Calculation Sheet

Crusher

Data Awal
Capacity 15 ton/h
D roll 300 mm
P roll,Effective 600 mm
P roll,Total 800 mm
N Roll 900 rpm
Motor Power 22 kW
N Motor 1500 rpm
Distance
Bearing to Bearin 1200 mm
Shaf 1470 mm
Gap1 1 mm Gap2 0.7 mm
Material Roll AISI 4340
Rho 7.85 g/cm3 SUmber www.azom.com
Material Bahan
DAP
Bulk Density 0.9 g/cm3 Sumber www.impactfertilisers.com.au/profucts/phosphorus/dap/
Commpressive St 3 Mpa Sumber http://www.lifosa.com/en/diammonium-phosphate
Urea Sumber Karmanshah Petrochemical Company
Crushing Strengt 3 kg
Bulk Density 0.75 g/cm3 Sumber www.impactfertilisers.com.au/profucts/nitrogen/urea/
Feedrate untuk gap(0.6mm)
Q= PI*60*D Roll*P Roll*N Roll*Gap*Bulk Density Material
Q1 DAP 27.48265 t/h Q2 DAP 19.23786 t/h
Q1 UREA 22.90221 t/h . 16.03155 t/h

Gap untuk Feedrate(15 t/h)

Gap = Q/(PI*60*D Roll*P Roll*N Roll*Bulk Density Material)
Gap DAP 0.000546 m
Gap UREA 0.000655 m

Solving for the Crusher Power

Spec Promil Trio Drum Crusher
Power 11+22 kW
Feedrate 15 t/h
Nsf 2
Transmitted kW = Design Hp/Nsf
Transmitted kW motor1 11 kW
Transmitted kW motor2 5.5 kW

Comparing power and feedrate for commercial crusher

P1 and C1 Power and Capacity foP1/C1=P2/C2
P2 and C2 Power and Capacity for a commercial crusher
P1 Motor 1 11 kW
P1 Motor 2 5.5 kW

Solving for Torque

T= P/(2*PI*N*)
T Drum 1 58.35681 N.m dengan asumsi daya pada motor 1 terbagi rata pada drum 1 dan 3
T Drum 2 58.35681 N.m
T Drum 3 58.35681 N.m dengan asumsi daya pada motor 1 terbagi rata pada drum 1 dan 3

Solving for the Force Required

F drum 1 389.0454 N
F drum 2 389.0454 N
F drum 3 389.0454 N
drum 1 dan 3

drum 1 dan 3
Design Horsepower to drive mechanism including losses belt 1
Transmitted power on V belt = Required Power/0.95 According to Morse, p.452, losses in V-belt is 5%
Transmitted power on V belt 11.57895 kW 15.52762 hp
Solving for Design kW
Design kW = Transmitted kW*Nsf
Design kW 23.15789 kW

Using Faires calculation formula and table

Solving for Diameter of the drive and driven sheave
N2*D2=N1*D1
from figure 17.14 Belt selection from horsepower and speed by faires, p.457, we choose section C. with minimum diameter 9 i
Iterasi
N1 1500 rpm 1500 rpm 1500 rpm
D1 9 in 9.5 in 10 in
D2 14 in 16 in 16 in
N2 964.2857 rpm 890.625 rpm 937.5 rpm
FIX D1 9 in
FIX D2 14 in
FIX N1 1500 rpm

Solving for center distance

C = [(D2+D1)/2]+D1 or C=D2, Whichever is longer Eq. by Faires, p. 457
C Perhitungan = 25.5 in
Solve C = 25.5 in The center distance is made adjustable so that the belts can

Solving for belt length

L= [(PI/2)(D2-D1)]+2C+[((D2-D1)^2)/4C]
L= 58.85398 in 1494.891
from table 17.3, standard V-velt length (by Faires p.458) at section C, select C60 with pitch length equal to 62.9 in
pitch length 62.9 in
C Fix = 27.409 in 696.1885
Solving for V-belt speed
Vm = PI*D1*N1/12
Vm = 3534.292 f/min 58.90486 f/sec

Solving for kd (small diameter factor)

D2/D1 = 1.555556
Kd 1.11 From table 17.4, by Faires, p.459

Solving for Rated Hp from equation by Faires, p.456

Rated Hp = [a*((10^3/Vm)^0.09)-(c/(Kd*D1))-e*((Vm^2)/10^6)]*Vm/(10^3)
Rated Hp Constants (Section C)
a= 8.792
c= 38.819
e= 0.0416
Rated Hp = 17.07072 Hp

Solving for Adjusted Power

Horsepower rating must be corrected for length of belt (Ki) and arc of contact (KΘ). Faires,p.457
Adjusted Hp = Ke*Ki*Rated Hp
Ki = 0.82 length correction factor from table 17.6 Length Correction Factors by Fa
(D2-D1)/C = 0.196078
KΘ = 0.970784 arc of contact factor from table 17.5, Atc of Contact Factors. Faires, p.45
Adjusted Power = 13.58903 Hp
Adjusted Power = 10.13334 kW

Solving for Number of Belts

Number of Belts = Design Power / Adjusted Power
2.285318
Number of Belts = 3
use leather material type
C60, pitch length 62.9 in
b 0.875 22.225
t 0.53125 13.49375

Solving for the Tension

F1/F2 = e^(fΘ) Eq.1
f= 0.25 table 16-15 coefficient of friction belt, leather on cast iron dry
Θ (arc of contact) = (180-2*arcsin((D2-D1)/2C))*(pi/180)
2.945199 rad
F1/F2 = 2.088194 Eq.2

Power Transmitted on the V Belt

transmitted Hp ((F1-F2)/550)*Vm
F1-F2 = 144.9828
F1 = 2.088194 F2 Eq.2
F2 = 133.2325 lbf 592.6476 N
F1 = 278.2153 lbf 1237.563 N

Using Martin calculation formula and table

Solving for Diameter of the drive and driven sheave
from Table 2 Martin Stock Drive Selection using Design Power and RPM Shaf
Min D1 = 125 mm
we can use Belt Section SPB and SPA
if we use SPA the capacity of kW per Belt is too low so we must use much more belt number than the SPB. (Shaf Dimension C
Belt Section SPB

N1 1450 RPM 1450 RPM 1450 RPM

D1 140 mm 190 mm 150 mm
D2 224 mm 300 mm 236 mm
N2 906 RPM 918 RPM 924 RPM
Rated Power on Belt 7.32 kW 12.65 kW 8.16 kW
Arc&Length Correction Factor 0.82 0.84 0.86
C-C 337 mm 270 mm 395 mm
Belt Length 1250 mm 1400 mm 1400 mm
3.858106 2.179361 3.299974
Number of Belts 4 3 4

use leather material type

es in V-belt is 5%

with minimum diameter 9 in

PILIH 1
1500 rpm
12 in
20 in
900 rpm

ustable so that the belts can be mounted into the grooves without harmful stretching and so that initial tension can be maintained ( Faires,

a 2
qual to 62.9 in b -55.04602
c 6.25
ngth Correction Factors by Faires, p.459

Contact Factors. Faires, p.459

her on cast iron dry

the SPB. (Shaf Dimension Consideration)

1450 RPM
200 mm
315 mm
 918 RPM
13.69 kW
0.86
412 mm
1600 mm
1.966967
2
n can be maintained ( Faires, p.457)
Design Horsepower to drive mechanism including losses belt 2
Transmitted power on V belt = Required Power/0.95According to Morse, p.452, losses in V-belt is 5%
Transmitted power on V belt 5.789474 kW 7.763812 hp
Solving for Design kW
Design kW = Transmitted kW*Nsf
Design kW 11.57895 kW

Using Faires calculation formula and table

Solving for Diameter of the drive and driven sheave
N2*D2=N1*D1
from figure 17.14 Belt selection from horsepower and speed by faires, p.457, we choose section B
Min D1 5.4 in
Iterasi
N1 1500 rpm 1500 rpm 1500 rpm 1500
D1 5.4 in 5.6 in 6.8 in 7.4
D2 8.6 in 9.4 in 11 in 12.4
N2 941.8605 rpm 893.617 rpm 927.2727 rpm 895.1613
FIX D1 6.8 in
FIX D2 11 in
FIX N2 1500 rpm

Solving for center distance

C = [(D2+D1)/2]+D1 or C=D2, Whichever is longerEq. by Faires, p. 457
C Perhitungan = 15.7 in
Solve C = 15.7 in The center distance is made adjustable so that the belts can be mo

Solving for belt length

L= [(PI/2)(D2-D1)]+2C+[((D2-D1)^2)/4C]
L= 38.27824 in
from table 17.3, standard V-velt length (by Faires p.458) at section B, select B42 with pitch length equal to 43.8 in
pitch length 43.8 in 1112.52 mm
fixed C-C = 18.48202 in 469.4434 mm
Solving for V-belt speed
Vm = PI*D1*N1/12
Vm = 2670.354 f/min 44.5059 f/sec

Solving for kd (small diameter factor)

D2/D1 = 1.617647
Kd 1.11 From table 17.4, by Faires, p.459

Solving for Rated Hp from equation by Faires, p.456

Rated Hp = [a*((10^3/Vm)^0.09)-(c/(Kd*D1))-e*((Vm^2)/10^6)]*Vm/(10^3)
Rated Hp Constants (Section C)
a= 8.792
c= 38.819
e= 0.0416
Rated Hp = 6.965792 Hp

Solving for Adjusted Power

Horsepower rating must be corrected for length of belt (Ki) and arc of contact (KΘ). Faires,p.457
Adjusted Hp = Ke*Ki*Rated Hp
Ki = 0.82 length correction factor from table 17.6 Length Correction Factors by Faires, p
(D2-D1)/C = 0.267516
KΘ = 0.956497 arc of contact factor from table 17.5, Atc of Contact Factors. Faires, p.459
Adjusted Power = 5.463462 Hp
Adjusted Power = 4.074103 kW

Solving for Number of Belts

Number of Belts = Design Power / Adjusted Power
2.842085
Number of Belts = 3
use leather material type
C60, pitch length 62.9 in
b 0.875 22.225
t 0.53125 13.49375

Solving for the Tension

F1/F2 = e^(fΘ) Eq.1
f= 0.25 table 16-15 coefficient of friction belt, leather on cast iron dry
Θ (arc of contact) = (180-2*arcsin((D2-D1)/2C))*(pi/180)
2.873273 rad
F1/F2 = 2.050981 Eq.2

Power Transmitted on the V Belt

transmitted Hp ((F1-F2)/550)*Vm
F1-F2 = 95.94452
F1 = 2.050981 F2 Eq.2
F2 = 91.29045 lbf 406.0802 N
F1 = 187.235 lbf 832.8626 N

Using Martin calculation formula and table

Solving for Diameter of the drive and driven sheave
from Table 2 Martin Stock Drive Selection using Design Power and RPM Shaf
Min D1 = 100 mm
we can use Belt Section SPB and SPZ
if we use SPZ the capacity of kW per Belt is too low so we must use much more belt number than the SPB. (Shaf Dimension C
Belt Section SPB

N1 1450 RPM 1450 RPM 1450 RPM 1450

D1 140 mm 112 mm 118 mm 125
D2 224 mm 180 mm 190 mm 200
N2 906 RPM 901 RPM 901 RPM 906
Rated Power on Belt 7.32 kW 4.6 kW 5.19 kW 5.87
Arc&Length Correction Factor 0.82 0.86 0.86 0.86
C-C 337 mm 470 mm 457 mm 443
Belt Length 1250 mm 1400 mm 1400 mm 1400
1.929053 2.926933 2.594199 2.293678
Number of Belts 2 3 3 3

use leather material type

 PILIH 3

o that the belts can be mounted into the grooves without harmful stretching and so that initial tension can be maintained ( Faires, p.457)

a 2
al to 43.8 in b -37.2027
c 4.41

equation l by faires page 456

ection Factors by Faires, p.459

Factors. Faires, p.459

e SPB. (Shaf Dimension Consideration)

RPM
mm
mm
RPM
kW

mm
mm
be maintained ( Faires, p.457)
Design Horsepower to drive mechanism including losses belt 3
Transmitted power on V belt = Required Power/0.95According to Morse, p.452, losses in V-belt is 5%
Transmitted power on V belt 5.789474 kW 7.763812 hp
Solving for Design kW
Design kW = Transmitted kW*Nsf
Design kW 11.57895 kW

Using Faires calculation formula and table

Solving for Diameter of the drive and driven sheave
N2*D2=N1*D1
from figure 17.14 Belt selection from horsepower and speed by faires, p.457, we choose section B
Min D1 5.4 in
Iterasi
N1 900 rpm 900 rpm 900 rpm 900
D1 5.4 in 8.6 in 9.4 in 7.4
D2=D1 5.4 in 8.6 in 9.4 in 7.4
N2=N1 900 rpm 900 rpm 900 rpm 900
FIX D1 9.4
FIX D2 9.4
FIX N1 900

Solving for center distance

C = [(D2+D1)/2]+D1 or C=D2, Whichever is Eq. by Faires, p. 457
C Perhitungan = 18.8 in 477.52
Solve C = 18.8 in The center distance is made adjustable so that the belts can be mounted

Solving for belt length

L= [(PI/2)(D2-D1)]+2C+[((D2-D1)^2)/4C]
L= 37.6 in 955.04
from table 17.3, standard V-velt length (by Faires p.458) at section B, select B35 with pitch length equal to 36.8 in
pitch length 36.8 in 934.72
Fix C-C 18.4 in 467.36
Solving for V-belt speed
Vm = PI*D1*N1/12
Vm = 2214.823 f/min 36.91371 f/sec

Solving for kd (small diameter factor)

D2/D1 = 1
Kd 1 From table 17.4, by Faires, p.459

Solving for Rated Hp from equation by Faires, p.456

Rated Hp = [4.737*(((10^3)/Vm)^0.09)-(13.962/(Kd*D1))-0.0234*((Vm^2)/10^6)]*Vm/
Rated Hp = 6.223063 Hp

Solving for Adjusted Power

Horsepower rating must be corrected for length of belt (Ki) and arc of contact (KΘ). Faires,p.457
Adjusted Hp = Ke*Ki*Rated Hp
Ki = 0.81 length correction factor from table 17.6 Length Correction Factors by Faires, p.459
(D2-D1)/C = 0
KΘ = 1 arc of contact factor from table 17.5, Atc of Contact Factors. Faires, p.459
Adjusted Power = 5.040681 Hp
Adjusted Power = 3.758835 kW

Solving for Number of Belts

Number of Belts = Design Power / Adjusted Power
3.080462
Number of Belts = 4
use leather material type
C60, pitch length 62.9 in
b 0.65625 16.66875
t 0.40625 10.31875

Solving for the Tension

F1/F2 = e^(fΘ) Eq.1
f= 0.25 table 16-15 coefficient of friction belt, leather on cast iron dry
Θ (arc of contact) = (180-2*arcsin((D2-D1)/2C))*(pi/180)
3.141593 rad
F1/F2 = 2.19328 Eq.2

Power Transmitted on the V Belt

transmitted Hp ((F1-F2)/550)*Vm
F1-F2 = 115.6778
F1 = 2.19328 F2 Eq.2
F2 = 96.94102 lbf 431.2151 N
F1 = 212.6188 lbf 945.7756 N

Using Martin calculation formula and table

Solving for Diameter of the drive and driven sheave
from Table 2 Martin Stock Drive Selection using Design Power and RPM Shaf
Min D1 = 112 mm
we can use Belt Section SPB , SPA and SPZ
if we use SPA and SPZ the capacity of kW per Belt is too low so we must use much more belt number than the SPB. (Shaf Dim
Belt Section SPB

N1 950 RPM 950 RPM 950 RPM 950

D1 140 mm 190 mm 150 mm 200
D2 224 mm 300 mm 236 mm 315
N2 906 RPM 918 RPM 924 RPM 918
Rated Power on Belt 7.32 kW 12.65 kW 8.16 kW 13.69
Arc&Length Correction Factor 0.82 0.84 0.86 0.86
C-C 337 mm 270 mm 395 mm 412
Belt Length 1250 mm 1400 mm 1400 mm 1600
1.929053 1.089681 1.649987 0.983484
Number of Belts 2 2 2 1

use leather material type

 PILIH 3

-0.20663 0.776478 0.776987

101.9247 39.06079 39.01446

o that the belts can be mounted into the grooves without harmful stretching and so that initial tension can be maintained ( Faires, p.457)

a 2
h equal to 36.8 in b -36.8
c 0

equation l by faires page 456

ection Factors by Faires, p.459

Factors. Faires, p.459

umber than the SPB. (Shaf Dimension Consideration)

RPM
mm
mm
RPM
kW

mm
mm
be maintained ( Faires, p.457)
Sheave 1
Solving for the thickness of the sheave
T= width belt*number of belt
T= 2.625 in

Computing the weight of the motor sheave

WS1 = (PI/4)*(D1^2)*t*ρ
ρ= 0.256 lb/(in^3) density of pulley material used, ordinary cast iron from Table 2-1, General Properties of commo
WS1 = 42.75079 lbs
WS1 = 190.165 N

Computing the weight of the driven sheave

WS2 = (PI/4)*(D2^2)*t*ρ density of pulley material used, ordinary cast iron from Table 2-1, General Properties of commo
ρ= 0.256 lb/(in^3)
WS2 = 103.4464 lbs
WS2 = 460.1523 N

Sheave 2
Solving for the thickness of the sheave
T= width belt*number of belt
T= 2.625 in

Computing the weight of the motor sheave

WS3 = (PI/4)*(D1^2)*t*ρ
ρ= 0.256 lb/(in^3) density of pulley material used, ordinary cast iron from Table 2-1, General Properties of commo
WS3 = 24.4049 lbs
WS3 = 108.5584 N

Computing the weight of the driven sheave

WS4 = (PI/4)*(D2^2)*t*ρ density of pulley material used, ordinary cast iron from Table 2-1, General Properties of commo
ρ= 0.256 lb/(in^3)
WS4 = 63.8623 lbs
WS4 = 284.0736 N

Sheave 3
Solving for the thickness of the sheave
T= width belt*number of belt
T= 2.625 in

Computing the weight of the motor sheave

WS5 = (PI/4)*(D1^2)*t*ρ
ρ= 0.256 lb/(in^3) density of pulley material used, ordinary cast iron from Table 2-1, General Properties of commo
WS5 = 46.63531 lbs
WS5 = 207.4442 N
Computing the weight of the driven sheave
WS6 = (PI/4)*(D2^2)*t*ρ density of pulley material used, ordinary cast iron from Table 2-1, General Properties of commo
ρ= 0.256 lb/(in^3)
WS6 = 46.63531 lbs
207.4442 N
-1, General Properties of commonly used materials. Doughtie and Vallance, p.11

-1, General Properties of commonly used materials. Doughtie and Vallance, p.11

-1, General Properties of commonly used materials. Doughtie and Vallance, p.11

-1, General Properties of commonly used materials. Doughtie and Vallance, p.11

-1, General Properties of commonly used materials. Doughtie and Vallance, p.11
-1, General Properties of commonly used materials. Doughtie and Vallance, p.11
Solving for the Force Required to Crush the UREA & DAP
R UREA = 0.004 m
R DAP = 0.00536 m
F breaking force UREA 90 N
F breaking force DAP 150 N
σ UREA = 1790493 Pa
σ DAP = 1661926 Pa
X= SQRT((FeedD/2)^2 - (Gap/2)^2)
X UREA = 0.001969 m
X DAP = 0.002657 m
W UREA = 0.003938 m
W DAP = 0.005314 m
A = W*Peffectieffective length of the roll is 60%
A UREA = 0.002363 m^2
A DAP = 0.003188 m^2
Fr = σ*A
Fr UREA = 4230.871 N
Fr DAP = 5298.981 N
µ UREA = 0.35
µ DAP = 0.55
Shaf 1
Computing the Angle of Wrap
Cosα = (D2-D1)/(2*C) From eq. by Spotts, p.293
D1 = 9 in
D2 = 14 in
C= 27.40899552 in
α= 84.76672511 °

Solving the Forces on Belt at Section A

F1 = 1237.563367 N
F2 = 592.647633 N
FX1 = 1232.404702 N
FX2 = 590.1772378 N
FY1 = 112.8793069 N Downward
FY2 = 54.05594238 N Upward
FX = 1822.58194 N Out
FY = 58.82336452 N Downward

Forces at Section A Due to Weight of the Driven Sheave, WS2

WS2 = 460.1523475 N

Total Load at Section A

FHA = 1822.58194 N
FVA = 518.975712 N Downward

Solving dor the weight of the roll and shaf 1

Dshaf = 40 mm asumsi
W Shaf = 142.2544507 N
M roll = Rho*Volume
M roll 436.0153612 kg
W roll = 4277.310693 N

Solving the Forces on Belt at Section B

Computing the Angle of Wrap
Cosα = (D2-D1)/(2*C) From eq. by Spotts, p.293
D1 = 9.4 in
D2 = 9.4 in
C= 9.4 in
α= 90 °

Solving the Forces on Belt at Section B

F1 = 945.7755675 N
F2 = 431.2151415 N
FX1 = 5.793577E-14 N
FX2 = 2.641513E-14 N
FY1 = 945.7755675 N Upward
FY2 = 431.2151415 N Downward
FX = 8.43509E-14 N
FY = 514.5604259 N Upward

Forces at Section B Due to Weight of the Driven Sheave, WS2

WS2 = 207.4441909 N

Total Load at Section B

FHA = 0N
FVA = 307.116235 N Upward

Crushing Load
Material DAP
Fr 5298.980579 N
α= 39.06078952 °
µ= 0.55
F Friksi = 2914.439318 N
Fx = 5602.121359 N In terdistribusi sepanjang roller
Fy = 6555.333518 N Downward terdistribusi sepanjang roller

Shaf 2
Computing the Angle of Wrap
Cosα = (D2-D1)/(2*C) From eq. by Spotts, p.293
D1 = 6.8 in
D2 = 11 in
C= 15.7 in
α= 82.31319502 °

Solving the Forces on Belt at Section A

F1 = 832.8626354 N
F2 = 406.0801645 N
FX1 = 825.3785568 N
FX2 = 402.4311403 N
FY1 = 111.4020086 N Downward
FY2 = 54.31645512 N Upward
FX = 1227.809697 N Out
FY = 57.08555344 N Downward

Forces at Section A Due to Weight of the Driven Sheave, WS4

WS4 = 284.0736431 N

Total Load at Section A

FHA = 1227.809697 N
FVA = 341.1591965 N Downward
Solving dor the weight of the roll and shaf 1
Dshaf = 40 mm asumsi
W Shaf = 142.2544507 N
M roll = Rho*Volume
M roll 436.0153612 kg
W roll = 4277.310693 N

Crushing Load 1
Material UREA
Fr 4230.871191 N
α= 39.06078952 °
µ= 0.35
F Friksi = 1480.804917 N

Crushing Load 2
Fr 4230.871191 N
α= 39.01446125 °
µ= 0.35
F Friksi = 1480.804917 N
Fx = 7629.842322 N Out terdistribusi sepanjang roller
Fy = 2414.153008 N Upward terdistribusi sepanjang roller

Shaf 3
Computing the Angle of Wrap
Cosα = (D2-D1)/(2*C) From eq. by Spotts, p.293
D1 = 9.4 in
D2 = 9.4 in
C= 2.050980836 in
α= 90 °

Solving the Forces on Belt at Section A

F1 = 945.7755675 N
F2 = 431.2151415 N
FX1 = 5.793577E-14 N
FX2 = 2.641513E-14 N
FY1 = 945.7755675 N Downward
FY2 = 431.2151415 N Upward
FX = 8.43509E-14 N Out
FY = 514.5604259 N Downward

Forces at Section A Due to Weight of the Driven Sheave, WS6

WS6 = 207.4441909 N

Total Load at Section A

FHA = 0N
FVA = 722.0046169 N Downward

Solving dor the weight of the roll and shaf 1

Dshaf = 40 mm asumsi
W Shaf = 142.2544507 N
M roll = Rho*Volume
M roll 436.0153612 kg
W roll = 4277.310693 N

Crushing Load 1
Material UREA
Fr 4230.871191 N
α= 39.01446125 °
µ= 0.35
F Friksi = 1480.804917 N
Fx = 1512.836992 N Out terdistribusi sepanjang roller
Fy = 57.78720516 N Downward terdistribusi sepanjang roller
shaf 1
Section A (0<X<75mm)
N 0
Vy = Ws*X+58.8233
Vx = 1822.5819395695 IN
Mx = 1822.56*X CW
My = 124.254*(X^2)/2+58.8233*X CW
T 114.6660174791 CCW
Section B (75<X<150mm)