Mechanical Maintenance department

Additive and corrective crushers

Prepared by
Eng. Feras Sulaiman Alhamdi
Additive and corrective Supervisor
CRUSHING PRINCIPLES
Size reduction of rock can be obtained in three different ways, which all relate to differ-
ent crusher types:

1- crushing by means of compression

2- crushing by means of impact
3- crushing by means of attrition
Factors for choice crusher type
1- feed size
2- feed material type
3- capacity
4- cost

Operating principle
The chamber of crusher consists of rotor, the first impact plate, the second impact crusher,
grinding plate and lining plates. The reasonable chamber can improve crushing efficiency
and ensure regular product size. The main motor drives the rotor with big inertia by V-belt.
The material are fed trough the inlet opening by a feeder and fall down to the rotating
rotor with high speed. The comminution occurs when the blow bars of rotor hit the
material at a high peripheral speed. The thrown material is further reduced in size in the
crusher chamber by colliding with each other
Tertiary crushers (Line 5)

Impact crusher
Impact crusher serves to crush similar brittle material, such as limestone, siltstone,
shale, gypsum, coal etc. by impact principle. Comparing with extrusion crusher such as
jaw crusher, gyratory crusher, taper crusher, roller crusher etc., the impact crusher can
reduce the materials from the run-of-quarry to product of minus 75mm by only one
stage. Thus the capital cost can be cut down and the crusher system become simple
he impact crusher, as a general rule, can work well only when the materials are fed over
entire width of the rotor. The materials are crushed in the crusher by the blow bars at a
high peripheral speed, thus the feeding of different size will result in different energy
consumption. To keep the balance between required energy and the imposed energy, the
speed of the feeder MUST be adjustable according to the load of the rotor motor.
 Technical characteristics
Crusher type NPF1618
Rotational speed of the rotor 365 rpm

Capacity 350~400 t/h

Motor Type 1RR5504-6JA90-Z

Rating power 500KW

Rotational speed 1194 r/min

Total weight (excluding the about 52.7 t

motors)
Product size passing 80 mm

Weight of rotor 18.5 t

Structure
he crusher is mainly composed of rotor, casing, first impact plate, second impact plate,
grinding plate, and drive unit. The outline of the crusher is shown in Fig. 1.
Rotor
he rotor is the key assembly of the crusher (Fig. 2). It is composed of rotor body,
blow bars, main shaft, bearings and large belt wheel etc.
The rotor body is rigid cylindrical structure, mainly composed of roller bush, disc
plates
The blow bars are inlayed in the four slots which are distributed evenly on the
cylindrical surface of the rotor body. These bars are made of special hard alloy
steel which is high-quality abrasion-resistant

241BC2
 Casing
The casing is welded by high-quality steel plates with reasonable welding process. All flanges
are safely connected by bolts. All the parts of the casing that may be touched by stone are
protected by abrasion-resistant liner plates. Liner plates have high interchangeablity, fixed by
bolts. Both sides of the most liner plates can be used. The inspection door and the maintenance
door are set upon the casing. The anti-rotating pin holes are set beside both sides of the casing,
and the position-limit curved rod is set into the pin hole when the maintenance is hold on to
protect the worker and the crusher.
First impact plate
The first impact plate bears strong crush of the ore. The plate body is totally forged by
abrasion-resistant alloy steel. The up side of the plate body is hinged with the crusher
casing, the down side of the plate body is hinged with the spring mechanism which is
specially designed to absorb shock and vibration of the crush. The gap between the plate
and the working circle of the rotor is adjustable by the spring mechanism, and the
reference value of the gap is 150mm. The actual value is set according to the size of the
feeding and the product of the stone.
Second impact plate
Similar to the first impact plate, the second impact plate also has the spring buffer and
adjustment structure. The gap between the plate and the working circle of the rotor is
75mm, it can be adjusted according to the working condition to make the crushed stone
distributed reasonably between the work area of the second impact plate and the
grinding plate. The gap will affect the particle size coming to the next crushing stage.
The liner plates on the impact plate are totally interchangeable. When the liner plate in
the lowest part is worn obviously, it can be changed with the plate on the upper part
which wear less. The structure is shown in Fig.
 Grinding plate
The grinding plate is set in the bottom cavity of the casing, and composed of toothed plate,
support frame and a set of spring adjustment mechanism which is designed specially. The
contour of the plate and the working circle of the rotor form the wedge cavity, the gap in
the lowest part is less than the product size. The reference value of the gap is 35mm, it can
be adjusted according to the actual working condition. In this work area, the material which
is oversize will be crushed further
Drive Unit
The drive unit is the power source of the crusher, and it is composed of belt wheel, flywheel,
shaft, bearings, couplings, motor, base frame and slide rail etc. The small belt wheel is
driven by motor through couplings, and the large belt wheel of the rotor is dragged by the
small belt wheel through the high-quality V-belt. And then make the rotor rotate correctly.
With the help of the adjustment bolts on the base frame, the enough tensity of V-belts can
be achieved. The structure is shown in Fig
Maintenance
General requirements:
♦ When the operation is to stop, the rotor motor should not be switched off until
the materials in the crusher chamber have been completely discharged.
♦ Never permit to feed extra-large lumps into the crusher.
♦ Care must be always taken to monitor the running of the crusher. If any
unusual sound be heard, the crusher must be stopped and checked with order.
♦ All bearings should be lubricated regularly with lithium soap grease.
♦ The bearing blocks are equipped with electric thermo-couples (WZPM-201BA2)
which have temperature measuring scope of –100℃~+100℃.The warning device,
cooperating with the temperature transmitter, will alarm when the temperature
surpass the warning temperature. If the temperature goes up to the top of safe
temperature, the motor will be switched off automatically. The alarm and switch
off temperatures can be reset on the warning device. The bearings can suffer a
temperature of 100℃ without damage.
♦ The rotation parts, such as belt wheels, belts and so on, should be guarded by
protective cover.
Maintenance Schedule
Breakdown and handling
Hammer crusher ( single stage )
single stage hammer crusher serve to crush medium-hard rock and similar brittle
material, such as limestone, marlstone, argillaceous siltstone, shale, gypsum, coal and
the mixture of limestone and clay. Comparing with the traditional multi-stage crushing
process, it can reduce the materials from the run-of-quarry to product of minus 25mm for
feeding of the ball mill by only one stage
Technical characteristics
Crusher type PCF2018

Rotational speed of the rotor 310 rpm

Capacity 450~500t/h

Motor Type 1RR5566-6JA80-Z

Rating power 710KW

Total weight (excluding the 1RR5566-6JA80-Z

motors)
Product size 90% passing 25 mm

Weight of rotor 31 t
 main assemblies
 The crusher consists mainly of rotor, crushing plate, outlet grate, casing, emergency gate and
drive unit
Rotor
The rotor is the core assembly of the crusher, which is composed of middle discs, side
discs, hammers, hammer axles, main shaft, flywheel, bearings, and bearing housings and
so on. The middle discs and side discs are fixed on the shaft
Breaking Wall
The breaker wall is fitted in the front of the rotor above the horizontal central line. The
top end of breaker wall is jointed on the upper casing and can swivel by screwing the
adjusting bolt on the bottom end, to gain a variation of gap between the breaker wall and
the working circle of rotor. The gap will affect the particle size coming to the discharge
zone and normally is to keep 20 mm.
 Outlet Grate
 The outlet grate mounted beneath the rotor has an 130º enclosure angle. The gap between the
tooth-tip of the grate plate and the working circle of the rotor is adjustable. With the help of
jacks and adjusting bolts, the gap a, b and c (illustrated in Fig.4) can reach the demanding
value of about 25 mm. The oversize of the gap will lead to the pileup of the materials at the
grate area, and the crushing efficiency will descend obviously
Emergency gate( fens)
 The emergency gate next to the outlet grate is hinged on the lower casing. It can be
adjusted, by turning the axle holders upside down, according to the position of the
outlet grate. The gap between the toothed surface of the arc gate and the working
circle of the roto should be about 25 mm. The emergency gate will be opened by
centrifugal force of foreign inclusions and evacuate them immediately and then close
automatically by means of counter weight to protect the uncrushed grain from spilling.
 Casing
The casing composed of upper casings, lower casings, door frames and lining plates, is of solid welded
design . The interior surfaces of casing which may contact with material are protected with lining
plates from wearing.
 Drive Unit
The rotor is driven through V-belts by the drive unit. The drive unit is composed of motor,
couplings, base frame, slide rail and adjustment bolts. The motor is mounted on the base
frame. With the help of the adjustment bolts, the correct tensity of V-belts can be achieved.
Maintenance Schedule
Maintenance Schedule
Breakdown and handling
Breakdown and handling
L5 Flow sheet
Clay crusher ( double stage crushing )
Twin shaft sizer (Technical characteristics)
Type MMD 625 series (twin shaft sizer)

Crushing rate Max 450t/h

Motor 1*250kw

Feed size 1500mm

Product size 150mm

Roll crusher (Technical characteristics)
Type WB2S-3-80/250M.H (Roll crusher)

Crushing rate Max 450t/h

Motor 2*160kw

Feed size 150mm

Product size 25mm

Operating principle
Operating principle
Sizer Assembly
Sizer Assembly
Sizer Assembly
Sizer Assembly
Sizer Assembly
Sizer Assembly
Sizer Assembly
Sizer Assembly
Breaker shaft Assembly
Breaker shaft Assembly
Bearing Assembly
Tertiary Crs L4 ( Double stage crushing )

Type PEG160/210 (Impact crusher)

Crushing rate 400t/h

Rotor diameter 1600mm

Rotor width 2100mm

Feed size 1500mm

Product size 0-250mm

Technical characteristics
Technical characteristics
Technical characteristics
Operating principle
design
Design
Design
Design
Breakdown and handling
Breakdown and handling
Check list
Check list
Check list
[Link] department organization

Eng. Ehab Medht

Mechanical Manger

Eng. Abdelmottaleb
Boussaada
Crushers Superintendent

Eng. Feras Alhamdi Eng. Amjad Almattrafi

Additive and corrective
Limestone Supervisor
supervisor
Mechanical Engineer responsibilities
 Managing maintenance activities in additive &corrective crushers
 Maintain records on equipment histories and costs, coordinates with
 Analyse, record, troubleshoots equipment problems, and proffer
 procedure
 Diagnose root cause and specify method of repair for plant equipment.
 Provide guidance to the technicians in the execution of maintenance
 Works
 Plan and excite minor & Major Maintenance (Kiln shut-down) for
crushers area .
 Responsible for prepare yearly spare parts budget
Example for KSD plan
Thank you