Crushers for Raw materials

©FLSmidth Private Limited 2017, all rights reserved 1

Cement Crushing solutions

 Raw Material
- The challenges
- chemical and physical testing
 Cement Crushing Solutions
- crushing solutions – general information
- Apron feeders
- Impact crushers
Hammer Crusher
Strike-Bar Crusher
- Roller Crusher
- Gyro Crusher
- Jaw Crusher
- Cone Crusher
 Questions

©FLSmidth Private Limited 2017, all rights reserved 2

1
 Raw Material Challenges:
Hard/Soft, Dry/Wet, Dense/Porous, Sticky/non sticky

Chalk
soft/high moisture limestone
~15-25% H2O <10% H2O

< 1% H2O
~5-15% H2O
Marble Limestone/marl
dense/low moisture

©FLSmidth Private Limited 2017, all rights reserved 3

Raw Material properties:

Hard/Soft, Dry/Wet, Dense/Porous, Sticky/non sticky
Shale
hard/dense/abrasive
Clay
soft/sticky

~5-15% H2O

Clay
soft/
medium
sticky
~15-30% H2O up to ~40% H2O

©FLSmidth Private Limited 2017, all rights reserved 4

2
 Quarry Operation
Good quarry practice
Keep the moisture content in the raw materials low by:
• Proper draining of water
• Arranging for trenches to evacuate surface water
• Avoiding operation when raining
• Removing materials that are soaked with water

©FLSmidth Private Limited 2017, all rights reserved 5

Operation
Good quarry practice

©FLSmidth Private Limited 2017, all rights reserved 6

3
 The objective of Crushing

Run of Mine (ROM)

Crushed product

©FLSmidth Private Limited 2017, all rights reserved 7

ROM - Operation
Good quarry practice

(1)ROM

(2) Oversize - screened

(3) Fines - screened

©FLSmidth Private Limited 2017, all rights reserved 8

4
 Chemical and Physical testing

Material reception hall

Dania test centre

©FLSmidth Private Limited 2017, all rights reserved 9

Point load test

 Load is added to the material until

it brakes in its natural patter
 Result is converted into UCS

©FLSmidth Private Limited 2017, all rights reserved 10

5
 Point load test

 The result’s are presented in a LAB report

©FLSmidth Private Limited 2017, all rights reserved 11

Wear Test – Impact Crushers

 Wear (g/ton)

 Power determination (kWh/ton)

©FLSmidth Private Limited 2017, all rights reserved 12

6
 Impact wear test – Impact crushers

 Test specifically made for Impact crusher – EV and SB in

order to determine the wear in g/t of processed material

©FLSmidth Private Limited 2017, all rights reserved 13

Wear Index results for Limestone

45

40

35

30
No. of Samples

25

20

15

10

0
0,5 1,5 2,5 3,5 4,5 5,5 6,5 7,5 8,5 9,5 10,5 11,5 12,5 13,5 14,5 15,5 16,5 17,5 18,5 19,5 More

Wear index [gr/ton]

©FLSmidth Private Limited 2017, all rights reserved 14

7
 Principle of Crushing
(Vice)
Hammers and Strike Bar
Impactors
(mainly impact and some shear/
attrition as crushing principle)
(Hammer)

Jaw, Gyratory and (File)

Cone Crushers
(mainly compression
as crushing principle)
(Pair of
Scissors)

Roller and Toothed Roller /

Sizer Crushers
(mainly compression and some
shear as crushing principle)

©FLSmidth Private Limited 2017, all rights reserved 15

Different Crusher types / Groups

EV Hammer Impact Crusher

AF Apron Feeder (Crusher and mill feed
(inclined / horizontal or negative)

Single Toggle Jaw

crusher
DUI Double
SB / ”Strike Bar ”® rotor impact
Impact Crusher crusher

Gyrotory Crusher

Cone Crusher
UKC Hammer Crusher

EH Roller Crusher MHC Twin Shaft

Low Speed Sizer
Breaker

©FLSmidth Private Limited 2017, all rights reserved 16

8
 Selection of crusher type

 Stickiness of material: Is the type of crusher suitable

for handling the material to be crushed?

 Abrasiveness of material: Can an reasonable lifetime

of crusher wear parts be expected?

 Reduction ratio: Is it possible to crush down the

material from feed size to desired product size in a single
pass, or will it be necessary to use a multiple stage
solution?

 Product control: How well is the top size controlled and

are there measures for adjustment to compensate for
wear?

©FLSmidth Private Limited 2017, all rights reserved 17

Selection of crusher type

Crusher Type Hammer & StrikeBar Gyratory; Roller, Toothed
Impactors Jaw and Roller and Sizer’s
Characteristics Cone Crushers Crushers
Reduction Ratio 100: 1 40:1 7:1 (Gyratory) 4:1
4:1 (Jaw)
3:1 (Cone)
Wear Resistance Reasonable Excellent Good

Power Consumption Moderate Excellent Good

Max. Lump Size Good with grate Questionable Questionable

Control Questionable without
grate
Ability to Handle Good Poor Excellent
Sticky Material
Dust Creation High Low Low

©FLSmidth Private Limited 2017, all rights reserved 18

9
 Receiving Hopper & Feeders to Crusher

Apron Feeder

Recommended material surface:

Sloping approx 40o downward
from dumping point.

Grizzly Feeder

©FLSmidth Private Limited 2017, all rights reserved 19

Apron Feeder – Support roller

system
 Is the grease pump
actually working – or does
it look like the picture?
 Are the grease pipes in
Check the functionality i.e.
that they can rotate.
 Are the rollers greased, or
“welded” with the result
shown below?

©FLSmidth Private Limited 2017, all rights reserved 20

10
 Apron Feeder – NEW! Support
roller system - Lubrication FREE!

 NOW FLS apron feeders are

equipped with a lifetime
lubricated support roller
system - supporting the
apron’s
 No more issues with
 Clogged grease pipes
 Freezing grease systems
 Grease pump not working!

©FLSmidth Private Limited 2017, all rights reserved 21

Crusher Group :
Hammer Crusher and StrikeBar Impactors

Hammer Impactor Strike bar Impactor

©FLSmidth Private Limited 2017, all rights reserved 22

11
 EV- Hammer Crusher
Mix Crusher principle

• Capacity up to 2250 t/h

• UCS 150 Mpa
• Moisture up to 10%
• MIX crushing installtion – EV Hammer crusher -Main Apron
Feeder (Limestone) + Side Apron Feeder (clay)

©FLSmidth Private Limited 2017, all rights reserved 24

EV Crusher – Design Features

1. Hammer rotor.
2. Inlet roller (1 or 2)
3. Hammers.
4. Outlet grate.
5. Rails for sliding grate.
6. Braker plate.
7. Spare hammers.
8. Top part.
9. Hydraulic opening.

EV150x150 EV150x200 EV200x200 EV200x300 EV250x250 EV250x300

2500

2000
Capacity [t/h]

1500

1000

500

0
30 36 44 56 65 85 100 125
Outlet Grate Opening [mm]

©FLSmidth Private Limited 2017, all rights reserved 25

12
 EV design features
 1 or 2 inlet rollers
 Material flow control to the rotor

©FLSmidth Private Limited 2017, all rights reserved 26

Rotor design

 Rotor Shaft
 Roller bearing
 Hammer disc’s
 Hammer bolts
 Stay bolts
 No flywheel
 Staggered hammer pattern

©FLSmidth Private Limited 2017, all rights reserved 27

13
 Strike-Bar™ Impact crusher
 No outlet grate
 Final grinding plate controls
output size
 Reduction ratio1:40
 Adjustable grinding plates –
both vertical mill output as
well as ball mill output from
one machine.
 Capacity up to 2600 t/h
 UCS up to 150 Mpa
 Moisture up to 10%

©FLSmidth Private Limited 2017, all rights reserved 31

Strike-Bar™ Impact crusher

 Primary crushing effected by

impacting
 Secondary crushing takes
place by shearing and
compression between
impact bars and the breaker
plate and
 Final crushing between
impact bars and the grinding
plate
 No oversize particles leaves
the crusher

©FLSmidth Private Limited 2017, all rights reserved 32

14
 Impact Crusher: Dedusting

©FLSmidth Private Limited 2017, all rights reserved 35

Impact Crusher without outlet Grate

(UKC Crusher)

Breaker Plate

Outlet

©FLSmidth Private Limited 2017, all rights reserved 36

15
 Siliceous Limestone / Iron Ore

©FLSmidth Private Limited 2017, all rights reserved 37

Crusher Group: Gyro, Jaw and Cone

©FLSmidth Private Limited 2017, all rights reserved 38

16
 Single Toggle JAW

©FLSmidth Private Limited 2017, all rights reserved 39

Gyratory & Cone Crusher

Gyratory crusher Cone crusher

©FLSmidth Private Limited 2017, all rights reserved 40

17
 Potentially Sticky Raw materials

~15-30% H2O Up to -40% H2O

Clay Clay
soft/ soft/
medium sticky Extremely sticky

©FLSmidth Private Limited 2017, all rights reserved 41

Crusher Group: Roller, Toothed Roller

& Sizer’s

©FLSmidth Private Limited 2017, all rights reserved 42

18
 EH Roller crusher

 Reduction ratio 6:1

 Capacity +1500 t/h (depending
on raw material, output size
etc.
 UCS up to 150 MPa
 Moisture + 20%
 Application dependent drive
system – Fixed / VFD
 1. stage / 2. Stage or 3 stage
set-up depending on
application and requirements

©FLSmidth Private Limited 2017, all rights reserved 43

EH Roller Crusher Inside

 Fixed roller

 Fly Wheel

 Floating roller

 Tooth segments

 Cleaning system, scrapers

 Hydraulic system

©FLSmidth Private Limited 2017, all rights reserved 44

19
 EH Roller Crusher Tooth segments

 Teeth height based on output

size

©FLSmidth Private Limited 2017, all rights reserved 45

EH 150x200 Rollers

 Inside the Chalk crusher

 Wear liners at the sides

 Chalk crusher in operation

©FLSmidth Private Limited 2017, all rights reserved 46

20
 MHC crusher – Soft Sticky materials

©FLSmidth Private Limited 2017, all rights reserved 47

MHC Crusher Range

Crusher Rotor dia. Rotor Tooth Tooth Tooth

series (mm) width config. config. config.
(m)
MHC 500 1.45 50/110 50/80 25/40
2.1 50/110 50/80 25/40

MHC 630 1.45 50/110 50/80 25/40

2.1 50/110 50/80 25/40

©FLSmidth Private Limited 2017, all rights reserved 48

21
 Crusher performance as function of
Rawmaterial compressive strenght (UCS)

Pressure gauge with peak load indicator

©FLSmidth Private Limited 2017, all rights reserved 49

Crusher Type proposals

Limestone Siliceuos Limestone

©FLSmidth Private Limited 2017, all rights reserved 50

22
 Crusher Type proposals

Clay Marl

©FLSmidth Private Limited 2017, all rights reserved 51

Crusher Type proposals

Laterite
Iron Ore

©FLSmidth Private Limited 2017, all rights reserved 52

23
 Stickiness Problems:
Apron Feeder and EV Impact Crusher

©FLSmidth Private Limited 2017, all rights reserved 53

Crusher Application Summary

Reduction
Type of crusher Ratio
Typical Feed Material

Hammer & Strike Medium to hard, moderate

80:1
Bar Impactor abrasiveness. Low stickiness.

Jaw Crusher 4:1

Hard, tough, high abrasiveness.
Cone & Gyratory 4-7:1 Non sticky.
Crusher

Soft, moderate to very sticky.

(Mix. of hard & sticky materials for
Roller Crusher 4-6:1
high duty EH-Rollers).
Moderate to high abrasiveness.

©FLSmidth Private Limited 2017, all rights reserved 54

24