QUARRY

Introduction:
A quarry is a kind of open-pit mine from which rock or minerals are extracted. Quarries are
normally utilized for extracting building materials, like dimension stone. Quarries are normally
shallower than other kinds of open-pit mines. Quarries are also at times used as filming locations
In other words a quarry is a big man-made hole in the ground from where minerals or rock are
taken out. Quarries are made when big deposits of commercially helpful minerals or rock are
found close to the Earth's surface. Quarrying is a type of mining and is also called as open pit
mining or strip mining. When minerals are found profound beneath the surface, a deep mine has
to be dug to dig out them. Quarries are normally dug deeper and bigger; awaiting the mineral
resource is worn out. When they are no longer used, quarries are frequently utilized as landfill
sites for the disposal of waste.
Kinds of rock
Kinds of rock extracted from quarries comprise:

Clay
Gypsum
Limestone
Iron Ore
Silica sand

Problems
Quarries in level areas frequently have particular engineering problems for drainage. The
Coquina Quarry is excavated to more than 60 feet (18 m) beneath sea level. To lessen surface
leakage, a moat lined with clay was constructed round the complete quarry. Ground water that
leaks into the pit is pumped up into the moat.
Many quarries fill with water after desertion and turn into lakes. Further quarries are made into
landfills.

Page 1

Study of Different Raw Materials Quarries

Limestone
Limestone is a sedimentary rock composed largely of the minerals calcite and aragonite, which
are different crystal forms of calcium carbonate (CaCO3). Most limestone is composed of
skeletal fragments of marine organisms such as coral or foraminifera.

Limestone makes up about

10% of the total volume of all
sedimentary
rocks.
The
solubility of limestone in water
and weak acid solutions leads
to landscapes, in which water
erodes the limestone over
thousands to millions of years.
Most cave systems are through
limestone bedrock.
Limestone has numerous uses
as a building material, as
aggregate for the base of roads,
as white pigment or filler in
products such as toothpaste or
paints, and as a chemical
feedstock.

Most carbonate rocks were deposited from seawater. These sedimentary carbonate rocks are
common on every continent and have formed through most of geologic history; they are still
forming today in the tropics as coral reefs and at the bottoms of shallow seas.
Marine limestone forms because seawater has high concentrations of two key dissolved
chemicals-calcium (Ca++) and bicarbonate (HCO3-) ions. In the near-surface layer of most
oceans, corals, clams, and other sea-dwelling creatures use these two chemicals to make
protective shells by combining them to form calcite or "aragonite," which is the same chemical
composition as calcite but has a different crystal form.

Page 2

Sedimentary limestone deposits can be extensive, covering hundreds of square miles, and can be
relatively uniform in thickness and quality. Therefore, limestone quarries can be large and long
lived, mining limestone layers that can be hundreds of feet thick over areas of several square
miles. Many quarries produce multiple products, and crushed rocks that are not pure enough for
certain uses may still be suitable as road aggregate. Marble quarries can also be very large.
However, these rocks that were once regularly bedded have been metamorphosed into irregularly
shaped bodies that are more difficult and costly to mine.
Shale
Shale is a fine-grained sedimentary rock that forms from the compaction of silt and clay-size
mineral particles that we commonly call "mud". This composition places shale in a category of
sedimentary rocks known as "mudstones". Shale is distinguished from other mudstones because
it is fissile and laminated. "Laminated" means that the rock is made up of many thin layers.
"Fissile" means that the rock readily splits into thin pieces along the laminations.
Cement is common material that
is often made with shale. To make
cement, crushed limestone and
shale are heated to a temperature
that is high enough to evaporate
off all water and break down the
limestone into calcium oxide and
carbon dioxide. The carbon
dioxide is lost as an emission but
the calcium oxide combined with
the heated shale makes a powder
that will harden if mixed with
water and allowed to dry. Cement
is used to make concrete and
many other products for the
construction industry.

Shale is a rock composed mainly of clay-size mineral grains. These tiny grains are usually clay
minerals such as illite, kaolinite and smectite. Shale usually contains other clay-size mineral
particles such as quartz, chert and feldspar. Other constituents might include organic particles,
carbonate minerals, iron oxide minerals, sulfide minerals and heavy mineral grains. These "other
constituents" in the rock are often determined by the shale's environment of deposition and often
determine the color of the rock.

Page 3

Like most rocks, the color of shale is often determined by the presence of specific materials in
minor amounts. Just a few percent of organic materials or iron can significantly alter the color of
a rock.

Iron Ore
Earth's most important iron ore deposits are found in sedimentary rocks. They formed from
chemical reactions that combined iron and oxygen in marine and fresh waters. The two most
important minerals in these deposits are iron oxides: hematite (Fe2O3) and magnetite (Fe3O4).
These iron ores have been mined to produce cement.
Nearly all of Earth's major iron
ore deposits are in rocks that
formed over 1.8 billion years
ago. At that time Earth's oceans
contained abundant dissolved
iron and almost no dissolved
oxygen. The iron ore deposits
began forming when the first
organisms
capable
of
photosynthesis began releasing
oxygen into the waters. This
oxygen immediately combined
with the abundant dissolved
iron to produce hematite or magnetite. These minerals deposited on the sea floor in great
abundance, forming what are now known as the "banded iron formations." The rocks are
"banded" because the iron minerals deposited in alternating bands with silica and sometimes
shale. The banding might have resulted from seasonal changes in organism activity.

Silica sand
Silica sand is one of the most common varieties of sand found in the world. It is used for a wide
range of applications. Silica sand is used in industrial processing, to make cement, glass, as fill,
and to create molds and castings.
Sand is the general term for broken down granules of minerals or rocks, technically between
about one-sixteenth of a millimeter to two millimeters in diameter, falling between silt and
gravel in the spectrum of sizes. There are many varieties of sand in the world, each with their
own unique composition and qualities. The white sandy beaches of iconic tropical destinations,
for example, are made up primarily of limestone that has been broken down, while many black
sands are either volcanic in origin or contain magnetite. Other sands have high levels of iron in
them, and so are rich and yellow in color.

Page 4

The most common mineral in the Earths continental crust is quartz, and most silica sand is made
up of broken down quartz crystals. Silica is another name for silicon dioxide, SiO2, of which
quartz is a specific latticed structure. So silica sand is quartz that over the years, through the
work of water and wind, has been broken down into tiny granules. These granules can be used
for many different purposes, and can be found in most non-tropical regions of the world.
Gypsum
Gypsum is a naturally occurring mineral mined from deposits formed by ancient sea beds as a
raw material. Composed of calcium sulfate and water, it is used for a variety of manufacturing,
industrial, and agricultural uses. An important property of gypsum is that it is naturally fireresistant.
Cement is produced from a chemical combination of
calcium, silicon, aluminum, iron and small amounts
of other ingredients that are carefully measured to
get the right result. Often gypsum is added during
the final grinding process since it helps regulate how
long
the
concrete
takes
to
set.
Gypsum is added to control the setting of cement.
If not added, the cement will set immediately after
mixing of water leaving no time for concrete placing.

Average Chemical Analysis

Limestone
L.o.I

43.30 %

SiO2

0.82%

CaO

53.87 %

Al2O3

0.57%

SO3

0.16 %

MgO

0.76 %

Na2O

0.12 %

K2O

0.01%

Moisture

0.17 %

Page 5

Shale
L.O.I

11.23 %

SiO2

46.64

Al2O3

13.21 %

Fe2O3

6.65 %

CaO

7.48 %

MgO

3.72 %

K2O

2.02%

MnO

0.02 %

P2O5

0.04 %

TiO2

0.53 %

Moisture

6.88 %

Gypsum
Ig loss

16.48 %

SiO2

0.51 %

Al2O3

(12 ----- 32)

(0--------1)
(0-------.5)

Fe2O3

0.02 %

CaO

35.23 %

MgO

0.77 %

MnO

0.00 %

P2O5

0.00 %

TiO2

0.02 %

SO3

47.77 %

Na2O

0.12 %

K2O

0.02 %

Total

100.87 %

(0------.1)

Page 6

Mining:
Mining is the extraction of valuable minerals or other geological materials from the earth from
an ore body, lode, vein, seam, or reef, which forms the mineralized package of economic interest
to the miner.
Ores recovered by mining include metals, coal, oil shale, gemstones, limestone, dimension
stone, rock salt, potash, gravel, and clay. Mining is required to obtain any material that cannot be
grown through agricultural processes, or created artificially in a laboratory or factory. Mining in
a wider sense includes extraction of any non-renewable resource such as petroleum, natural gas,
or even water.

Limestone Mining and Processing Operations

Limestone
Limestone is a sedimentary rock composed primarily of calcium carbonate with the occasional
presence of magnesium. Most limestone is biochemical in origin meaning the calcium carbonate
in the stone originated from shelled oceanic creatures. Limestone can also be chemical in origin
as is the case with travertine. Chemical limestone forms when calcium and carbonate ions
suspended in water chemically bond and precipitate from their aquatic sources.
Because of its high calcium content, limestone is usually light in color, although many
variations exist. Commercially, the term limestone includes dolomite, dolomite limestone, oolitic
limestone, and a porous calcite rock that is commonly formed near hot springs.

Limestone Mining Operations

Limestone mining operations mainly consists.

Drilling

Blasting (Primary and Secondary)

Loading/Transporting

Crushing (Hammer Crusher)

Page 7

Drilling:
There are three drilling techniques to choose from:
i.

Solid bit drilling with removal of the cuttings by circulating water or other flushing
medium

ii.

Core drilling with continuous core extraction

iii.

Rotary drilling with removal of cutting by means of compressed air

Solid bit drilling with rotary bits and removal of cutting with flushing medium is suitable only in
solid rock deposits.
The selection of the most suitable drilling method in terms of technical suitability and also of
economy is the fundamental condition for successful exploration.

Page 8

Rotary Drilling (Crawler Mounted Machines)

In rotary drilling crawler mounted machines are used to for the drilling of blast holes. This
method is unsuitable for deposits consisting of loose or soil type deposits. Crawler mounted
machines used for the drilling of large diameter holes for blasting.
The drill bit, operating by rotary action, shatters the rock, and the cuttings are removed from the
hole by air issuing from the bit.
The dust carried out of the hole with this flushing air can be trapped in a dust collector, which is
mounted on the drilling machine. It comprises a cyclone In which the coarser particles are
precipitated, while the finer ones are retained in special fitters. The suction extractor is
connected to a flexible tube which terminates in a plastic sleeve forming an airtight closure over
the mouth of the borehole, so that alt the dust can be collected.

Page 9

Drilling machines
Modern rotary drilling machines are operated by just one man. They mostly have fully hydraulic drive
systems, are reliable in operation and attain drilling rates of up to 30 m/hour, depending on the nature of
the rock and the diameter of the hole. The power pack compressor, hydraulic units, drilling mast, rod
magazine, operator's platform and dust suppression system are mounted on a traction unit usually
equipped with crawler tracks, The prime mover is generally a diesel engine, Although it is more
expensive in energy consumption than an electric motor, it is nevertheless preferred because It provides
better mobility of the drilling machine and make it independent of power feed cables. On some machine
a slewing ring enable the superstructure to swivel on the crawler chassis. The use of increasingly long
drill rods likewise aims at Increasing the efficiency of the machine, a trend which has led to the
development of the '"single-pass" machine which drills the hole to its full depth with just one long rod,
i.e., without having to couple successive rods as drilling proceeds.

There are some drilling machines and air compressors are listed below used in QUARRY;
No

Description

Engine Model/Machine
Model

Capacity

1.

Crawler drill Furukawa no.1

PCR-200

75 mm dia hole

2.

Crawler drill Furukawa no.2

PCR-200

75 mm dia hole

3.

Crawler drill Atlas no. 3

ROC-460

110 mm dia hole

4.

Crawler drill Atlas no. 4

ROC-460-5

110 mm dia hole

5.

Hydraulic Rig Rock Atlas no 6

L6-44/CAT C-11

110-152 mm dia hole

6.

Air Compressor Airman no 1

PDR-250

250 CFM

7.

Air Compressor Sulair no 2

750HH

750CFM

8.

Air Compressor Sulair no 3

750HH

750CFM

9.

Air Compressor Atlas Copco

no 4

XAHS-830

830CFM

10.

Air Compressor Atlas Copco

no 5

XAHS-830

830CFM

Page 10

Page 11

Blasting
When the blast holes have been drilled, they are charged with explosive and the charges are
fired. The object of blasting is to loosen and fragment the rock so as to obtain rock pile suitable
for loading. The amount of explosive to be used in any given case will depend on the specific
explosive consumption, i.e., the amount needed for producing a tone of rock pile or for loosening
and fragmenting a cubic meter of solid rock. It is an empirical value which varies from one set of
quarrying conditions to another and should be known in any quarry where production is in
progress.
The smaller the spacing and the burden, with correspondingly smaller blast hole diameter the
better will be the fragmentation obtained, because the explosive will be more uniformly
distributed along the face. A finer location grid is more particularly advantageous in dealing with
thick-bedded rock tending to produce a coarsely fragmented rock pile
With increasing blast hole diameter, spacing and burden there is an Increase both in the
Proportion of very finely fragmented material (due to shattering of the rock in the immediate
vicinity of the charge) arid in that of Large lumps (dislodged from the Darts of the rock farthest
from the charge) A coarse grid of this kind will as a rule be economically advantageous only in
rock which is fractured finely fissured and brittle Blasting by the tunneling method, now seldom
used represents an extreme case of fining large concentrated charges.

Page 12

Emulsion explosives
Emulite
This cap sensitive explosive has plastic consistency and is very suitable for achieving high
loading density. It has excellent blasting properties. It can be used as bottom charge for any kind
of blasting. Due to its consistency and high water resistance it can be confidently employed for
deep under water blasting.
Technical data
Density

1.25 g/cc

Gas Volume

860 lit. / Kg

V.O.D (unconfined) 4600 - 5000 m/sec

Sensitivity

Detonator No. 8

Consistency

Emulsion

Powder explosives
ANFO
ANFO is a low density explosive of relative high weight strength well suited mainly as a column
charge in all types of rocks where conditions are moderately dry. It is non cap sensitive explosive
and require premier for initiation. ANFO has excellent storage properties and offer maximum
safety in handling and transportation.

Composition
Ammonium nitrate
Fuel oil

95.5 %
4.5 %

Page 13

Technical data
Density

0.90 g/cc

Gas Volume

918 lit. / Kg

V.O.D (unconfined) 3000 m/sec

Sensitivity

Primer Required

Consistency

Prills

Blasting Accessories:
DETONATOR
Standard type Plain Detonator consists of base charge of high explosive and a primary charge of
an initiating explosive pressed in to an aluminum tube. It is used with safety fuse.

TECHNICAL DATA
Length of Aluminum casing 41mm(Nominal)
Outer Dia
Use

7mm

In combination with safety fuse

PACKING
100 Detonators packed in a smaller card box. 50 small boxes packed in a master card
board box containing total of 5000 detonators.

WABOCORD (DETONATING CORD)

Wabocord consist of a core of high explosive contained in polythene and wrapped in various
layers of cottons /jute yarn. The detonating cord is then coated with PVC , giving it a high tensile

Page 14

strength and making it water proof . the structure of Wabocord assures its efficient field
performance as it is unaffected by both heat and cold within a wide range from - 60 C to 30 C

Technical Data
Velocity of detonation
Water resistance

6000-7000 m/sec
Water proof ,can

Withstand pressure of 25 meters water head for 48 hours.

Explosive grammage 10 + 1 g/m

SAFETY FUSE
Safety fuse consist of a central core of specially formulated black
power with jute and cotton countering. Water proofing is done by
bitumen, wax as well as PVC. It is designed to propagate flame to
the plain detonators within time limit.

Composition
Charcoal

10---20 %

Sulfur

10---15%

Potassium nitrate

70---80%

Technical data
Burning Time 100-120 m/sec
Suitable for damp and dry conditions
Coating

PVC / Bitumen

Packing
4 reels of 250 meters each, packed in a cardboard box.

Page 15

Delay
Short-delay blasting is performed by means of short-delay electric detonators or, when blasting
with a detonator fuse, by means of pyrotechnic delay mechanisms (relays). Single-row and multi
row short-delay blasting arrangements are used. The principal single-row short-delay blasting
arrangements are sequential row blasting, in which the charges are detonated one by one from
one end to the other, and consecutive-counter blasting, in which the detonation proceeds from the
center of a row toward its flanks, providing head-on collision of the fragments and formation of a
pile against the center of the face. In cases of a large face, the method can be repeated, forming
several collision centers along the front (wave arrangement).
Advantages of Delay:
1.

Reduce to fly rock.

2.

Reduce free face between two lines.

3.

Control vibration

4.

Control boulders during steaming and to control over size

Secondary blasting
No blasting method can completely avoid the products of a certain proportion of oversize pieces
of rock ("boulders"). These oversize pieces have to be further reduced; otherwise they would
have an obstructive effect on the further operations of loading, haulage and crushing. The
maximum size of bounders that can be tolerated will of course depend also on the size and
capacity of the handling and crushing plant used in the quarry. Boulders are usually broken up by
blasting (secondary blasting) because this nearly always give a suitable products, whatever the
type of rock This is mostly done by drilling small-diameter holes to a depth equal to a little more
than the diameter of the boulder.

Page 16

Page 17

LOADING
Loading machines
The machines used for loading in open-pit quarrying in solid rock. Including limestone and shale
are:

Cable Operated Excavators

Hydraulic Excavators
Wheel Loaders
Crawler Loaders

The choice of machine to be used in any given instance must be made with great care.be use
once a particular system has been adopted. Large ones usually operate with several systems of
loading machinery, enabling these to be interchanged suit varying conditions of service.

Wheel loaders
The wheel loader, or wheel-mounted loading shovel, has been further improved in recent years.
Besides carrying out rock loading duties in the quarry, the wheel loader is suitable for clearing
and trimming work as well as for other handling and loading duties in the cement works itself.
Most of t base machines used in the cement industry have bucket capacities of between 3 and 8
m3. About 80% of all these machines employed in rock quarrying, and 100% of those with more
than 2m3 bucket capacity. Such machines are higher loading rates than rigid framed wheel
loaders of equal bucket capacity, Because of the travel movements that the loader has to perform
between scooping up the material and depositing it in the haulage vehicle, its working cycle time
is longer than that of the excavator. The travel movements cause heavy wear on tyres. Efforts to
improve tyre service life include the use of tyre chains for protection against cuts by sharp pieces
of rook. Another development with the same purposes the so called headless tyre, which has a
carcass formed as a oval-section air chamber, to the circumference of which a renewable rutting
belt ts attached.

Page 18

The service ice of a wheel loader is shorter than that of an excavator. The mechanical and
hydraulic systems of the articulated wheel loader with center pivot steering are sophisticated and
subject to severe operating loads and stresses, requiring a correspondingly large amount of
servicing and maintenance. Against this the initial cost of the machine is relatively low, and
when used for load and carry duties it enables savings in haulage vehicles and personnel to be
effected.

Excavators
Excavators have long been used in quarrying. they Initially made little headway because of their
small size (.3-.7m3 bucket capacities) and the Flood attachment of the bucket to its arm It was
only with the Introduction of the movable loading bucket in Iieu with the fixed bucket that the
advantages of these machines began to be widely recognized.
Excavators are heavy construction equipment consisting of a boom, stick, bucket and cab on a
rotating platform known as the "house". The house sits atop an undercarriage
with tracks or wheels. A cable-operated excavator uses winches and steel ropes to accomplish
the movements. They are a natural progression from the steam shovels and often called power
shovels. All movement and functions of a hydraulic excavator are accomplished through the use
of hydraulic fluid, with hydraulic cylinders and hydraulic motors. Due to the linear actuation of
hydraulic cylinders, their mode of operation is fundamentally different from cable-operated
excavators.

Page 19

The bucket of the hydraulic excavator has three degrees of freedom.

1. raving the bucket,
2. crowding (forward motion of the bucket)
3. swiveling of the bucket in relation to the arm
Hydraulic excavators mostly have a service weight in the range between 50 and 90t. the bucket
capacities of 3 to 4m3. Larger machines are seldom used an cement raw materials quarrying. In
the open pit mining of other minerals, however, there is a trend towards the use of machines
weighting more than 100 t. with buckets of 6 to 8m3.
The three degrees of freedom enable the hydraulic excavator bucket to perform a swiveling
movement up or down, so as to adjust the postilion of its teeth to obtain the best possible
penetration for digging, without causing a collapse of a heaped up rock pile. Also, larger pieces
of rock can be selectively scooped up from the pole.
For digging from a rock face the angle of the teeth can be suited to the direction of the strata. The
excavator can in fact be used for the direct breaking out of material from a quarry face, though of
course the loading cycle time will then be increased and the performance of the machine In terms
of loading rate {tons/hour) correspondingly reduced. However, as an adjunct to blasting, the
hydraulic excavator can suitably be used for clearing and trimming the quarry floor and for
removing any toe rock masses that have been left standing.

On the other hand, hydraulic excavators are usually at a disadvantage in having a shorter service
life and a lower degree of operational availability. Although the drive and hydraulic units are
generally so designed as to be readily exchangeable and renewable repairs nevertheless require
more skill and care.

Page 20

Hydraulic excavators are available as diesel or as electrically powered machines The high cost of
diesel fuel is a strong argument s favor of electric drive, which has the additional advantage of a
higher service life expectation. On the other hand, it receives its power supply through a cable
which not only limits its range of action but may also Impede the movements of the haulage
vehicles
The use of hydrostatic drive in combination with power summation control achieves favorable
operating efficiency. With this method of control the power and the working speed can be
adapted to the working conditions, while the oil pressure in the dual circuit hydraulic system
plays a major part on applying the appropriate force in performing the required motion (bucket
slewing gear, bucket arm, boom, travel machinery), The rate of oil supply is the deciding factor
for the speed with which the motion is performed.
Specifications of different loading machines used at quarry.
No

Description

Model/Engine No

Capacity

1.

Komatsu wheel loader no.1

Komatsu SA6D110-1

3.3 m3

2.

Komatsu wheel loader no. 2

Komatsu SAA6D170E-3

8.7 m3

3.

CAT wheel loader no. 1

CAT 3408

6.1 m3

4.

CAT wheel loader no. 2

CAT 3408

6.1 m3

5.

CAT wheel loader no. 3

CAT 3406C

4.2 m3

6.

CAT wheel loader no. 4

CAT 3406-E

4.5 m3

7.

CAT wheel loader no. 5

CAT C-11

4.0 m3

8.

CAT wheel loader no. 6

CAT C-18

6.4 m3

9.

Komatsu dozer no.1

Komatsu S6D155-4

14 m3

10.

Komatsu dozer no. 2

Komatsu SAA6D140E-2

9.4 m3

11.

CAT dozer no 1-4

16.4 m3

Page 21

Transporting:
DUMPER:
A dumper is a vehicle designed for carrying bulk material, often on building sites. Dumpers are
distinguished from dump trucks by configuration: a dumper is usually an open 4-wheeled vehicle
with the load skip in front of the driver, while a dump truck has its cab in front of the load. The
skip can tip to dump the load; this is where the name "dumper" comes from. They are normally
diesel powered.
A towing eye is fitted for secondary use as a site tractor. Dumpers with rubber tracks are used in
special circumstances and are popular in some countries.

Early dumpers had a payload of about a ton and were 2-wheel drive, driving on the front axle
and steered at the back wheels. The single cylinder diesel engine (sometimes made by Lister)
was started by hand cranking. The steering wheel turned the back wheels, not front. Having
neither electrics nor hydraulics there was not much to go wrong. The skip was secured by a catch
by the driver's feet. When the catch is released, the skip tips under the weight of its contents at
pivot points below, and after being emptied is raised by hand.

Page 22

Specifications of different loading machines used at quarry.

No

Description

Engine/model no

Capacity

1.

Komatsu dump truck no

Cummins NTA-855C

20 m3 (32 tone)

2.

Volvo dump truck

Volvo Sweden D-13

15 m3 (13 tone)

3.

CAT dump truck no (1-6)

4.

CAT dump truck no 7,8

35.2 m3 (52.3 tone)

CAT-C-27

42.5 m3 (63.5 tone)

Page 23

Impact Hammer Crusher (limestone Crusher)

A crusher is a device that is designed to reduce large solid chunks of raw material into smaller
Chunks. Crushers are commonly classified by the degree to which they fragment the
starting material with primary crushers that do not have much fineness, intermediate
crushers having more significant fineness and grinders reducing it to a fine power.

Here the material is held within a cage, with openings of the desired size at the bottom, end
or at sides to allow crushed material to escape through them. Here the breakage can take
place in a much shorter scale compared to fragmentation process used in cone or jaw
crushers .

An impact crusher can be further classified as Horizontal impact crusher and vertical shaft
impact crusher based on the type of arrangement of the impact rotor and shaft. These break rock
by impacting the rock with hammers/blow bars that are fixed upon the outer edge of a spinning
rotor. Here the rotor shaft is aligned along the horizontal axis. The input feed material hits
the rotating hammers of the rotor and due to this sudden impact it breaks the material and further
breaks the material by throwing it on to the breaking bar/anvils. These have a reduction ratio of
around 10:1 to 25:1 and are hence used for the extracted materials, sand, gravels etc.

Here the feed material is crushed by highly rigorous impacts originating in the quick rotational
movement of hammers/bars fixed to the rotor. The particles are then crushed inside the
crusher as they collide against crusher parts and against each other, producing finer, bettershaped product. Adjusting the distance between impact frame and rotor frame can change
the shape and size of the output. In an impact crusher the breakage takes place in a lesser time
span as compared to the conical or jaw crushers. So here the nature and magnitude of forces as
well as the energy dissipated due to impact breakage is different from that of the relative
slow breaking that occurs due to compression or shear in other type of crushers.

Page 24

Operating principle:
The Impact Crusher Machine rotor revolves in fixed direction by means of driving action
of triangle belt that connects with motor. Above rotor, there are sets of suspended impact plates.
Material enters into the crushing chamber through the charging hole and feeding guide plate. The
blow bars fixed on rotor strikes the feed material onto impact plate and then fall from it
to mutually shock material blocks. Therefore, material will be moved recurrently and
repeatedly in the crushing chamber that is composed of rotor, impact plate/ anvils, hammers/
blow bars , by means of which intense shock phenomenon will act predominantly, and the
material will be crushed along its natural crack and hence bulge. The gap between impact plate
and hammer/blow bar can be adjusted according to practical requirement by adjusting the angle
and distance of the impact anvils. Product output is easily controlled by varying the rotor speed,
input feed rate and the grinding screen configuration.
For good performance, all the factors below should be taken into account:

Proper crushing chamber for the material

Feed rate control
Discharge conveyor with regards to crushers capacity
Selection of proper material and size for the impacting members.
Setting of the optimum number of hammers, rotor speed, etc.
The input material properties like density, strength, etc.

The factors below, when not taken care of may affect the performance of a crusher

Occurrence of humid material in the crushers feed

Extreme humidity
Isolation of feed in the crushing chamber
Irregular dispersal of feed over the crushing chamber
Deficiency of feed control
Incorrect motor size
Deficient capacity of the crushers discharge conveyor
Extremely hard material for crushing
Crusher functioning at a rotation speed below required conditions.

The average life if a hammer in an impact crusher depends on the kind of operation it is being
used, the hardness of the material of the hammer, the usage of the crusher, depth of penetration
of material into the hammer faces and the kinetics of the hammer rotation.

Page 25

Technical Specifications
No

Description

Crusher I

Crusher II

Material

Limestone

limestone

Company

UBE JAPAN

FLS DENMARK

TYPE

Impact hammer crusher

Impact hammer crusher

Capacity

400 T/Hr.

800 T/Hr.

Feed size

1200 mm

1800 mm

Product size

90% <50mm

95% <50mm

Main motor

450 KW

1250 KW

Power consumption

2-3.10 KWH/T

1.5 KWH/T

FRAME

Steel plate, cast steel

Steel plate, cast steel

10

Hammer

Special wear resisting steel

Special wear resisting steel

11

Breaker plate

High manganese chrome steel

High manganese chrome steel

12

Shaft

Nickel chrome molybdenum

steel

Nickel chrome molybdenum

steel

Page 26

Clay Crusher: (Roller Crusher)

The Roller Crusher consists of two rollers with cast bosses. One of the roller shafts is adjustable
while the other has a fixed position and is provided with a flywheel. The gap between the two
rollers can be varied according to the degree of crushing required. The motor power is
transmitted through a gear drive and two cards a shaft to permit the adjustment of the space
between the rollers. Both rollers have scrapers to remove any material sticking to the surface.
The clay is drawn into the gap between the rolls by their rotating motion and a friction angle
formed between the rolls and the particle, called the nip angle. The two rolls force the particle
between their rotating surface into the ever smaller gap area, and it fractures from the
compressive forces presented by the rotating rolls. Some major advantages of roll crushers are
they give a very fine product size distribution and they produce very little dust or fines.

Technical Specifications
No

Description

Unit II (FLS, Denmark)

1.

Type

Roller crusher

2.

Capacity

350 T/Hr.

3.

Feed size

500 mm

4.

Product size

100% <50mm

5.

Main motor

250 KW

6.

Power consumption

0.6 KWH/T

Page 27

Belt conveyors
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor). A belt conveyor system is one of many types of conveyor systems.
A belt conveyor system consists of two or more pulleys (sometimes referred to as drums), with
an endless loop of carrying medium - the conveyor belt - that rotates about them. One or both of
the pulleys are powered, moving the belt and the material on the belt forward. The powered
pulley is called the drive pulley while the unpowered pulley is called the idler pulley. There are
two main industrial classes of belt conveyors;
Those in general material handling such as those moving boxes along inside a factory and bulk
material handling such as those used to transport large volumes of resources limestone, clay,
coal, iron ore, silica sand, overburden and more.
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials.

The belt consists of one or more layers of material. Many belts in general material handling have
two layers. An under layer of material to provide linear strength and shape called a carcass and
an over layer called the cover.
The carcass is often a woven fabric having a warp & weft. The most common carcass materials
are polyester, nylon and cotton.
The cover is often various rubber or plastic compounds specified by use of the belt. Covers can
be made from more exotic materials for unusual applications such as silicone for heat or gum
rubber when traction is essential.
Material flowing over the belt may be weighed in transit using belt scale. Belts with regularly
spaced partitions, known as elevator belts, are used for transporting loose materials up steep
inclines. Belt Conveyors are used in self-unloading bulk freighters and in live bottom trucks. Belt
conveyor technology is also used in conveyor transport such as moving sidewalks or escalators,
as well as on many manufacturing assembly lines.

Page 28

Encouraged by the good experience gained in lignite mining, belt conveyor systems have
evolved into an important means of transport in open pit quarrying and mining operations in
loose-textured material or soft ground. In rock quarrying on the other hand this method of
maternal handling is only sporadically used and then for the most part only in the production of
raw materials for the cement industry.
The coarsely fragmented material produced by rock blasting has to undergo suitable primary
crushing in a mobile or portable plant and has to be fed carefully on to the belt conveyor by
means of a special device so as to prevent damage to the belt.
The sequence:

Drilling and Blasting

Loading
Haulage (e.g, in Dump Trucks)

Is Replaced By

Drilling and Blasting

Loading
(Primary) Crushing
Conveying (Belt Conveyor)

Overland belt conveyor systems are usually designed for carrying the quarried materials over
medium distances. These installations are characterized by flexibility of design, enabling them to
adapt themselves to uneven terrain conditions. For example, by the use of catenar type idler sets
with rollers mounted on steel wire ropes. The specific cost of transport with the belt conveyor
decreases with Increasing length of the system and increasing material handling rate. The latter
in turn being dependent on belt width, speed and cross-sectional shape. The speed may be
anything up to 3 second and instead of a standard trough angle of 20", more deeply roughed
cross-sections with angles of 25" or 30 may be used. With increasing center to-center distances
the steel wire cable belt becomes the type predominantly employed. Depending on the length of
the belt, its slope (angle of ascent) and handling rate, one or more drive motors, installed at one
or both ends of the belt, are used to power it.
In comparison with haulage, the overland belt conveyor makes much more modest demands
upon route alignment and the structures for bridging any traffic routes that have to be crossed not least because the uniformly distributed loading of the conveyor does not require any
appreciable bearing capacity of the subsoil. Gradients of up to 18" can moreover easily be
overcome.

Page 29

A drawback of the belt is its limited adaptability to alignments curved on plan and the
susceptibility of the belt to suffer damage from coarse hard lumps of material. Furthermore,
somewhat limited positional adaptability in the quarry in order to cope with varying locations of
the mobile crusher (which In turn will depend on variations in the working and loading points in
the quarry) is another disadvantage of the belt conveyor.

Page 30

Keeping the belt conveyor in good operational order some devices is used.
Technical classifications
No.

Description

LBC C3

LBC C4

LBC C5

1.

Capacity

800 T/Hr.

800 T/Hr.

800 T/Hr.

2.

Horizontal

2346 m

2088 m

1777 m

3.

Vertical

13.5 m

29.93 m

2.53 m

4.

width

800 mm

750 mm

750 mm

5.

Speed

1.33 (*2.66) m/s

1.33 (*2.66) m/s

1.33 (*2.66) m/s

6.

Main motor

2 x 110 KW

2 x 110 KW

2 x 110 KW

Page 31

Bag House Filter

A bag house filter is a particular air pollution control device, used in similar applications as
electrostatic precipitators. In the 1970s, introduction of fabrics capable of withstanding high
temperatures (> 350 degrees Fahrenheit) made bag houses practical for use in electrical
generation and industrial processes. Bag houses are highly efficient particulate collection
devices, regardless of the incoming dust loading or particle size. Bag houses also offer
adaptability as dry collection devices using absorbents for removing gases and heavy metals.
Dust enters the bag house compartment through inlet on
the hoppers. Larger particles drop out while smaller dust
particles collect on filter bags. When the dust layer
thickness reaches a level where flow through the system
is sufficiently restricted bag cleaning is initiated.
Cleaning can be done while the bag house is still online
(filtering) or in isolation (offline). Once cleaned, the
compartment is placed back in service and the filtering
process starts over.
Components of a reverse air bag house:

Isolation dampers
Filter bag tensioning system
Anti-collapse rings on bags
Reverse air fan

Most bag houses use long, cylindrical bags (or tubes) made of woven or felted fabric as a filter
medium. (For applications where there is relatively low dust loading and gas temperatures are
250 F or less, pleated, nonwoven cartridges are sometimes used as filtering media instead of
bags.) Dust-laden gas or air enters the bag house through hoppers (large funnel-shaped
containers used for storing and dispensing particulate) and is directed into the bag house
compartment. The gas is drawn through the bags, either on the inside or the outside depending on
cleaning method, and a layer of dust accumulates on the filter media surface until air can no
longer move through it. When sufficient pressure drop (delta P) occurs, the cleaning process
begins. Cleaning can take place while the bag house is online (filtering) or is offline (in
isolation). When the compartment is clean, normal filtering resumes

Page 32