Aggregate Production

AGGREGATE
PRODUCTION

AGGREGATE
PRODUCTION
Four basic functions:
Size reduction - crushing
Size separation - screening
Elimination of undesirable
material
- washing
Movement and storage

AGGREGATE
PRODUCTION

Crushers
Crusher Production
Screening
Screen sizing

CRUSHERS

Jaw
Gyratory
Cone
Roll
Impact
Specialty

JAW CRUSHERS
Rock flows into the space between
two vertical jaws. One jaw is
stationary. The other jaw moves
in an elliptical-downward motion
toward the stationary jaw while
crushing, and upward and away
from the stationary jaw allowing
the crushed material to exit.

JAW CRUSHERS
Moves in an
ellipticaldownward
motion
toward the
stationary
jaw while
crushing

JAW CRUSHERS
Table 14.3 gives representative
capacities.

JAW CRUSHERS
Jaw
crushers are
primary
units, that
receive
material
directly
from the
quarry.

GYRATORY CRUSHER
Has a gyrating mantle mounted
within
a deep
bowl.

Table 14.4
gives
representative
capacities.

GYRATORY
CRUSHER Gyratories are

used as primary or
secondary units.

CONE CRUSHER
Works like a gyratory with an
eccentric rotating cone around a
vertical shaft to cause a gyrating
movement of the head.
Differs from a gyratory:
A shorter head
Smaller receiving opening
Higher rotation speed

GYRATORY & CONE

CRUSHERS
Gyratory
Cone shorter head

GYRATORY & CONE

CRUSHERS
Cone smaller
receiving opening

Gyratory

GYRATORY & CONE

CRUSHERS
Gyratory

Cone higher
rotation speed

ROLL
CRUSHERS

ROLL CRUSHERS
Roll crushers are used for
intermediate stages of
reduction.
Very limited reduction
capability, see Table 14.2,
page 411.

ROLL CRUSHERS
The maximum size stone that may
be fed a roll crusher is directly
proportional to the diameter of the
rolls. If the stones are too large,
they will not grip the material and
pull it through the crusher.
See Figure 14.10, page 421.

IMPACT
CRUSHERS
Impact breakers
provide a
cubical product
even with slabby
material.

IMPACT CRUSHERS
Speed of
rotation is
important
to the
effective
operation
of these
crushers.

SPECIALTY CRUSHERS
Ball Mill
Ball mills use steel
balls to produce fine
material.

BALL MILL

PRODUCTION EXAMPLE
A 42X48-in jaw crusher w/ a closed
setting of 3 in. will produce what
tonnage per hr in the following size
ranges of a stone having a unit
weight of 110 lb/cf crushed:
- 2 in. +
- Between 2 and 1 in.
- 1 in. -

CRUSHER
PRODUCTION
Table 14.3 gives capacities for
Blake-type jaw crushers.
Table 14.4 for gyratory
crushers.

Table 14.5 for cone crushers.

STEP 1. CAPACITY
OF CRUSHER
42- by 48-in jaw crusher
Closed setting of 3 in.

Capacity of crusher

STEP 1. CAPACITY
OF CRUSHER
42- by 48-in jaw crusher
Closed setting of 3 in.

Capacity of crusher
Table 14.3, p. 413

190 tph

CRUSHER
PRODUCTION

Read the fine print.

STEP 2. CAPACITY
ADJUSTED
Capacity of crusher 190 tph
Stone unit weight of 110 lb/cf

110 lb / cf
Weight
Adjustment=
1
UnitUnit
weight
adjustment
100 lb / cf

or 1.1

190 tph 1.1 = 209 tph

STEP 3. SIZE
DISTRIBUTION
Jaw closed setting, 3 in.
Refer to Figure 14.5, page 415

Horizontal scale is the crusher

setting: Read down the 3 in.
line and find the % passing a
2 1/2 and 1 1/2 inches.

STEP 3 SIZE DISTRIBUTION

Fig. 14.5, read down the 3 line to the size.

Percent
passing
is on
the left
side of
the
figure.

STEP 3 SIZE
DISTRIBUTION
Figure 14.5, page 415

Horizontal scale is the crusher

setting: Read down the 3 in.
line and find the % passing at
2 1/2 and 1 1/2 inches.

2 in. 73 % passing
1 in. 46 % passing

STEP 4. QUANTITY
Output of crusher, 209 tph
Size,
%
% in Total Produced
passing range output
tph
in.
Over 2 100-73 27
209
56.4
2- 1
1- 0

73-46
46-0

27
46

209
209

56.4
96.2

STEP 4. QUANTITY
Output of crusher, 209 tph
Size,
%
% in Total Produced
passing range output
tph
in.
Over 2 100-73 27
209
56.4
2- 1
1- 0

73-46
46-0
Total

27
46
100

209
209

56.4
96.2
209

STEP 5. CHECK
Check your work, always total
Percent must come to 100%
Output must equal quantity
Output of crusher, 209 tph
2 - 1
1- 0

73-46
46-0
Total

27
209
46
209
100
OK

56.4
96.2
209
OK

ROCK TYPE EFFECT

Is there data available

concerning rock type?

ROCK TYPE EFFECT

Adjustment factors for rock type,
limestone as a production base
Rock
Factor

Limestone

1.00

Dolomite

1.00

Gneiss

0.95

Slate

0.90

Granite

0.90

coursed grained

ROCK TYPE EFFECT

Rock

Factor

Chert

0.80

Quartzite

0.80

Rhyilite

0.80

Granite

0.80

Diorite

0.80

Basalt

0.75

fine grained

ROCK TYPE EFFECT

190 tph 1.1 209 tph

If the rock in the previous example
was limestone the 209 tph is correct.
However, consider that it is a diorite.
What would be the production?

209 tph 0.8 167 tph

EXAMPLE No. 2
Select a jaw crusher for
primary crushing and a roll
crusher for secondary
crushing to produce 110 tons
per hour of limestone rock.
The maximum-size stone from
the quarry will be 16 in.

EXAMPLE No. 2
The stone is to be crushed to
the following specifications:
Passing

Retained on

Percent

2
2

100
40-60

18-30
15-25
10-20

STEP 1 Select a Jaw

Crusher
The maximum-size stone from
the quarry will be 16 in.
Minimum top width (opening)
of the jaw crusher:
16 in. + 2 in. = 18 inches
Text page 412

STEP 1 Select a Jaw

Crusher
Produce 110 tons per hour
of limestone rock.

Try a 24 X 36 in. crusher

with a 3 in. closed setting,
114 tph
Table 14. 3

STEP 2 Size Distribution

Fig. 14.5, read down the 3 line to the
size. Percent passing is on the left
side of the figure.
Size
% passing
Over 2

100-73

2-1

73-39

1-

39-26

26-11

-0

11-0

STEP 2 Size Distribution

Size

% passing % in range

Over 2

100-73

27

2-1

73-39

34

1-

39-26

13

26-11

15

-0

11-0

11

STEP 3 Output Ranges

Size

% range Feed tph Size tph

Over 2

27

110

29.7

2-1

34

110

37.4

1-

13

110

14.3

15

110

16.5

-0

11

110

12.1

STEP 3 Output Ranges

Size

% range Feed tph Size tph

Over 2

27

110

29.7

2-1

34

110

37.4

1-

13

110

14.3

15

110

16.5

-0

11

110

12.1

100%

110 tph

STEP 4 Select a Roll

Crusher
Size

% range Feed tph Size tph

Over 2

27

110

29.7

2-1

34

110

37.4

The roll crusher must handle

29.7 plus its own return feed.
See discussion page 430.

STEP 4 Select a Roll

Crusher
The roll crusher must handle
29.7 plus its own return feed.
29.7 tph
34.9 tph
0.85

Maximum size from the

jaw crusher 3 in.

STEP 5 Roll Diameter

Try a 2 in roll crusher setting.
Radius (R) of the rolls = ?
C, roll setting = 2 in.
A, maximum feed-size feed = 3 in.
Equation 14.1

1
R
11.8 in.
0.085

STEP 5 Roll Diameter

The roll diameter must be at
least 23.5 in. and the crusher
must handle 34.9 tph.
Table 14.6
Try a 24 X 16 crusher with a 2 in.

closed setting -- 115 tph.

The first number indicates the

diameter of the rolls.

STEP 6 Roll Crusher

Size Distribution
Fig. 14.5, read down the 2 line to the size.

Size

% passing % in range

2-1

100-56

44

1-

56-36

20

36-16

20

-0

16-0

16

STEP 7 Roll Crusher

Output Ranges
Size

% range Feed tph Size tph

2-1

44

29.7

13.1

1-

20

29.7

5.9

20

29.7

5.9

-0

16

29.7

4.8

100%

29.7 tph

STEP 8 Combined Output

Size

Jaw tph Roll tph

2-1

37.4

13.1

Total
tph
50.5

1-

14.3

5.9

20.2

19

16.5

5.9

22.4

20

-0

12.1

4.8

16.9

15

110 tph

% in
range
46

100%

STEP 9 Check
Requirement
Size

Require
ment
2-1 40-60

% in
range
46

ok

1-

18-30

19

ok

15-25

20

ok

-0

10-20

15

ok