CE 3220 13-1 aggregate Production.pdf

8/17/2019 CE 3220 13-1 aggregate Production.pdf

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Aggregate Production


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AGGREGATE

PRODUCTION


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AGGREGATE

PRODUCTION

Four basic functions:

Size reduction - crushing Size separation - screening

Elimination of undesirablematerial - washing

Movement and storage


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Crushers

Crusher Production

Screening

Screen sizing

AGGREGATE

PRODUCTION


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CRUSHERS

Jaw

Gyratory

Cone

Roll

Impact Specialty


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JAW CRUSHERS

Rock flows into the space between

two vertical jaws. One jaw is

stationary. The other jaw movesin an elliptical-downward motion

toward the stationary jaw while

crushing, and upward and awayfrom the stationary jaw allowing

the crushed material to exit.


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JAW CRUSHERS

Moves in anelliptical-

downwardmotiontoward the

stationary jaw whilecrushing


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JAW CRUSHERS

Table 14.3 gives representativecapacities.


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JAW CRUSHERS

Jawcrushers areprimaryunits, thatreceivematerialdirectlyfrom thequarry.


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GYRATORY CRUSHER

Has a gyrating mantle mounted

within

a deepbowl.


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Table 14.4 givesrepresentativecapacities.


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GYRATORY

CRUSHER

Gyratories are

used as primary orsecondary units.


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CONE CRUSHER

Works like a gyratory with aneccentric rotating cone around a

vertical shaft to cause a gyrating

movement of the head.

Differs from a gyratory:

Ø A shorter head

Ø Smaller receiving opening

Ø Higher rotation speed


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GYRATORY CONE

CRUSHERS

Cone shorter head

Gyratory


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GYRATORY CONE

CRUSHERS

Gyratory

Cone smaller

receiving opening


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GYRATORY CONE

CRUSHERSCone higherrotation speed

Gyratory


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ROLL

CRUSHERS


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ROLL CRUSHERS

Roll crushers are used forintermediate stages ofreduction.

Very limited reductioncapability, see Table 14.2,page 411.


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ROLL CRUSHERS

The maximum size stone that may

be fed a roll crusher is directly

proportional to the diameter of therolls. If the stones are too large,

they will not grip the material and

pull it through the crusher.See Figure 14.10, page 421.


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IMPACT

CRUSHERS

Impact breakers

provide acubical product

even with slabby

material.


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IMPACT CRUSHERS

Speed of

rotation is

importantto the

effective

operationof these

crushers.


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SPECIALTY CRUSHERS

Ball Mill

Ball mills use steel

balls to produce fine

material.


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BALL MILL


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PRODUCTION EXAMPLE

A 42X48-in jaw crusher w/ a closedsetting of 3 in. will produce what

tonnage per hr in the following sizeranges of a stone having a unit

weight of 110 lb/cf crushed:

- 2½ in.+

- Between 2½ and 1½ in.

- 1½ in. -


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CRUSHER

PRODUCTION

Table 14.3 gives capacities for

Blake-type jaw crushers.

Table 14.4 for gyratory

crushers.Table 14.5 for cone crushers.


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STEP 1. CAPACITY

OF CRUSHER

42- by 48-in jaw crusher

Closed setting of 3 in.

Capacity of crusher ?


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STEP 1. CAPACITY

OF CRUSHER

42- by 48-in jaw crusher

Closed setting of 3 in.

Capacity of crusherTable 14.3, p. 413

190 tph


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CRUSHER

PRODUCTION

Read the fine print .


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STEP 2. CAPACITY

ADJUSTED

Capacity of crusher 190 tph

Stone unit weight of 110 lb/cf

Unit weight adjustment =

or 1.1

cf lb100

cf lb110

/

/

190 tph 1.1 = 209 tph


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Jaw closed setting, 3 in.

Refer to Figure 14.5, page 415

Horizontal scale is the crusher

setting: Read down the 3 in.line and find the % passing a

2 1/2 and 1 1/2 inches.

STEP 3. SIZE

DISTRIBUTION


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Fig. 14.5, read down the 3” line to the size.

STEP 3 SIZE DISTRIBUTION

Percent

passing

is on

the left

side ofthe

figure.


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Figure 14.5, page 415

Horizontal scale is the crusher

setting: Read down the 3 in.

line and find the % passing at

2 1/2 and 1 1/2 inches.2½ in. 73 % passing

1½ in. 46 % passing

STEP 3 SIZE

DISTRIBUTION


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STEP 4. QUANTITY

Output of crusher, 209 tph

Size,

in.

%

assin

% in

ran e

Total

out ut

Produced

tph

Over 2½ 100-73 27 209 56.4

2½- 1½ 73-46 27 209 56.4

1½- 0 46-0 46 209 96.2


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STEP 4. QUANTITY

Output of crusher, 209 tph

Size,

in.

%

assin

% in

ran e

Total

out ut

Produced

tph

Over 2½ 100-73 27 209 56.4

2½- 1½ 73-46 27 209 56.41½- 0 46-0 46 209 96.2

Total 100 209


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STEP 5. CHECK

Check your work, always total

Percent must come to 100%

Output must equal quantityOutput of crusher, 209 tph

2½ - 1½ 73-46 27 209 56.41½- 0 46-0 46 209 96.2

Total 100 209

OKOK


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ROCK TYPE EFFECT

Is there data availableconcerning rock type?


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ROCK TYPE EFFECT

Adjustment factors for rock type,limestone as a production base

Rock Factor

Limestone 1.00

Dolomite 1.00

Gneiss 0.95Slate 0.90

Granite 0.90 coursed rained


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ROCK TYPE EFFECT

Rock Factor

Chert 0.80

Quartzite 0.80Rhyilite 0.80

Granite 0.80 fine grained

Diorite 0.80

Basalt 0.75


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ROCK TYPE EFFECT

tph20911tph190 .

If the rock in the previous example

was limestone the 209 tph is correct.

However, consider that it is a diorite.

What would be the production?tph16780tph209 .


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EXAMPLE No. 2

Select a jaw crusher for

primary crushing and a roll

crusher for secondarycrushing to produce 110 tons

per hour of limestone rock.

The maximum-size stone from

the quarry will be 16 in.


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EXAMPLE No. 2

The stone is to be crushed tothe following specifications:

Passing Retained on Percent

2½ 100

2½ 1¼ 40-60

1¼ ¾ 18-30

¾ ¼ 15-25

¼ 0 10-20


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STEP 1 Select a Jaw

Crusher

The maximum-size stone from

the quarry will be 16 in. Minimum top width (opening)

of the jaw crusher:

16 in. + 2 in. = 18 inches

Text page 412


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Produce 110 tons per hour

of limestone rock. Try a 24 X 36 in. crusher

with a 3 in. closed setting,

114 tph

Table 14. 3

STEP 1 Select a Jaw

Crusher


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Fig. 14.5, read down the 3” line to thesize. Percent passing is on the left

side of the figure.

STEP 2 Size Distribution

Size % passingOver 2½ 100-73

2½-1¼ 73-39

1¼-¾ 39-26

¾-¼ 26-11

¼-0 11-0


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STEP 2 Size Distribution

Size % assin % in ran e

Over 2½ 100-73 27

2½-1¼ 73-39 34

1¼-¾ 39-26 13

¾-¼ 26-11 15

¼-0 11-0 11


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STEP 3 Output Ranges

Size % ran e Feed t h Size t h

Over 2½ 27 110 29.72½-1¼ 34 110 37.4

1¼-¾ 13 110 14.3

¾-¼ 15 110 16.5

¼-0 11 110 12.1


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Over 2½ 27 110 29.7

2½-1¼ 34 110 37.4

1¼-¾ 13 110 14.3

¾-¼ 15 110 16.5¼-0 11 110 12.1

100% 110 tph

STEP 3 Output Ranges


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STEP 4 Select a Roll

Crusher Size % ran e Feed t h Size t h

Over 2½ 27 110 29.7

2½-1¼ 34 110 37.4

The roll crusher must handle

29.7 plus its own return feed.

See discussion page 430.


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STEP 4 Select a Roll

Crusher The roll crusher must handle

29.7 plus its own return feed.

tph34.90.85

tph29.7

Maximum size from the

jaw crusher 3 in.


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STEP 5 Roll Diameter

Try a 2 in roll crusher setting.

Radius (R) of the rolls = ?

C, roll setting = 2 in.A, maximum feed-size feed = 3 in.

Equation 14.1in.11.8

0.085

1R


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STEP 5 Roll Diameter

The roll diameter must be atleast 23.5 in. and the crusher

must handle 34.9 tph.Table 14.6Try a 24 X 16 crusher with a 2 in.

closed setting -- 115 tph.The first number indicates the

diameter of the rolls.


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STEP 6 Roll CrusherSize Distribution

Size % assin % in ran e

2½-1¼ 100-56 44

1¼-¾ 56-36 20

¾-¼ 36-16 20

¼-0 16-0 16

Fig. 14.5, read down the 2” line to the size.


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STEP 7 Roll Crusher

Output Ranges


2½-1¼ 44 29.7 13.11¼-¾ 20 29.7 5.9

¾-¼ 20 29.7 5.9¼-0 16 29.7 4.8

100% 29.7 tph


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STEP 8 Combined Output

Size Jaw t h Roll t h Total

tph

% in

range

2½-1¼ 37.4 13.1 50.5 461¼-¾ 14.3 5.9 20.2 19

¾-¼ 16.5 5.9 22.4 20

¼-0 12.1 4.8 16.9 15

110 tph 100%

S 9 C


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STEP 9 Check

Requirement

Size Require

ment

% in

range2½-1¼ 40-60 46

1¼-¾ 18-30 19

¾-¼ 15-25 20

ok

okok

Documents

CE 3220 13-1 aggregate Production.pdf