure and by impact. There are internal stresses in
material broken by pressure which can later cause cracking. Impact causes immediate
fracture with no residual stresses. This stress-free condition is particularly valuable in
stone used for brick-making, building, and roadmaking. Impact crushers, therefore, have a
wider use in the quarrying industry than in the metal-mining industry. Impact crushers are
also favoured in the quarry industry because of the improved product shape. Due to the
high rate of wear on these machines (wear can be taken up by moving the hammers on the
pins) they are limited in use to relatively non-abrasive materials. They have extensive use
in limestone quarrying and in the crushing of coal. A great advantage in quarrying is in the
fact that they produce a very good cubic product.
GYRATORY crusher ANİMATİON ile ilgili görsel sonucu
GYRATORY crusher ANİMATİON ile ilgili görsel sonucu
Large impact crushers will reduce 1.5 m top size run-of-mine ore to 20 cm, at capacities of
around 1500th -1, although crushers with capacities of 3000t/h have been manufactured.
Since they depend on high velocities for crushing, wear is greater than for jaw or gyratory
crushers. Hence impact crushers should not be used on ores containing over 15% silica.
However, they are a good choice for primary crushing when high reduction ratios are
required (the ratio can be as high as 40:1) and a high percentage of fines, and the ore is
relatively nonabrasive.
Hammer mill is a kind of impact crusher. The hammers are made from manganese steel
or, more recently, nodular cast iron, containing chromium carbide, which is extremely
abrasion resistant. The breaker plates are made of the same material. The hammers are
pivoted so that they can move out of the path of oversize material, or tramp metal,
entering the crushing chamber. Pivoted hammers exert less force than they would if
rigidly attached, so they tend to be used on smaller impact crushers or for crushing soft
material. The hammers can weigh over 100 kg and can work on feed up to 20 cm. The
speed of the rotor varies between 500 and 3000rev/ min.
VERTICAL SHAFT IMPACTOR
• The vertical-shaft impactor can be considered a ‘stone pump’ that
operates like a centrifugal pump. The material is fed through the
centre of the rotor, where it is accelerated to high speed before being
discharged through openings in the rotor periphery. The material is
crushed as it hits the liners of the outer body at high speed and also
due to the rock-on-rock action.