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PROCESSING
THE ART OF CRUSHING
Machines
&
Processes
Products
Raw material?
How big? (Size of rawmaterial)
How much? (Capacity)
Final products?
Contamination?
Feedcurves
Max Topsize
Impact Work index (Wi)
Abrasion index (Ai)
Type of rock / geology
Density
– Wi measured x B.D./1.6 = Wi real
Moisture
Contamination
British norms L
3
NORMS
German norms
French norms
Slots
“US” norms
Impact crusher
r 9 High reduction ratio
she
9 Low investment
cr u
r
s he 9 High wear cost
c ru
act
/ C
a w
J
Jaw / Cone crusher
9 Low reduction ratio
Total cost
9 Big investment
9 Low wear cost
Production (tons)
Quarry Academy 2005
Primary Crusher station
¾ Continuous process
¾ Conveyable product
¾ Remove Contaminations
1 feeder
1 feeder 3 feeders
4 feeders
2 feeders
Hydrocone
S4800 C
Alt.
Hydrocone
C.S.S: 150-175 mm H6800 CXD
Railway
0-18 0-35 flakes Ballast
¾ Calibrated product
¾ Higher reduction ratio.
¾ Better cubical shape
¾ More machines
¾ Lower capacity
¾ discrepancy:
4/5 – Short jobs
– Prod of sand
Demands:
Optimised feed
Capacity
Product shape
90
Feed
80 H3800 F
70
60
%-Passing
50
40
30
20
10
0 Aperture (mm)
0,1 1 10 100
Good shape product area
¾ Good Flexibility
¾ Higher crushing forces
¾ Limited good shape range
¾ Uniform reduction ratio
90
Feed
80 RP108
70
60
%-Passing
50
40
30
20
10
0 Aperture (mm)
0,1 1 10 100
Good shape product area
¾ Better shape
¾ Uneven Reduction
¾ Limited topsize capacity
¾ High fines production
Quarry Academy 2005
HYDROCONE – MERLIN RP
100
60
C.S.S: 16 mm
%-Passing
50
ASR Plus
40
30
20
10
0 Aperture (mm)
0,1 1 10 100
1 5 25 100
Movements/Year
Wheel-mounted
Track-mounted
1 10 50
Hours
300
250
200
150
100
10 20 30 40 50 60
Machine Weight (Tonnes)
Wheel Loader
Excavator
Bin with
Hydrocone Feeder
Feed station H-4800 EC
Jawmaster
JM 1108 HD
Screen
CS 86-IV
Bin with
Hydrocone Feeder
S-3800 EC
Feed station
Hydrocone
Jawmaster H-3800 M
JM 1108 HD
Screen
CS 86-II
Screen
CS 86-II
0-4 4-8 8-16 16-32
Hydrocone Screen
S-3800 EC CS 86-II
Feed station
Hydrocone Hydrocone
H-3800 MF H-3800 M
Hydrocone
S-3800 EC
Feed station Screen
CS 126-II
Bin with
Jawmaster Feeder
JM 1108 HD
VSI Hydrocone
H-3800 M
Hydrocone
S-4800 C
Jawmaster
JM 1312 HD
Hydrocone
H-4800 M
EFC EFC
0-10
2x Hydrocone
H-4800 EF
Quarry Academy 2005
Quarry Academy 2005
Quarry Academy 2005