Crushers-aggregate production

machinery

By: Hailu Abebe

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 Introduction
• Crushing is the process of reducing
the size of solid particles into definite
smaller sizes.
• The crusher crushes the feed by some
moving units against a stationary unit or
against another moving unit by the
applied pressure, impact, and shearing or
combine action on them.
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Contd.

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 Old crushing
• People crush stones using hammer and anvil
showed that a hardworking person could
produce up an average of five wheelbarrows
of aggregates a day.

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 Types of crusher
• They are classified based on different
factors like product size and
mechanism used.
• Based on the mechanism used crushers
are of five types namely Cone crusher,
Jaw crusher, roller crushers, gyratory
crusher and Impact crusher.

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Types of crusher

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 Jaw crushers
• Jaw crushers consist of two jaws. One fixed
and the other reciprocating.
• The opening between them is largest at the
top and decreases towards the bottom.
• A belt pulley; which is driven by a motor
drives the eccentric shaft to rotate. This makes
the attached jaw to approach and leave the
other jaw repeatedly, to crush, rub and grind
the feed.

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• The fixed jaw mounted in a “V” alignment
is the stationary breaking surface.
• The swinging jaw exerts impact force
on the material by forcing it against
the stationary plate.

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 Contd.
• Jaw crushers are classified on the basis of
the position of the pivoting of the swing
jaw
1. Blake crusher-the swing jaw is fixed at the
upper position
2. Dodge crusher-the swing jaw is fixed at
the lower position
3. Universal crusher-the swing jaw is fixed at
an intermediate position
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 Contd.
1) Blake type jaw crusher may be divided into two
types.
(i) Single toggle type: - the swing jaw is suspended on
the eccentric shaft which leads to a much more
compact design than that of the double toggle jaw
crusher. These type of jaw crushers are preferred
for the crushing of softer particles.
(ii) In the double toggle jaw crushers, the oscillating
motion of the swing jaw is caused by the vertical
motion of the pitman. This type is commonly used
in mines due to its ability to crush tough and
abrasive materials. 10
 Contd.

Single toggle type Double toggle jaw

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 Cone crusher
• Cone crusher is consisting of a crushing chamber,
a crushing cone and a operating mechanism.
• The cone is built in to a vertical shaft, which is
supported from the top with a bowl-shaped
bearing and from the other end to an eccentric
operating mechanism.
• Feed is dropped to the crusher from the top and
it is crushed between the crushing chamber and
the slowly rotating cone.
• Cone crushers are mostly used in large scale
crushing in mining industry.
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 Roller crusher
• Roller crusher is consisting essentially of two
opposite directions driven cylinders that are
mounted on horizontal shafts. The other shaft is
mounted permanently in the frame and the other
is leaning on robust springs.
• The gap between cylinders can be adjusted, so
the size of crushed product is easily adjustable.
• Usually both cylinders are covered with
manganese steel.
• Crushing ratio is usually lower than in other
crusher and roll crusher is suitable for fine
crushing. 17
Contd.

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Contd.

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 Impact mill
• Impact mills are often used with materials,
which are soft or which are easily cleaving
from the surface.
• Unlike many other crushers or mills, in the
impact mill the size reduction is based on
impact, not to compression.
• The mill is constructing of a fast spinning
rotor and beaters attached to the rotor.

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 Contd.
• Feed is entering to the mill from the top
and crushing starts immediately when
the feed is impacted with beaters
towards the mills inner surface.
• Impact mill can also be equipped with a
bottom screen, which prevents material
leaving the mill until it’s fine enough to
pass through the screen.
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Contd.

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 GYRATORY CRUSHERS
• Gyrators are the most efficient of all primary
type crushers. A gyrating mantle mounted
within a deep bowl characterizes these
crushers. They provide a continuous crushing
action and are used for both primary and
secondary crushing of hard, tough, abrasive
rock.
• To protect the crusher from un-crushable
objects and overload, the outer crushing
surface can be spring-loaded or the mantle
height may be hydraulically adjustable 23
Gyratory Crushers

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 Stages of crushing
• Generally crushers are very rugged, massive
and heavy in design.
• The contact surfaces are equipped with
replaceable liners made from high tensile
manganese or other alloy steel sheet having
either flat or corrugated surfaces.
• Crushers are classified according to the stage of
crushing which they accomplish, such as:
➢Primary
➢Secondary or reduction crushers
➢Tertiary crushers
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 Stages of crushing
• Primary crusher – The raw material from
mines is processed first in primary crushers..
The input of such crushers is relatively wider and
the output products are coarser in size. Example
- Jaw crusher, Gyratory crusher.
• Secondary crusher- The crushed rocks from
primary crusher are sent to secondary crusher
for further size reduction. Example - Cone
crusher, reduction gyratory crusher, spring
rolls, etc.
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 Stages of crushing
• Fine crushers- Fine crushers have
relatively small openings, and are used to
crush the feed material into more
uniform and finer product.

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 Crushing Process
• Crushers reduce the size of stones
through
➢Attrition: rubbing and grinding down by
friction (for producing maximum amount of
fine materials)
➢Pressure: Squeezing action between two
surfaces like jaw crushers (for hard , tough
materials, when minimum amount of fines
is required )
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 Crushing Process
• Crushers reduce the size of stones
through
➢Impact: instantaneous blows delivered
by a hammer on the material as in
hammer mill crushers
➢Shear: cutting or slicing action as may
be seen in gyratory or roll crushers
➢Combination of the above
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 Aggregate production
• A primary crusher receives the stone
directly from a quarry after blasting, and
produces the first reduction in size.
• The output of the primary crusher is fed to
a secondary crusher, which further reduces
the stone size. Some of the stone may pass
through four or more crushers before it is
reduced to the desired size.

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 Aggregate production
• As stone passes through a crusher, the
reduction in size may be expressed as
reduction ratio. (the ratio of the distance
between fixed and moving face at the top
divided by the distance at the bottom of the
crusher)
• The gape is the distance between the fixed
and moving faces at the top, divided by the
distance of the open-side setting at the
bottom.
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• Primary crushers
– Jaw
– Gyratory
– Hammer mill
• Secondary crushers
– Cone
– Roll
– Hammer mill
• Tertiary crushers
– Rod mill
– Roll
– Ball mill 34
 Crushing plant
• Mobile crushers are portable which is
equipped with crawler type running gear
that can be driven to the place of
abundant rocks or stone.
• Stationary crushers are not portable.

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Mobile crusher

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Stationary crusher

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Thank you!

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