Quarry Academy 2005

SANDVIK ROCK PROCESSING

THE ART OF CRUSHING

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Feed

MachinesMachines&&

ProcessesProcesses

Products

What is a C&S system ?

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Super Quarries & Mines 600-2000 tphMedium Quarries 300-600 tphSmall Quarries & Mobiles 150-300 tph

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THE ART OF CRUSHING

Raw material?How big? (Size of rawmaterial)How much? (Capacity)Final products?Contamination?

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THE ART OF CRUSHING

FeedcurvesMax TopsizeImpact Work index (Wi)Abrasion index (Ai)Type of rock / geologyDensity

– Wi measured x B.D./1.6 = Wi realMoistureContamination

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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 !

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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

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Product properties

NORMSBritish norms

Slots

L

L3German norms

“US” norms

French norms

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Reduction Ratio (1)

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

80

80

PF

=Reduction Ratio

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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

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Reduction Ratio (3)

P80 Feed: 400 mmP80 Products: 16 mm

Min. required plant reduction ratio:

2-stage Impact Plant:

10x7=70OK, Only for Ai

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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 / C

one cru

sher

Impa

ct c

rush

er

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Primary Crusher station

Continuous processConveyable productRemove Contaminations

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Primary Crusher station

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Primary Crusher station

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Primary Crusher station

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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

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Intermediate Storage (2)

1 feeder

2 feeders

3 feeders

4 feeders

1 feeder

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Secondary Circuit

Big feed opening

High capacity

Controlled feed

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Secondary Crushers

Hydrocone H / S Secondary Impactor

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Production of railway ballast

C.S.S: 150-175 mm

HydroconeS4800 C

HydroconeH6800 CXD

Alt.

0-18 0-35 flakesRailwayBallast

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ScreeningOpen / Closed circuit

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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.

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Open Circuit – Examples

Splitting of crusher feed

By-passing fine material

Scalping

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Closed Circuit

Calibrated productHigher reduction ratio.Better cubical shapeMore machinesLower capacity

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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

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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

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Final Crusher

Demands:

Optimised feed

Capacity

Product shape

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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

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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

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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

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Storage at Crusher

Choke fed Crusher;Higher ReductionBetter shape (cubical)Better utilization of mantle and linersBin volume; 5-10 min operation

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Crusher feed

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Process Control

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Stationary / MobileStationary

Long term ContractsValuable productsRange of productsProduction on demandFlexibility with manystagesHigh Production control

MobileContract crushingCrushing at constructionsiteLow product demandsFew productsFlexibility with Fleet

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Mobile Units (1)

Portable Track-mountedWheel-mounted

1 5 25 100Movements/Year

Mobility selection chart

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Mobile Units (2)

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Mobile Units (3)

Portable

Track-mounted

Wheel-mounted

1 10 50

Hours

Dismounting time

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Mobile Units (4)

10 30 40 5020

100

150

200

250

300

60

Machine Weight (Tonnes)

Nom. loading Capacity (m³/h)

Wheel LoaderExcavator

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2-Stage Plant ApplicationExampleCapacity:200 tph

Feed station

JawmasterJM 1108 HD

Bin withFeederHydrocone

H-4800 EC

ScreenCS 86-IV

0-4 4-8 8-16 16-32

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3-Stage Plant ApplicationExampleCapacity: 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

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4-Stage Plant, Cone ApplicationExampleCapacity: 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

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4-Stage Plant, VSI ApplicationExampleCapacity: 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

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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

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Mining Plant ApplicationExample

EFCEFC

JawmasterJM 1312 HD

HydroconeS-4800 C

2x HydroconeH-4800 EF

0-10

HydroconeH-4800 M

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Quarry Academy 2005