Crushing 101: Machinery Types

1. Primary

2. Secondary, Tertiary,

Quaternary

3. Milling & Grinding

Crushing 101: Compression, Cone

1. Compression Crusher

2. Wide Range of Applications

1.Standard – Large Coarse

2.Short Head – Coarse to Fine

3. Screening ahead of the

machine is done typically with a

Screen

4. Should ALWAYS be choke fed

and controlled

Crushing 101: Parameters

Crushing Force

Volumetric Capacity

Horsepower

Crushing 101: Parameters

Crushing Force

1. Reduction Ratio

2. Work Index of the Rock

3. Stage of Crushing

4. Geometry of Cavity

5. Feed and Feed Distribution

Crushing 101: Parameter – Crushing Force

Hydroset Drops

Ring Bounces

Crushing 101: Parameters

Volumetric Capacity

1.Throw

2.Speed

3.Reduction Ratio

4.Liner Configuration

5.Closed Side Setting

6.Head Angle

7.Feed and Feed Distribution

Crushing 101: Parameter – Volumetric Capacity

Crushing 101: Parameter – Volumetric Capacity

New Liners

Opening: 5.25”

Worn Liners

Opening: 3.25”

Crushing 101: Parameter – Volumetric Capacity

New Liners

Opening: 5”

Worn liners

Opening: 4-3/4”

Crushing 101: Parameter – Volumetric Capacity

Crushing 101: Parameters

Horsepower

1.Selected Parameter

Productivity Requirements

Manufacturers Recommendations

2. Influences

Feed Distribution

Reduction Ratio

Crushing 101: Parameter – Horsepower

Symons 4-1/4' 150 HP

Symons 5-1/2' 300 HP

Symons 7' 400-500 HP

1560 Omnicone 300 HP

Metso HP300 300 HP

Metso HP400 400 HP

Metso HP500 500 HP

Sandvik CH440 300 HP

Sandvik CH660 450 HP

Crushing 101: ExpectationsManufacturers Manual

Crushing 101: ExpectationsCharts

Percent Passing Capacity

CS Setting TPH

4" 3" 2" 1-1/2" 1" 3/4" 1/2" 3/8" 1/4" #4 #8

2" 100 92 60 40 22 16 11 8 6 4 2 495

1-1/2" 100 84 60 33 22 14 11 7 6 3 455

1-1/4" 100 94 76 43 29 17 13 9 7 4 390

1" 100 92 60 40 22 16 11 8 4 370

3/4" 100 84 60 33 22 14 11 6 336

1/2" 100 92 60 40 22 16 8 277

Symons 5-1/2' Crushers

Crushing 201: Modeling Aggflow

Crushing 201: Modeling Aggflow

Crushing 201: Modeling Aggflow

Crushing 201: Modeling Comparison

AggFlow OEM Model

1 ½” 100 100

1” 96 95.5

3/4” 80 82.7

1/2” 51.4 56.5

3/8” 37 41.2

#4 20 23.5

Crushing 201: Modeling Comparison

AggFlow OEM Model Actual

1 ½” 100 100 100

1” 96 95.5 96.4

3/4” 80 82.7 80

1/2” 51.4 56.5 48.6

3/8” 37 41.2 37.9

#4 20 23.5 21.1

Crushing 301: Advanced Modeling Software

Crusher specific focus• Requires existing performance data

• Chamber arrangement

• Throw

• CSS

• Feed gradation

• Discharge gradation

• Model adjusts expectations based on actuals

Crushing 301: Advanced Modeling Software

Before Calibration After Calibration

Crushing 301: Advanced Modeling Software

Crusher specific focus• Requires existing performance data

• Chamber arrangement

• Throw

• CSS

• Feed gradation

• Discharge gradation

• Model adjusts expectations based on actuals

• Crusher set-up can be modified - yield

comparison to original data• Gradations

• Crusher Parameters (TPH, HP, CF)

Crushing 301: Modeling Manufacturer’s Software

Crushing 301: Modeling Manufacturer’s Software

Crushing 301: Modeling Manufacturer’s Software

Crushing 301: Conclusions

1. Effective crushing is an vital component of a profitable

plant

2. Sampling procedures and data collection are essential

components of intelligent modeling

3. OEM software packages include PI to enhance modeling

accuracy

4. Utilization of all “tools” is necessary to ensure the

greatest probability of accuracy in your project

5. The only constant is change – modeling there to help you

adapt quickly and with improved accuracy

Thank You