Crushing & Screening

Small Cone Crusher

From the discussion so far it is obvious that two energy factors determine a crusher’s productivity:

(1) Total power drawn affects the quantity produced of any given size or range of sizes.
(2) The energy applied, previously defined as the crusher’s Power Rate (kilowatt hours per ton of feed) will determine the size reduction. This has just been clearly demonstrated by the pendulum tests.

In a previous paper, we have shown that the theoretical forces achieved in a crushing chamber are a direct result of the design geometry and driving power applied to the crusher. Machines from three manufacturers can theoretically apply different crushing forces to processed material, according to Table (1).

The energy intensity within the crushing chamber will differ for various machines. The wide range of eccentric throws and connected powers for various units will give different crushing impacts, which might be considered anologous to the pendulum. The angle of the mantle for the crushing head varies between manufacturers as does the length of the crushing zone from less than 200mm (8 inches) to more than 600mm (24 inches) but as has been indicated from the pendulum size distribution correlations it is the energy input to the feed material which determines the ….Read more

Compression Tests Iron Pellets

A number of compressive tests were conducted on iron ore pellets obtained from the Samarco pelletizing plant located at Ponta Ubu, Brazil. These pellets are formed by disk pelletizing of a mixture consisting of hematite iron ore, (particle size less than 50 µm) water, and lime; they are hardened in a traveling-grate furnace and the nominal diameter varies between 9 and 16 mm. The pellets were tested at ambient temperature in a Tinius-Olsen and in a Riehle universal testing machine. A cross-head velocity lower than the one recommended by I.S.O. (1974) was chosen in order to allow for a greater ability to control the test parameters. The fracture occurred most often along a vertical plane; the sphere was divided into two or more parts by the fracturing process. Figure 4 shows a top view of a fractured pellet, which was divided into two and three parts. A closer observation of the fracture surface with a scanning-electron microscope revealed features that definitely establish, the fracture process as a tensile cleavage-type (Fig, 5) . The fracture is transgranular: it goes through the original hematite particles, that are smaller than 50 µm. These invididual particles can be seen very clearly. The fracture surface ….Read more

Calculating Stockpile Capacity

Calculating Stockpile Capacity: Once the minimum storage capacities which will assure maximum mill output are known, the appropriate stockpile configuration must be determined. Stockpiles fall into two general categories: conical and elongated.

Conical Stockpiles

The conical stockpile is the simplest and easiest to analyze. The total stockpile capacity is given by:

3.14 (Tan A)R³ D/3000 = capacity in metric tons…………………(1)

where: R = stockpile radius in meters
A = angle of repose for material to be stockpiled
D = density of material in kg/m³

Note that the capacity of the conical stockpile varies with the cube of the radius of the pile. This means that the capacity of the conical pile grows very rapidly as the height (and hence the radius of the pile) increases. Increasing the height of the stockpile by 26% results in a doubling of the stockpile capacity. One should also observe at this point that one-half of the capacity of the stockpile is in the lower 1/5 of the pile. This fact will become important later in considerations of live storage capacity.

For many common materials, the angle of repose, A, is about 38 degrees. Substituting this value for A reduces Equation 1 to:

8.18 x 10 -4 ….Read more

How to Size a Cone Crusher Motor

In the cone crusher capacity table, a maximum motor size recommendation is given for any eccentric throw. Only in rare circumstances is this maximum horsepower required; in many installations a motor of only half the rating of the maximum is required.

If there is any doubt regarding the proper motor size, a sample of the material to be crushed should be sent to the Basic Industries Research Laboratory for impact and compression tests, in order that the proper motor size recommendation can be made.

cone-crusher-product-size

Calculate Crusher MOTOR HORSEPOWER

Crushing horsepower required is dependent on the hardness and toughness of the material, the ratio of reduction, product size, and the specific gravity. The following method of approximating horsepower requirements may be used as a guide to proper motor selection and power cost estimation:

  1. Determine the feed size as the size, square mesh in inches, through which 80 percent of the fed material will pass.
  2. Determine the product size as the size, square mesh in inches, through which 80 percent of the product will pass. If screen analysis is not available, use this graph to estimate screen analysis of crusher.
  3. Calculate ratio of ….Read more

Cone Crusher Maintenance

Cone Crusher MaintenanceWOBBLE PLATE FEEDER

A wobble plate feeder is furnished as standard equipment with Fine crushing chambers and as optional equipment with Coarse and Intermediate crushing chambers. It consists of a distributing plate to which a wobbling motion is imparted by the gyrating motion of the main shaft. The feeder is equipped with an enclosing hopper and an adjustable feed pipe for varying the quantity of feed.Cone Crusher Maintenance

SPEED-SET CONTROL

Adjustment for product size and wear is accomplished in a cylinder cast integral with the bottom plate. This cylinder is fitted with a bushing, and the cylinder and piston, sealed at the bottom with an oil-proof packing, form a hydraulic jack which supports the main shaft assembly. Oil is pumped into or out of the cylinder below the piston by means of a hand pump in crusher sizes up to and including 48-in. The larger Hydrocone crushers are equipped with a motor-driven pump operated by push-button control to speed up adjustment.

AUTOMATIC RESETcone-crusher-reset

The Automatic Reset consists of an accumulator charged to a predetermined pressure and connected by flexible hose to ….Read more

Cone Crusher Installation

Tabulated installation drawings show the principal dimensions of the Hydrocone cone crusher, and are sufficiently accurate for preliminary plant layout work. In the smaller sizes (up to 48-in.) the Hydrocone crusher can be discharged vertically downward, or a feed spout can be provided which will convey the crushed product off to one side. Rubber shear mountings permit the crusher to be installed on relatively light concrete foundations, or in the upper structures of a crushing plant.

cone crusher installation Cone Crusher Installation Layout

Cone Crusher Dimensions

cone-crusher-sizes

cone-crusher-size

cone-crusher-dimension

cone-crusher-weight

cone crusher installation

Cone Crusher Parts

Cone Crusher SPIDER CAPcone-crusher-spider-cap

The cast steel spider cap has been designed to serve as a feed distribution plate for coarse materials. It is recessed on the 22, 30, 36 and 48-in. crushers. For fine materials, the wobble plate feeder — a more effective means of distributing the feed — is recommended.

TOP SHELL AND SPIDER

The annealed cast steel top shell and spider are made in one piece. The spider is of the three arm type, equipped with a self-aligning, Scor-Proof plastic ball and socket bearing in crusher sizes 22 to 48-in., and with an hourglass type bearing in sizes above 48-in. The lubricant is sealed in with a garter type oil seal. Bearings can be lubricated from outside the topshell on the 51, 60 and 84-in. crushers through oil holes in spider caps of the four smaller sizes.

Cone Crusher MAINSHAFTcone-crusher-shaft

The mainshaft is of high grade forged steel, annealed for stress relief. It is tapered to gauge for head center fit. The bottom of the shaft is fitted with a polished bronze step bearing. The journal for the spider bearing is formed by a sleeve shrunk on the ….Read more

Vibrating Feeders

Electric Vibrating Feeder

The Electric Vibratory Feeder is a vibrator that provides an extremely efficient, simple and economical solution to the problem of making the most stubborn material flow freely. No longer need there be a sticking together of wet ore in the ore bin, or the arching over and hanging up of materials in hoppers and chutes with resulting lowered operating efficiency.

vibrating ore feeder Syntron Electric Vibrator Operating on Pyramidal Hopper Feeding Ore onto Conveyor Belt—Note Compactness and Rugged Construction

The powerful vibration of the simple, electro-magnetic vibrator is controlled by a separate, wall-mounted “Controller,” which is furnished with each vibrator. The dial rheostat in the controller varies the power of vibration. By merely turning the manual dial rheostat the power of vibration can be turned down to provide the most effective vibration required for the purpose. The controller is in a separate, dust-proof housing, arranged for wall-mounting at any desirable distance away from the vibrating mechanism attached to the bin, hopper, or chute.

These vibrators are furnished in many different sizes. Units are available that range from those equipped to handle large tonnages in ore bins down to the small noiseless model best suited ….Read more

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