Crushing 101- Let s not make this more complicated than it really is

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1 Crushing 101- Let s not make this more complicated than it really is Mark Krause Managing Director McLanahan Corp 1

2 Crushing 101 Mark Krause #T31 Tuesday 1:00 2:30 #F31 Friday 1:00 2:30 To earn Professional Development Hours (PDH): 1. Log into the CONEXPO CON/AGG App 2. Go to this session in Schedule 3. Check In using the Slider in Session Detail 2

3 MSHA: Mining deaths drop to all-time lows Preliminary Mine Safety & Health Administration (MSHA) data indicate that 28 miners died in 2015 in work-related accidents at U.S. mines. That figure is down from 45 in The 28 represent the fewest number of mining deaths ever recorded and the first year that mining deaths dropped below 30, according to MSHA. Seventeen of the deaths occurred in metal and nonmetal mines. Nevada had the most with four, followed by Missouri with two, and one each in California, Florida, Georgia, Iowa, Massachusetts, Nebraska, New Hampshire, North Dakota, Ohio, Pennsylvania and Virginia. The leading cause of death in these mines was machinery accidents, which led to five deaths. Falling materials killed four miners. The other 11 deaths occurred in coal mines three in Pennsylvania; two each in Kentucky, Illinois and West Virginia; and one each in Alabama and Virginia. The leading causes were powered haulage and machinery accidents, which accounted for six deaths. 3

4 The best and easiest way to help your company s bottom line is to be safe! Workplace injuries, illnesses and fatalities cost more than $170 billion per year in the U.S. Beyond the immediate financial impact, more than one million injuries and 2.3 million cases of ill health are experienced by workers in an average year, contributing to a loss of about 40 million working days. Overall, nearly 50 workers are injured every minute of every work week, and 17 will die on the job every day. 4

5 Our Challenge Making the right choice.. Making little ones out of big ones 5

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7 Plant Optimization The Goal is to Produce Required Aggregate Sizes at the Lowest Cost per Ton! 1) Maximize the Tons per Man Hour that can be produced within the existing processing circuit 2) Consistently operate all equipment at it s maximum design capacity 3) Make the sizes that you need within the production circuit 4) Avoid re handling finished sized aggregates 7

is hit or thrown Horizontal Shaft Impactor Vertical Shaft impactor Hammermill

8 Quick review of crusher types Compression Crushing Material is squeezed between two surfaces Gyratory crusher Jaw crusher Cone crusher Impact Crushing Material is hit or thrown Horizontal Shaft Impactor Vertical Shaft impactor Hammermill Attrition Material is worn down via a rubbing action Rod Mill Ball Mill Autogenous Mill 8

Crushing 101-Three types of crushing Compression- reduces material as it advances downward through the chamber by means of squeezing (compression)

9 Crushing 101-Three types of crushing Compression- reduces material as it advances downward through the chamber by means of squeezing (compression) the material between a moving piece of steel and a stationary. Output is changed by adjusting the gap setting at the discharge point of the crusher. 9

10 Crushing 101-Types of compression crushing Jaw Crusher Gyratory Cone Crusher Standard Head Short Head Roll Crusher Dual and Triple 10

11 Crushing 101-Three types of crushing Impacting- uses the theory of mass and velocity to reduce the feed material. Generally speaking the faster the speed of the crusher, the finer the output. The first break of the feed will occur along the natural fracture line of the material while the second break will be perpendicular to the first break. 11

12 Crushing 101-Types of impact crushing Horizontal Shaft Impact New Holland Andreas Vertical Shaft Impact Hammermill CageMill 12

Crushing 101-Three types of crushing Milling- uses the theory of mass and velocity combined with a milling or grinding action to reduce the feed

13 Crushing 101-Three types of crushing Milling- uses the theory of mass and velocity combined with a milling or grinding action to reduce the feed material. Usually used in softer and less abrasive materials. Also thought to create a higher quantity of fines. Provides high reduction ratio. 13

14 Crushing 101- As the topic suggests our focus today is on crushing. We cannot properly look at crushing 101 without including screening. Screening is so important it gets a session unto itself. 14

15 Crushing 101-Product Specifications Size #4(11/2) ASTM Requested Size #56 (1) ASTM Requested Size #6 (3/4) ASTM Requested Percent Used Material Spec Band Control Material Spec Band Control Material Spec Band Control Sieve Gradation #4 Band Gradation #56 Band Gradation #6 Band 1-1/2" " /4" /2" /8" No No. 8 2 No No No No No

16 Crushing 101-Calculating Reduction Ratio Feed Output 6 100% 5 97% 4 80% 3 70% 2 36% 100% 1-1/2 10% 98% 1 5% 90% ¾ 80% ½ 68% 3/8 58% Using the P80 (80% passing) method Using in/out method = 6 2 = 3 to 1 reduction Using P80 method = 4.75 = 5.3 to 1 reduction 16

17 Crushing 101-Basic Crusher Guide Crusher Type Maximum Feed Size Product Size Jaw Crusher 80% of opening generally x 0 Gyratory Feed opening reliant upon x 0 size of crusher Standard Head Cone 14 ¾ to 4 Horizontal Shaft Impactor 40 (primary) 6 16 (secondary) ¾ to 4 Hammermill 8 4M to 1-1/2 Short Head Cone 8 ¼ to 5 Vertical Shaft Impactor 6 4M to 1-1/2 17

18 Primary Gyratory Crusher 500 HP to 1400 HP 263,000 lbs.. To 1,297,000 lbs.. Naming = Feed Opening x Head Diameter Models 42x65 50x65 54x75 62x75 60x89 60x110 Large total feed area (both sides of spider) Feed Opening 18

19 Basic Gyratory Eccentric causes the main shaft with the head and mantle attached to move back and forth towards stationary concave liners. Rock is compressed/crushed between mantle and concaves Spherical Spider Bushing Concave Liners Head and mantle Hydroset System 19

20 Gyratory Operating Principles Gradation is controlled by adjusting the spacing between the mantle and the concaves at their closest point Main shaft is supported by a hydraulic system that provides adjustment and release when uncrushables enter the chamber. 20

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22 Jaw Crusher 22

23 Basic Jaw Crusher GENERAL The Size of a Jaw Crusher is defined by Feed opening IE: 42x54 = 54 wide by 42 depth Maximum feed size in R.O.Q. feed : 80% of depth IE : 42 x 54 Jaw Crusher Depth mm x 80% Maximum Lump = 34 (854 mm) 23 23

24 Basic Jaw Crusher Eccentric main-shaft causes the pitman to move back and forth towards stationary jaw die. Rock is compressed/crushed between stationary and moving jaw dies Stationary jaw Moving jaw Toggle seat Toggle plate 24

25 Jaw Crusher Operating Principles Gradation is controlled by adjusting the spacing between the dies at their closest point Toggle Plate is held in place by spring and supports lower portion of the pitman Toggle plate will bend/break first to protect crusher from damage Toggle plate 25

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28 Sizer or Toothed Roll Video 28

29 Horizontal Shaft Impact Crushers 29

Basic Impacting Feed material is reduced by : Initial impact with hammer ( 40-60 %) Impact

30 Basic Impacting Feed material is reduced by : Initial impact with hammer ( %) Impact with breaker plates ( 30-40%) Inter-particle collisions Attrition Breaker Plates Rotor Blow Bars 30

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33 HSI Basics 33

34 Blow Bar Condition must be checked 34

35 Houston we have a problem! 35

36 Cone Crusher Review 36

Basic Cone Crusher Compression Crusher Drive turns horizontal-countershaft Pinion-gear on countershaft rotates eccentric-gear Eccentric rotation causes the main-shaft and the head to wobble

37 Basic Cone Crusher Compression Crusher Drive turns horizontal-countershaft Pinion-gear on countershaft rotates eccentric-gear Eccentric rotation causes the main-shaft and the head to wobble Rock is compressed/crushed between mantle and concaves Gradation is controlled by adjusting the spacing between the mantle and concave at their closest point ie: closed side setting (css) 37

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40 Cone Crusher Review 40

41 Correct Feed Distribution A segregated feed distribution will lead to : ring bounce poor liners wear more oversized products poor particle shape Coarse fresh feed Fine recirculation feed 41

42 Correct Feed Distribution An off centered feed distribution will lead to : ring bounce poor liners wear poor particle shape 42

43 Reactive Maintenance HP400 Bushing Failure Discovered after crusher locked down during production shift. Safety interlock failed and operator attempted to manually bypass the control. Major parts damage. (bushings, eccentric, mainshaft) Extensive downtime, lost production of critical product. (40hrs at 100 $20/ton) Non-budgeted failure. 43

Proactive Maintenance 1560 Omnicone Bushing Failure Discovered during scheduled PM Service. Temperature Monitor trending higher. Damage not severe.

44 Proactive Maintenance 1560 Omnicone Bushing Failure Discovered during scheduled PM Service. Temperature Monitor trending higher. Damage not severe. Only bushing was damaged. No other parts were damaged. No production lost. No significant overage of budgeted costs by discovering failure early. 44

45 VSI Crushers 45

46 HOW IT WORKS 46

47 Vertical Shaft Impact Crushers Shoe Anvil (Steel on Steel) Indicates that the crusher is for large feed sizes and/or coarse products. The crusher will utilize an impeller table that typically incorporates three to six impellers. The top size to these machines will be reduced to control the reduction ratio. ROR (Rock on Rock) This machine will be using an enclosed rotor with a rock shelf. This configuration is typically used in abrasive or shaping applications with a feed size less than 75mm. ROS (Rock on Steel) This machine will be using an enclosed rotor and anvils. This configuration is typically used in abrasive applications with a feed size less than 75mm, requiring maximum reduction. 47

48 Shoe Table and Anvil Ring 48

49 VSI Rotor Configurations Closed Rotor (Autogenous) Feed size up to 50mm Lower wear costs Rock on Rock 49

50 VSI Configurations Rock Box Lower reduction Shaping Lower wear costs Rock on Rock Higher power draw 50

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52 Factors Affecting Cone Performance Factors affecting a compression crusher s performance Speed Setting Stroke 52

53 Affect of Speed on Compression Performance: Within the first 10% of slow down we will actually see an increase in the overall throughput of the machine. It is a balancing act of change in reduction and output gradation and throughput of the machine. 53

54 Cone Crusher Review Speed choice Low speed : Secondary applications, after a jaw crusher Medium speed : Gravel applications with coarse feed Standard speed : Tertiary applications (0 x ½ ) High speed : Sand applications (4M or less...) Speed ranges : Smaller Head Diameters : RPM Larger Head DIameters : RPM 54

55 Speed Change RPM = 950, 32mm RPM = 850, 32mm % Passing # 16 # 4 3/8" 7/16" 1/2" 9/16" 3/4" 1" 1 1/4" 1 1/2" size 55

56 Affect of Setting on Compression Performance: A closer setting will yield a finer output gradation with a lower throughput capacity Discharge gradation (percent passing) Mesh Size Closed Discharge Setting (mm and inches) 13mm 16mm 19mm 22mm 25mm 32mm (1 38mm (1 45mm 51mm (1/2") (5/8") (3/4") (7/8") (1") 1/4") 1/2") (1 3/4") (2") 90mm 3 1/2" mm 3" mm 2" mm 1 1/2" mm 1 1/4" mm 1" mm 3/4" mm 5/8" mm 1/2" mm 3/8" mm 1/4"

57 Affect of Setting on Compression Performance: A closer setting will yield a finer output gradation with a lower throughput capacity STPH Closed Side Setting (Capacities may vary +/ 15%)** Model MAX Feed Size* HP LBS 3/8" 1/2" 5/8" 3/4" 7/8" 1" 1 1/4" 1 1/2" 1 3/4" 2" MSP100 C 5 3/8" , MSP 100 M 4 1/8" , MSP 200 C 7 1/4" , MSP 200 M 5 3/4" , MSP 200 F 2 3/4" , MSP 300 C 7" , MSP 300 M 5 3/8" , MSP 300 F 4" , MSP 400 C 7 1/4" , MSP 400 M 6 3/4" , MSP 400 F 5 5/8" ,

58 Affect of Stroke on Cone Performance: As we decrease the stroke of the cone crusher, we will see a reduction in fines production. Or a reduction in the reduction. It is a balancing act of change in reduction and output gradation and throughput of the machine. Lowering the stroke, lowers the throughput, but lowering the stroke can increase the mechanical advantage of the crusher. 58

59 Affect of Stroke on Compression Performance: Higher stroke means higher nominal capacity : the relation is linear : i.e. roughly double stroke means double nominal capacity Higher stroke also means higher minimum possible setting The motor size selection depends on the stroke with higher stroke your need more power Stroke's effect on output curve is minimal and difficult to perceive. Choke fed cavity, cavity design and speed affect the output curve much more than stroke. 59

60 Factors affecting a HSI crusher s performance Speed Setting 60

61 Factors affecting an Impact crusher s performance Speed 845 RPM 1056 RPM 1268 RPM 1 100% 100% 100% ¾ 97.0% 98.0% 99.0% 5/8 86.0% 90.0% 94.0% ½ 70.0% 76.0% 84.0% 3/8 44.0% 55.0% 66.0% ¼ 30.0% 38.0% 48.0% 4M 19.0% 27.0% 35.0% 8M 11.0% 15.0% 20.0% 16M 8.0% 10.0% 13.0% 30M 6.0% 8.0% 10.0% 50M 5.0% 6.0% 8.0% 100M 4.0% 5.0% 7.0% 200M 3.0% 3.5% 5.0% 61

62 Affect of Speed on Impact Performance: Speed Increase Will make the discharge finer (when speed is to high, penetration decrease and limits the increase in reduction; Will not change the discharge volume; Will decrease the circulating load (as % of new feed rate); Will increase the reduction ratio; Will increase the specific horsepower (per TPH) 62

63 Setting Factors affecting an Impact crusher s performance GAP SETTING (inches) F=10 / R=5 F=8 / R=4 F=6 / R=3 F=4 / R=2 PERCENT PASSING EACH SIZE (Inches) ¾ ½ 3/8 ¼ 1/

64 Affect of # of Bars on Impact Performance: Rotor RPM Crusher output Return Product (1 1/2") 44" 4 bar " 4 x " 3 bar Rotor RPM Crusher output Return Product (1 1/2") 49" 4 x " 3 bar

65 Maintaining Crusher Performance o o o o o o o o o o Understand the crusher design limits ie: volume, power, force Keep a daily operator s log sheet (production, amp draw, issues, sounds) Maintain a proper blended feed to the center of the crusher Minimize feed segregation Select the proper crusher liner Change liners when a 10% decrease in productivity is noticed Maintain proper feed top size to the crusher Check the crusher closed side setting regularly Maintain proper drive belt tension Maintain crusher lubrication system 65

66 Creating A Rock Solid Maintenance Program Difference Between Re Active & Pro Active Maintenance Programs Reactive Maintenance consists of repairing equipment after it has broken down. This will be considered the exception rather than the norm. Pro active Maintenance will drive our maintenance program and will consist of activities used to identify and repair equipment before it breaks down. Performing equipment maintenance according to the manufacturer s schedule or best practices will be a priority. Date 66 66

67 Creating A Rock Solid Maintenance Program What a Pro active Maintenance Program Achieves More Effective Maintenance Spending Improved Operating Performance Increased Uptime and Reduction in Lost Tonnage Lower Total Operating Costs Extend Equipment Life Increased Safety Environmental Stewardship Date 67 67

68 Ten things I know about you. 1. You are reading this. 2. You are human. 3. You cannot say the letter ''P'' without separating your lips. 4. You just attempted to do it. 5. You are laughing at yourself. 6. You have a smile on your face and you skipped No You just checked to see if there is a No You laugh at this because you are a fun loving person & everyone does it too. 9. You will have fun showing this column to someone else. 68

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70 Questions? Please complete the session evaluation on the CONEXPO CON/AGG Mobile App Go to Schedule and Select This Session 70

Pioneer Jaw. Large Flywheels. Hydraulic Dual Wedge CSS Adjustment. Class-Leading Stroke. Jaw Die Retention Wedge. Wear Parts.

Pioneer Jaw. Large Flywheels. Hydraulic Dual Wedge CSS Adjustment. Class-Leading Stroke. Jaw Die Retention Wedge. Wear Parts. Crushing Pioneer Jaw The Pioneer Series from Kolberg-Pioneer, Inc. represents the very latest in jaw crusher technology. Engineered to be the highest capacity jaw crusher on the market, the Pioneer Jaw