VDZ-Onlinecourse 2 1 en PDF

Course 2 Raw Material Preparation
2.1 Primary Comminution

Imprint
German Cement Works Association

Research Institute of the Cement Industry
P.O. box 30 10 63, 40410 Duesseldorf, Germany
Tannenstrasse 2, 40476 Duesseldorf, Germany
Phone: +49 211 45 781
Fax: +49 211 45 78296
info@vdz-online.de
www.vdz-online.de
info@elearning-vdz.de
www.elearning-vdz.de
Issued: 7th January 2013

Contents
1 Introduction....................................................................................................... 1
2 Basic Principles and Types of Comminution.................................................. 1
3 Operational Configuration of Comminution Processes ................................ 3
4 Designs of Comminution Machine ................................................................. 5

4.1 Jaw Crushers ....................................................................................................... 5
4.1.1 Double-Toggle Jaw Crushers.............................................................................. 5
4.1.2 Single-Toggle Jaw Crushers ............................................................................... 7
4.1.3 Jaw Crusher Components: Crushing Plates and Overload Protection................ 9
4.2 Cone Crushers/Gyratory Crushers...................................................................... 11
4.2.1 Steep-Angle Cone Crushers................................................................................ 12
4.2.2 Shallow-Angle Cone Crushers............................................................................ 14
4.3 Roller Crushers ................................................................................................... 16
4.3.1 Double-Roller Crushers ...................................................................................... 16 i
4.3.2 Single-Roller Crushers........................................................................................ 18
4.4 Impact Crushers .................................................................................................. 19
4.5 Hammer Crushers ............................................................................................... 24
4.5.1 Single-Rotor Hammer Crushers ......................................................................... 25
4.5.2 Double-Rotor Hammer Crushers........................................................................ 25
4.5.3 Impact Hammer Crushers ................................................................................... 27
4.5.4 Position, Shape and Operation of Hammers in Hammer Crushers .................... 28
4.6 Drives and Auxiliary Devices............................................................................. 30
5 Health and Safety Practices ............................................................................. 31
6 Operation and Quality ..................................................................................... 31
7 Maintenance and Servicing.............................................................................. 32

8 Environmental Protection ................................................................................ 32
9 Questions on Course LB 2.1 Primary Comminution ................................. 33
Solutions............................................................................................................................... 34
Glossary ............................................................................................................................... 35
Index..................................................................................................................................... 36
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1 Introduction
The raw materials for cement production (limestone, marl, shale etc.) have to be com-
minuted for further processing in the cement plant. The various materials have different
properties, such as hardness or moisture, as well as different particle sizes depending
on the extraction method used (blasting, digging, scraping). The material properties and
the particle size of the feed material are key factors when choosing the most suitable com-
minuting equipment. Comminution takes place in crushers or mills. This course deals
with comminution in the coarse range using crushers.
Figure 1.0-1: Example of a Crusher in a Quarry (Source: Polysius) .
In this course you will learn more about comminution in the coarse range using crushers.
The basic physical and process-related principles will be presented first before the different
types of crusher and their characteristics are described.
Course Summary
The topics of health and safety practices, operation and quality, maintenance and servicing,
and environmental protection with regard to coarse comminution will then be discussed.
2 Basic Principles and Types of Comminution

In the cement industry the raw material in the production stage called primary comminu- Primary Comminution
tion is reduced to the size of crushed stone, i.e. to a size of up to 100 mm, Owing to Reduces Grinding
Energy
its increased flowability it can be conveyed in this coarsely comminuted state with over-
land belt conveyor systems and is in the optimum state for subsequent grinding. Primary
comminution reduces the energy required for grinding to an optimum level.
Primary comminution during cement production is based on four key methods of stressing Types of Load
(Fig. 2.0-1):
(1) Compression
The particles are crushed between two surfaces (steel plates) or in the material bed. This
type of stressing is characterized by physical constraint. In general terms, a particle tries
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2 Basic Principles and Types of Comminution
1 F 2
V v
V
F
F F
3 4
V v
F F
2 Figure 2.0-1: Types of Stressing .
to avoid the pressure until it is fixed in position between the plates or the neighbouring
particles. Once this has occurred the pressure exceeds the strength of the particle and
breaks it. Relatively low stressing velocities of 0.1 to 5 m/s are used, as is the case in a jaw
crusher.
(2) Percussion (Rapid Compression)
In percussion the material is shattered between a fixed working surface of the crusher and a
moving working surface, the striker plate. In this case a plate contacts the material, which
is located on the fixed working surface, at high speed. The considerably greater stressing
rate (5 m/s) compared to compression and shear stressing is crucial here.
(3) Shear (Abrasion)
The particles are compressed between two parallel working surfaces. One plate stays still
while the other plate is pressed against the particle and moves parallel to the fixed plate. In
this way the particle is deformed until it finally shears. A low loading rate is also typical
for shear stressing.
(4) Impact
The particle comes into contact with a working surface of the crusher or another particle
at high speed. The particle is therefore not subjected to physical constraint, i.e. it is not
fixed in position but is comminuted by the impact alone. The impact speeds vary between
20 to 60 m/s for coarse and intermediate comminution. Finer particles exhibit greater
strength than coarser particles so they require substantially higher speeds and therefore
more energy.
Normally, the different types of stress overlap in the various types of crushers but one type
of stress is often dominant:
Examples of Compression:
in Crushers double-toggle jaw crusher, steep-angle gyratory cone crusher
Percussion:
flat gyratory cone crusher, jaw crusher, hammer crusher
Shear:
double-roller crusher with different or identical circumferential roller speeds
Impact:
impact crusher
Size and The size (edge length) of the feed material and its material properties are important for
MaterialProperties
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the selection of an appropriate crusher and therefore also for the type of stress applied.
For hard, abrasive rock (quartzites, ores, silicate rocks) it is sensible to select primary
comminution equipment that subjects the feed material to compression.
When comminuting moist, soft or abrasive feed material (marl, clay, shale), a machine
that exerts shear stressing should be selected.
Percussion comminution should be chosen for brittle and hard feed material.
The degree of comminution is used to assess the comminution process. Degree ofComminution
The degree of comminution e is defined as the ratio of the longest edge length of the
feed material (dA) to the longest edge length of the finished product (dF):
e = ddFA
A degree of comminution of 6 therefore indicates that the edge length of the finished
product corresponds to 1/6 of the edge length of the feed material. If the feed material
measured up to e.g. approx. 500 mm, the finished product will now measure approx. 90
mm.
3
3 Operational Configuration of Comminution

Processes
Process engineering systems for coarse comminution may be configurated and combined
in different ways. The number of comminution stages may differ and the comminuted
material may be recycled to the crusher or not.
Single-Stage Comminution
Figure 3.0-1: Flow Diagram of Single-Stage Comminution .

In single-stage comminution the feed material is comminuted to the desired finished fine-
ness using only one comminuting machine (Fig. 3.0-1).
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3 Operational Configuration of Comminution Processes
Multi-Stage Comminution
Figure 3.0-2: Multi-Stage Comminution System Consisting of a Cone Crusher and a Hammer Crusher
.
In multi-stage comminution the feed material is brought to the desired finished fineness
with several comminuting machines arranged in series (Fig. 3.0-2). In this case the
machines may all be of the same or of a different type. They are generally different as
each machine is adapted to the changing particle size distribution of the feed material (the
intermediate product) after each stage.
Closed-Circuit Comminution
Figure 3.0-3: In closed-circuit comminution the crushed material is classified. The coarse material is
fed back to the first machine to be comminuted again.
When crushing in a closed circuit the material is separated (classified) according to par-
ticle size after passing through the comminution machine (Fig. 3.0-3). The fine material
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(undersize) is finished product whereas the coarse material (oversize) is fed back to
the machine. This procedure generally uses less energy and prevents particles that are too
coarse from entering the finished product.
4 Designs of Comminution Machine

There are a large number of crusher designs which differ in terms of performance, com-
minution mechanisms, mobility etc.. The main basic types (jaw crushers, cone crushers,
roller crushers, impact crushers and hammer crushers) will be described in greater detail
below.
4.1 Jaw Crushers

In machines of this type the feed material is comminuted by compression. Depending on 5
the design, the compression may be accompanied by shear.
The development of the first jaw crusher (patented in 1858) by Blake, a North American, Blake Crushers
made continuous mechanical comminution of coarse, hard pieces of rock possible for the
first time. The design principle of the Blake crusher is still used today in double-toggle
jaw crushers. There are, however, jaw crushers that deviate from this principle.
Current Blake crusher designs include: Designs
double-toggle jaw crushers
single-toggle jaw crushers
double-toggle jaw crushers with direct drive of the jaw stocks
percussion jaw crushers
The basic configuration of the crushing chamber is the same in all types of jaw crushers. Crushing Chamber
The chamber consists of two crushing jaws, one of which is fixed and the other of which
oscillates. The moving crushing jaw may be mounted at its upper or lower end and is
generally moved by an eccentric disc.
At this point in the online course you would watch an animation of a jaw crusher.
The material fed to the crushing chamber is comminuted between the two jaws predom-
inantly by compression by the periodic movement back and forth of the mobile crushing Function
jaw. The crusher feed slides downwards during the opening of the jaws due to gravity until
it leaves the crushing chamber.
The degree of comminution (e) is approx. 5-9 when this type of crusher is used as a Degree ofComminution
coarse crusher, and approx. 3-6 when used as a secondary or fine crusher.
4.1.1 Double-Toggle Jaw Crushers
Double-toggle jaw crushers (Fig. 4.1-1) are primarily used for primary and secondary Use
comminution of medium-hard to very hard rock.
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Figure 4.1-1: Double-Toggle Jaw Crusher (SKET Magdeburg Design) .
1 housing of crushing jaw
2 oscillating element with crushing jaw
3 crusher housing
4 cheek plates
5 front toggle plate
6 rear toggle plate
7 oscillating shaft with bearing
8 drive shaft with cam
9 connecting rod element
10 connecting rod bearing
11 spring-loaded connecting rod
12 restoring spring
13 skewback
14 fly wheel and drive wheel
15 gap adjustment parts (wedge, slide block, distance plates and adjusting spindle)
16 toggle plate bearing
17 clamping wedges for retaining the crushing jaws
18 lubricant lines
19 spring housing
Table 4.1-1: Key to Fig. 4.1-1.

Force Transfer The oscillating crushing jaw (2) which is moved by the toggle plate (5) in a periodic
reciprocating motion transfers the crushing force to the crusher feed in the working area.
The two toggle plates (5 + 6) and the connecting rod (9) form the toggle system. This is
particularly suitable for the transfer of strong forces.
Drive and Movement The toggle system is driven by the eccentric driveshaft (8) via the connecting rod (9). The
up and down movement of the connecting rod (9) extends the toggle system to a varying
extent. During the upward movement the oscillating crushing jaw is moved towards the
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4.1 Jaw Crushers
fixed jaw by the extension of the toggle plates leading to crushing of the feed. During
the downward movement the oscillating crushing jaw is withdrawn, allowing the crusher
feed to slide downwards. In order to ensure a reliable transfer of force from the toggle
system to the oscillating crushing jaw (2) a spring-loaded connecting rod (11) is fixed at
the lower end of the jaw. This rod holds the toggle system together via a restoring spring
(12) and retracts the oscillating crushing jaw (2) when the connecting rod is lowered into
the starting position. The rear toggle plate (6) is supported by a skewback (13) that can be
adjusted to change the width of the gap between the crushing jaws.
Figure 4.1-2: Mode of Operation of a Double-Toggle Jaw Crusher .

As a result of its periodic mode of operation (crushing/sliding) this type of crusher causes
intermittent stresses in the drive system which can be offset by fly wheels on either side.
One of the fly wheels also acts as a belt pulley for the drive system.
4.1.2 Single-Toggle Jaw Crushers
The field of application for single-toggle jaw crushers is primary and secondary comminu- Use
tion. Compared with double-toggle jaw crushers which are primarily suitable for very hard
crusher feed with high comminuting forces single-toggle jaw crushers are mainly used for
comminution of medium-hard, less solid and less abrasive material.
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8
Figure 4.1-3: Single-Toggle Jaw Crusher (SKET Magdeburg Design) .
1 crusher housing (frame)
2 housing of crushing jaw
3 drive shaft (eccentric shaft)
4 oscillating member
5 oscillating crushing jaw
6 cheek plates
7 clamping wedges
8 toggle plate
9 toggle plate bearing
10 spring-loaded connecting rod
11 restoring spring
12 slide block
13 distance plates
14 adjusting device (hand wheel) with spindle
15 clamping wedge
16 fly wheel and drive wheel
17 v-belts
18 belt pulley and drive motor
19 motor base with fixing frame for adjusting the required distance between the centres of the belt
pulleys
Single-toggle jaw crushers (Fig. 4.1-3) do not have a connecting rod. The oscillating
crushing jaw (4) is mounted directly on the eccentric shaft (3) above the feed opening.
It is supported underneath against an adjustable slide block (12) by a toggle plate (8). A
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4.1 Jaw Crushers
circular motion is thus produced in the upper part of the jawstock, which turns into an in-
creasingly flatter elliptical motion toward the discharge opening. The oscillating crushing
jaw describes an almost linear up and down motion at the discharge opening.
8 9
12
Figure 4.1-4: Drive Principle of the Single-Toggle Jaw Crusher .
The crusher feed is comminuted not only by compression, but also by shearing as a result Comparison
of this oscillating movement. This leads to improved nipping of the material downwards,
and therefore to greater throughput than with a double-toggle jaw crusher. However, this
also results in the disadvantage of increased wear of the crushing jaws.
Owing to their simpler design, single-toggle jaw crushers are approximately 20 to 30 %
lighter and less expensive than double-toggle jaw crushers. For this reason, and as a result
of being more compact, they are also used for mobile crushers.
4.1.3 Jaw Crusher Components: Crushing Plates and Overload Pro-

tection
Crushing Plates
The crushing plates which are screwed or fixed to the base elements are toothed in the Use
longitudinal direction to promote cracking in the crusher feed to be comminuted. The
shape and service life of these wearing plates have a considerable effect on the operating
costs of the crusher. For this reason, the crushing plates must be adapted to the respective
conditions of use.
The point of the tooth is always aligned with the base of the tooth of the opposing plate.
Fig. 4.1-5 shows various structural designs of the fins of jaw crusher liner plates.
The designs must be adapted to the material to be crushed in order to optimize service life
and reduce operating costs.
Plates with a tooth angle of 70 to 90 are used to crush hard to medium-hard material (1).
Crushing plates with a tooth angle of 100 to 110 and rounded or flattened teeth are
suitable for crushing coarse, very hard crusher feed (2).
Plates with widely spaced fins are also used for lumps of material or very coarse lumps
(3).
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1 2 3
Figure 4.1-5: Various Crushing Plate Configurations .
In the case of extremely hard material the fins may cause lateral forces that have a negative
effect on the jaw shaft. In these cases smooth plates are also used.
The maximum particle size of the finished product may be influenced by the tooth spac-
ing (in addition to the gap width and geological conditions of the feed).
Wear Liner plates are made of austenitic manganese steel with approx. 12 to 14 % Mn. The wear
is greatest at the lower part of the crushing chamber near the discharge gap. The wearing
10 plates are therefore designed in such a way that they can be rotated through 180 once they
have reached the wear limit. In this way the worn part of the crushing jaw is moved to the
top and the service life of the plate can be extended. In spite of this measure, only approx.
25 to 30 % of the wearing material is worn down. Depending on the abrasiveness of the
material to be comminuted, wear occurs at a rate of 5 to 30 g/t of crusher feed.
In order to prevent the crushing jaws and parts of the crusher housing from being subjected
to wear due to the movement of loose crushing plates, it is necessary to ensure that the
wearing parts are
fixed securely and
well supported
.
Curved Plates Curved plates may also be used in addition to straight crushing plates. This enlarges
the crushing chamber. Curved crushing jaws have the following advantages over straight
crushing jaws:
good sizing properties owing to a practically parallel crushing zone at the discharge
gap
lower risk of clogging
improved comminution of material that is difficult to crush
In spite of these advantages, rounded or curved crushing jaws are only used with material
that is difficult to crush or when high demands are placed on quality, since the advantages
are offset by the fact that manufacture and maintenance are more expensive.
Overload Protection
If foreign bodies such as broken of excavator teeth should get between the crushing plates
with the material to be comminuted then individual parts of the crusher may become dam-
aged owing to the hardness of these foreign bodies. This could lead to prolonged produc-
tion stoppages. The crusher itself must therefore be provided with overload protection
against fracture damage caused by foreign bodies that cannot be comminuted.
It is possible to differentiate between:
overload protection ahead of the crusher driveshaft
couplings that limit torque
over-current trips
Overload protection in the crusher may be provided by:
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4.2 Cone Crushers/Gyratory Crushers
slip couplings
shear bolts or similar devices between oscillating discs and crushing elements
toggle plates

Modern gyratory crushers are based on the patent filed by the American C. M. Brown in
1878.
In cone crushers, comminution is carried out in an annular crushing chamber between Function
a circular gyrating crushing cone and a fixed conical crushing shell (see Fig. 4.2-1).
These form an annular gap that closes or opens as a result of the gyratory movement of
the cone relative to the respective opposing side. The crusher feed is comminuted when
the crushing cone approaches the crushing shell (annular gap is closed). The crusher feed
may slide downwards or fall out of the crushing chamber on the opposite side when the
crushing cone is moved away from the crushing shell (gap is opened).
11
At this point in the online course you would watch an animation of a steep-angle gyratory
cone crusher.
In comparison with jaw crushers, cone crushers provide virtually continuous comminu- Advantage
tion. Throughput is therefore also generally higher than that of comparable jaw crushers.
In addition, there is no need for a feed hopper if the crusher is supplied directly by the
loading or transport equipment.
Figure 4.2-1: Kinematic Behaviour of the Crushing Cone in Steep-Angle and Shallow-Angle Cone
Crushers .
a) steep-angle cone crusher with conical movement of the crushing cone shaft (suspended crushing
cone)
b) shallow-angle cone crusher with conical movement of the crushing cone shaft (supported
crushing cone)
c) steep-angle cone crusher with cylindrical movement of the geometric crushing cone shaft about
the axis (fixed crushing cone shaft with supported crushing cone and eccentric bush)
1 crushing bowl with crushing shell
2 crushing cone
3 crushing cone shaft
4 eccentric bush
5 top bearing
6 bevel gear drive
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The crushing cone describes a circular path that is not centred on its axis of symmetry
(gyratory movement).
In cone crushers, the loads exerted on the comminuted material have led to different de-
signs of crushing chamber and crushing cone(Fig. 4.2-1). Cone crushers are accordingly
divided into:
Steep-Angle Cone Crushers, p.12
Shallow-Angle Cone Crushers, p.14
Overview Tab. 4.2-2 gives a summarized comparison of the possible uses of steep-angle and shallow-
angle cone crushers.
Parameters Steep-Angle Cone Crusher Shallow-Angle Cone Crusher
12 Usage Options hard and medium-hard materi- hard and medium-hard materials
als (primary and intermediate (secondary comminution)
comminution)
Particle Size of the Feed 150 ... 1,800 25 ... 300

Material (mm)
Final Particle Size (mm) 25 ... 250 5 ...40
Throughput (t/h) 35 ... 3,500 10 ... 600
Specific Energy Demand 0.15 ... 0.5 0.4 ... 2.2

(kWh/t)
Type of Stress compression compression/percussion
Table 4.2-2: Options forCone Crusher Use.
4.2.1 Steep-Angle Cone Crushers
In steep-angle cone crushers (Fig. 4.2-2) the crushing chamber is defined by a hollow con-
ical crushing shell and a crushing cone. The crushing shell and the crushing cone oppose
each other. The crushing pressure is generated by the gyratory movement (not rotation)
of the crushing cone. This causes the crushing gap to change continuously. The mini-
mum gap width therefore moves around the circumference of the outer crushing surface
(4). This leads to relatively vibration-free operation and to high throughput. The crusher
shaft (3) with the crushing cone (5) is suspended from the cross beam (2) so that it can
oscillate. A heavy domed casing (7) protects the bearing against the impact of stones. The
cross beam also distributes the flow of feed material and achieves a good filling level in the
crusher. The lower part of the crusher shaft lies in the eccentric bush (6) which is moved
in a circle by the crown wheel.
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feed
13
discharge
Figure 4.2-2: Gyratory Crusher (Esch Werke Duisburg Design) .
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1 distribution of feed material
2 cross beam
3 crusher shaft
4 outer crushing surface
5 crushing cone
6 eccentric bush
7 domed casing
8 ball bearing
9 adjusting ring nut
10 transmission shaft
11 drive pinion
12 crown wheel
14 13 shear pins
14 crusher housing
15 v-belt pulley
The degree of comminution (e) of steep-angle cone crushers lies between 7 and 10.
The discharge gap is changed by lifting and lowering the crushing cone. In older crushers
the opening is altered by an adjusting screw located at the top bearing. In modern crushers
the lifting/lowering motion is achieved hydraulically via the top or eccentric bearing. This
also makes it possible to provide overload protection to a limited degree.
As in jaw crushers, the wearing parts are made of austenitic manganese steel. Plates or
segments that are wedged against one another are generally used to line the crushing shell.
The casing of the crushing cone is always in the form of rings as this is the only way the
lining can be fixed securely to the support cone.
If the feed material has a large particle size and if high throughput is desired, steep-angle
cone crushers are fitted with a feed/pre-crushing inlet that projects at one end or extends
on all sides. This allows the comminution ratios to be increased to e = 13 to 15.
4.2.2 Shallow-Angle Cone Crushers
The shallow-angle cone crusher, also known as the Symons crusher, is one of the most
commonly used machines for intermediate comminution (Fig. 4.2-3). The main differ-
ences of this design from the steep-angle cone crusher are the shallow shape of the crushing
chamber and the percussive stress exerted on the material to be comminuted as a result of
the higher speed and greater stroke of the crushing cone. The crushing cone and crushing
shell are also designed to have the same profile.
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15
Figure 4.2-3: Shallow-Angle Cone Crusher (KHB Design from IBAG) .
1 upper part of housing
2 crushing shell
3 supporting cone
4 crushing cone
5 hollow shaft
6 eccentric bush
7 supporting piston
8 two-piece support bearing
9 supporting or hydraulic piston
10 hydraulic accumulator
11 transmission shaft
In modern designs the eccentric bush (6) rotates in plain bearings on the hollow shaft (5)
fixed in the lower part of the housing. A two-piece support bearing (8) is located above the
supporting piston (7) and supports the crushing cone (4). The crushing shell (2) is fixed in
the upper part of the housing (1). The supporting/hydraulic piston (9) is positioned in the
hollow shaft to centrally support and displace the supporting cone (3). If uncrushable ma-
terial enters the machine, the supporting cone yields downwards against the pressure of the
pressurized hydraulic accumulator (10). The crushing gap can be adjusted continuously
by a hydraulic piston.
In the crushing process, the material falls into the inlet opening and is distributed in the
working area. The gyratory movement of the crushing cone throws the material against
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the crushing shell where it is subjected to compression, friction and impact stresses. The
comminuted crusher feed cannot follow the rapidly retreating crushing cone directly by
free-fall and is picked up again by the returning crushing cone and thrown against the
crushing shell. This process is repeated a number of times on the way to the discharge
gap.
The crushing chamber in shallow-angle cone crushers has a shallow profile and the stroke
is greater towards the discharge gap, so the crusher feed is broken up in such a way that
clogging is prevented. The stroke travel at the discharge opening is many times the width
of the narrowest discharge opening. In contrast to steep-angle cone crushers and jaw crush-
ers, this determines the maximum particle size of the material. The crushing shell and
crushing cone are designed in such a way that they run parallel to each other in the final
portion of the crushing chamber. The longer this parallel region, the better is the sizing of
the crusher product.
In addition to good sizing, shallow-angle cone crushers also offer high comminuting ratios
of e = 7 to 18.
16 Because of this shallow-angle cone crushers are suited especially for the production of
high-quality double-crushed aggregates. The feed material must not be mixed with loam
or clayey constituents as this could lead to clogging/plugging of the crusher.
4.3 Roller Crushers

In roller crushers comminution takes place between:
two rollers driven in opposite directions ( double-roller crusher) or
a driven roller and a working surface ( single-roller crusher)
The material is comminuted by pressure exerted by the two rollers on the feed material
located between them. The size of the final particles depends on the distance between
the rollers.
The crusher feed is comminuted
predominantly by compression if the rollers have the same circumferential speed,
by shearing and compression if the rollers have different circumferential speeds,
by compression, shearing and impact in rapidly rotating cam roller crushers.
The operating conditions and in particular the nature of the material determine the
design of the roller surfaces.
Roller crushers with rollers possessing teeth, projections, spikes or other devices are used
for the primary crushing of hard to soft materials. Smooth or furrowed rollers are used for
secondary and fine crushing of hard to soft materials.
4.3.1 Double-Roller Crushers
In double-roller crushers the material is crushed between two rotating rollers.

At this point in the online course you could watch an animation of a double-roller crusher.
In double-roller crushers (Fig. 4.3-1), one roller is generally mounted rigidly in the base
Protection frame. The bearings of the second roller can yield against the force of highly tensioned
spring assemblies or of a hydraulic system. The rollers can therefore yield when they come
into contact with uncrushable material like broken excavator teeth or other iron fragments
and therefore avoid damage (overload protection). The protection should be set so that
there is no substantial yielding during normal operation.
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4.3 Roller Crushers
The two rollers are driven either individually or jointly by a gear unit. Both rollers operate Drive
at the same rotaional speed so as to prevent friction between the crusher feed and the
roller wall during crushing. Shearing also occurs if the rotational speeds are different.
The structure of roller crushers is very simple, as shown for example in Fig. 4.3-1.
17
Figure 4.3-1: Double-Roller Crusher (SKET Magdeburg Design) .
1 rigidly mounted roller
2 displaceably mounted roller
3 high-carbon steel discs
4 anchor bolts
5+6 v-belt pulleys
7 springs
8 rods
9 plates

This simple structure results in the following advantages: Advantages
low specific energy requirement and power consumption
high specific throughput
not sensitive to the passing of uncrushable pieces
simple adjustment of gap width
not sensitive to greasy, plastic and moist feed material
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simple maintenance
In contrast, it has the following disadvantages:
low comminution ratios e = 4-6
high roller wear (particularly in the case of material with abrasive constituents)
plate-like/slaty crusher feed may pass through uncomminuted
The maximum particle size of the feed material is dependent on
the gap width,
the diameter of the rollers, and
the structure of the roller surface.
Comminution When greater comminution ratios are required several pairs of rollers are arranged above
each other. In this case the upper pair of rollers functions as a primary crusher in the coarse
range and the lower pair of rollers functions as a secondary crusher.
Increasing the circumferential speed in roller crushers in the coarse range may also in-
crease the comminution ratio slightly (e = 8), as this provides additional impact stress
above the roll gap.
18 Rollers The roller shells consist of wear-resistant steel castings of varying composition which are
either bolted or clamped to the roller base. Another roller structure option consists of a
number of replaceable high-carbon steel discs that are slid onto the shaft and are fixed to
one another by anchor bolts. Depending on the structure of the roller surface, double-roller
crushers can be used for secondary or fine crushing, and in rare cases even for the primary
crushing of soft, medium-hard and hard material and also for sticky and moist materials.
4.3.2 Single-Roller Crushers
Single-roller crushers are used for the same comminution tasks as double-roller crushers.
However, the comminution is carried out between a roller and a rigid (straight or curved)
working surface.
At this point in the online course you would watch an animation of a single-roller crusher.
Figure 4.3-2: Single-Roller Crusher .
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4.4 Impact Crushers
1 roller with projections
2 jaw stock
3 oscillating shaft
The crushing chamber in single-roller crushers (Fig. 4.3-2) is formed by the rigidly mounted
roller (optionally provided with projections) and the jaw stock. This is suspended from a
shaft with a sprung support at the bottom (overload protection). In addition to compression
and impact, shearalso plays a role in the crushing chamber.
Large machines (single- and double-roller crushers) with roller diameters of 2,500 x 2,500
mm can handle feed particles with an edge length of more than 1,000 mm and achieve
throughputs of more than 1,000 t/h.
19
4.4 Impact Crushers

Impact comminution is achieved by rapidly accelerating the particles to be comminuted
and throwing them against an impact surface so they shatter upon contact with a working
surface in the crusher.
At this point in the online course you would watch an animation of an impact crusher.
In impact crushers (Fig. ??) the feed material is initially struck by rapidly rotating impact
bars (impactor bars) and partly comminuted. The pieces of material are then thrown by the Basic Principle
impact bars against the impact plates. Since the impacts should be as straight and central as
possible, the impact plates are arranged at right angles to the theoretical trajectory thereby
achieving additional comminution. The particles thrown back from the impact plates are
either picked up again by the impact bars or first strike other particles in the impact cham-
ber. Comminution in an impact crusher is achieved by impact stressing, predominantly
at natural fracture surfaces. Fig. 4.4-1 shows different impact crusher designs.
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20
Figure 4.4-1: Impact Crusher Designs from Hazemag a) Andreas Design b) Andreas Design (with
grinding track) c) Compound Crusher .
Impactor Bars and The impact plates are either kinked or curved. In addition to individually-positioned im-
Impact Plates pact plates, it is also possible to use a continuous impact plate unit in the crushing chamber
of the impact crusher. The gap between the impact plate and the impactor bar as well as
the angle of inclination of the impact plates can be altered by adjusting the plates. As the
impact plates absorb the greatest number of impacts and the greatest number of impacts
per unit of surface area, they also experience the greatest wear. The majority of the wear
costs is therefore accounted for by the impactor bars and impact plates.
The housings of impact crushers are welded structures provided with wearing plates. Easy
access, in particular for changing the impact bars, should be ensured
Operation Impact crushers must be subject to uniform stresses and should not be overloaded. If
there is too much feed material, the force of the impacts in the crushing chamber will be
reduced. There will also be increased frictional impact and as a result, the particle size
distribution of the comminution product will become flatter and wider. It should also be
noted that the comminuted material leaves the impact crusher at high speed.
Equipment (suspended magnets) must also be installed ahead of rapidly operating impact
crushers with a narrow gap width to prevent pieces of metal that cannot be comminuted
from entering the crusher.
From the mechanical point of view the comminution results are substantially dependent
on:
the circumferential speed of the rotor (belt pulleys/frequency control),
the shape and number of the impactor bars,
the gap width,
the positioning and configuration of the impact plates.
Impact crushers used for the primary and secondary comminution of hard to soft materials
have the following advantages:
low investment costs compared to jaw/gyratory crushers
simple foundation with low dynamic loading
low overall height
low specific energy requirement (0.6 to 1.2 kWh/t)
high throughput compared to inherent weight
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4.4 Impact Crushers
high comminution ratio e = 20 to 50

good adaptability to the material to be comminuted (speed/gap)
cubic final product
simple overload protection (spring-loaded impact plates)
They have the following disadvantages:
high fine material fraction/ flat particle size distribution
high level of wear of the impactor bars and impact plates (approx. 10 g/t limestone)
not suitable for greasy, sticky crusher feed
high maintenance costs
The impactor bars must be easily accessible for turning/replacement in order to reduce
maintenance costs.
There is a wide range of impact crusher designs. Design
Single-Rotor Impact Crushers

The single-rotor impact crusher (Fig. 4.4-2) is the most common design with a wide field
21
of application from coarse to fine comminution. The feed material passes down a slope
and into the impact chamber. It is then picked up by the rotating impactor bars bolted
rigidly to the rotor and thrown against the impact plates. The impact plates are suspended
so that they can be adjusted and can yield backwards if foreign bodies enter the crusher.
Figure 4.4-2: Single-Rotor Impact Crusher (Source: Sandvik Mining and Construction Crushing Tech-
nology GmbH) .
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Double-Rotor Impact Crushers

Particularly high comminution ratios can be achieved with a double-rotor impact crusher.
With this compound impact crusher the comminution ratio is e = 60 to 70. Two rotors
running in the same direction and operating in series comminute the material in conjunc-
tion with three adjustable impact plates and a grinding track. The first/upper rotor performs
the primary comminution. The subsequent crushing is carried out by the secondary rotor
located lower down. The desired fineness of the finished product is adjusted via the lower
gap width and the additional grinding track.
Feed material with an edge length of approximately 1,500 mm can be crushed directly to
an end particle size < 25 mm by the compound crusher.
Material and Wear

The majority of the wear costs (approx. 70 %) is caused by the impactor bars so great care
must be paid to them when selecting material and shape.
22 The impact bars can be made from various high-carbon steel castings. However,consideration
must be given to the fact that the sensitivity to fracture caused by pieces of metal will in-
crease with increasing wear resistance/hardness.
Easy replacement or rotatability (max. 4x) as well as high material utilization (up to 70 to
75 %) should be ensured. The impactor bars are bolted, wedged, hydraulically clamped or
jammed in place automatically by the centrifugal force exerted during operation. For rotor
widths > 500/600 mm the impactor bars are subdivided for ease of handling,
Horizontal Impact Crushers

In contrast to the impact crushers mentioned above, in horizontal impact crushers (Fig. 4.4-
3) the material is not comminuted by impact bars. Instead, the crusher feed fed from above
is accelerated by a rotor and hurled outward against fixed impact plates or into a material
bed. Horizontal impact crushers are often used to comminute medium-fine material with
highly abrasive properties. They are also used, for example, as primary mills for clinker
grinding or as disagglomerators in grinding circuits with high pressure roller mills.
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4.4 Impact Crushers
23
Figure 4.4-3: Horizontal Impact Crusher .
1 inlet chute
2 dust collection louvre
3 rotor
4 rotor inlet
5 rotor shaft with bearing
6 air circulation opening
7 v-belt drive
8 rotor impeller bar
9 wear protection
10 inspection and maintenance hatch
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4.5 Hammer Crushers

Hammer crushers (Fig. 4.5-1) are similar to the impact crushers described previously.
However, for comminution they use the impact force of hammers attached to a rotor.
At this point in the online course you would watch an animation of a hammer crusher.
One or two rotors are positioned in a welded housing lined with armoured plates. The ro-
Structure tors are provided with a grate in the lower half of the working area (the discharge) in order
to avoid excessively large particles. In the upper part the material is comminuted by impact
and in the lower part it is comminuted by shock and shearing on the grate. The material
only leaves the working area when it can pass through the grate. The grate aperture setting
determines the final particle size since the size of the final particle is approximately half the
grate aperture. In contrast to impact crushers, the rapidly rotating rotors have articulated,
often hammer-shaped beaters. During operation the hammers adopt a radial impacting po-
sition owing to the centrifugal force. Rotor speed and hammer weight should be adapted
to the crusher feed so the hammers maintain their extended position during comminution
in normal operation. The hammers only pivot out of the extended position if there are large
24
clumps of feed material and very hard or uncrushable foreign bodies.
Figure 4.5-1: Double-Rotor Hammer Crusher, Cross-Section and Operational Diagram .
The material fed to the crushing chamber is subjected to:

impact in the inlet region
shock in the lower part
shearing in the crushing chamber
It remains in the crushing chamber until it is discharged through the grate apertures/openings
in the perforated metal plates.
Use Hammer crushers are used to comminute soft to medium-hard, less abrasive materials.
Even tough and moist materials can be comminuted.
Finished Product and Like impact crushers, the finished product contains a large fine fraction, but has a maxi-
Influencing Factors mum particle size of the finished product that is limited by grates. The comminution ratio
is e = 40 to 50. This can be considerably influenced by
rotor speed,
the aperture width of the discharge grate,
the shape of the hammers and their positions on the rotor,
the number of rows of hammers.
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4.5 Hammer Crushers
If the maximum particle size of the crushed material does not have to be limited or if
an excess fine material fraction is not desired, hammer crushers are also used without
grates/perforated metal plates.
Hammer crushers may also be used as coarse crushers up to a feed material particle size
of approx. 1,000 mm . The circumferential speed is 20 to 50 m/s.
The most common hammer crusher designs are: Designs
Single-Rotor Hammer Crushers, p.25
Double-Rotor Hammer Crushers, p.25
Impact Hammer Crushers, p.27
4.5.1 Single-Rotor Hammer Crushers
Single-Rotor Hammer Crushers

The hammers are attached to the rotors so that they can pivot. The bottom of the crushing Structure
chamber is defined by adjustable grate frames equipped with replaceable, conical grate 25
bars. The grate aperture and therefore the final particle size can be altered by spacers. The
upper part of the crusher housing is connected to an impact plate provided with breaker
bars. Grate bars are located on the feed hopper to retain oversized broken pieces of rock
until primary comminution has taken place by the hammers sweeping between the bars.
Newer hammer crushers are generally constructed without a primary grate, as this has
often proved to be susceptible to failure (arching).
At this point in the online course you will watch an animation of a single-rotor hammer
crusher instead of this image.
Single-Rotor Hammer Crushers with Rotating Crushing Plate

Machines of this design are used for moist, sticky material. The rotating strip-like crush-
ing plate stops material from sticking to the inlet side of the crusher. The feed material
is initially shattered by the hammers against the rotating crushing plate and the impact
element before final comminution takes place on the discharge grate.
4.5.2 Double-Rotor Hammer Crushers
Double-rotor hammer crushers (Fig. ?? and Fig. 4.5-4) are used for coarse and interme-
diate comminution of soft to medium-hard materials. The feed material is comminuted
between two rotors, which rotate in opposite directions and are provided with ham-
mers, and the crushing wedge/anvil by impact and shock. When used as coarse crushers,
oversized pieces of rock are prevented from falling in by a feed grate. In order to achieve
smaller final particle sizes it is possible to install additional secondary crushing grates
beneath the rotors. Secondary comminution is then carried out on these grates by the ham-
mers, as in the designs described above.
At this point in the online course you will watch an animation of a double-rotor hammer
crusher instead of this picture.
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26
Figure 4.5-2: Single-Rotor Hammer Crusher .
Figure 4.5-3: Double-Rotor Hammer Crusher, Titan .
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4.5 Hammer Crushers
27
Figure 4.5-4: Double-Rotor Hammer Crusher .
1 and 2 rotor
3 crushing wedge or anvil
4 feed grate
5 hammers
6 crusher housing
4.5.3 Impact Hammer Crushers
This type of crusher (Fig. ?? and Fig. 4.5-5) is a combination of an impact crusher and
a hammer crusher. The working area is increased in the inlet region to increase the pro-
portion of comminution achieved by impact. The feed material with edge lengths up to
2,000 mm is transported into the operating region of the hammers by two feed rollers. At
the same time, some of the finished product is pre-screened through the gap between the
rollers. The material is picked up by the hammers rotating at a circumferential speed of v
= approx. 40 m/s and thrown against the crushing plate. Comminution to the desired edge
length of a maximum of 25 mm then takes place in the working chamber between the rotor
and the discharge grate.
At this point in the online course you will watch an animation of an impact hammer
crusher.
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28
Figure 4.5-5: Impact-Hammer Crusher, F.L. Smidth .
1. feeder
2. chain curtain
3. feed rollers
4. hammer rotor
5. adjustable crushing jaws
4.5.4 Position, Shape and Operation of Hammers in Hammer Crush-

ers
Position The rotor generally consists of a number of discs or stars that are fixed to the shaft. The
hammers are attached uniformly over the circumference of continuous beater shafts. They
must be positioned in such a way that a good degree of overlap is achieved with each
rotation of the rotor (Fig. 4.5-6). The hammers are therefore not positioned directly above
one another, but offset against each other in the respective rows.
Wear The heavily stressed hammers are generally made of austenitic manganese steel or other
wear-resistant materials. Depending on the size of the crusher they weigh between 70 and
200 kg . Throughput decreases by up to 25 % with progressive wear which ranges from 2
to 15 g/t in the case of limestone. As the impact causes one-sided wear the hammers must
be first rotated and then replaced for deposit welding once a certain stage of wear has been
reached.
The beater shape and weight, the number of beater rows and the circumferential speed are
dependent on the selected application (Fig. 4.5-7).
Coarse Comminution
fewer beater rows
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4.5 Hammer Crushers
29
Figure 4.5-6: Positioning Principle of the Hammers on the Rotor, 1 to 4 Hammer Shafts with Hammers
Positioned to Avoid Impact-Free Strips .
Figure 4.5-7: Hammer Shapes for Different Fields of Application .
hammers with thickened heads

hammer weight up to 200 kg
low circumferential speed (20 to 50 m/s)
Medium/Fine Comminution
more beater rows
simple plate-shaped beaters
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hammer weight > 5 kg

high circumferential speed (40 to 100 m/s)
4.6 Drives and Auxiliary Devices

Types of Drives
The drive unit of the crusher used generally consists of V-belts and asynchronous motors
. As as result of the acceleration work required at start-up of the heavy inertia masses
slipring motors are used. Frequency convertors that allow the drive to start slowly, pro-
vided it is operated at low voltage, constitute a new development. This would be too
expensive with high-voltage motors.
The V-belt pulley of the rotor also acts as a fly wheel. In large crushers an additional
inertia mass is fitted to the opposite side of the rotor shaft to reduce the impact loading
on the drive. The drive units are equipped with a shear pin as the point that must fail if
30 damage occurs in order to prevent the drive from being completely destroyed if an incident
occurs.
Auxiliary Equipment, Peripheral Units

Hydraulic Systems Since the wearing parts are large and heavy, their removal without the use of lifting equip-
ment is time-consuming and exhausting. Hydraulic traction equipment may help to over-
come these problems. Hydraulic cylinders are used to open housings, remove discharge
grids or rotate impact plates. The impact elements may also be hydraulically spring-loaded
during operation in order to reduce the impact load on the structure.
Feed The type of feed differs depending on the type of crusher. As in gyratory crushers the feed
material is thrown directly into the crushing chamber and an separate feed hopper is not
required. The crusher can work itself free.
In impact and hammer crushers the feed material is thrown into a locally offset feed hop-
per. The material is fed to the crusher by a bin discharge device (apron conveyor, armoured
chain conveyor). The feed rate is constant, the crusher is supplied uniformly or else the
conveying rate is controlled depending on the loading of the crusher motors or stopped in
the case of overloading.
These feed hoppers are equipped with wear plates and steel rails.
The crusher must be dedusted when a large amount of dust is produced.
Discharge Different designs of rubber belt conveyor are generally used below a crusher discharge.
In roller crushers or crushers without grates the crushed material is accelerated vertically
downward and slabby fragments could damage rubber belt conveyors. In this case chain
conveyors, steel plate conveyors or specially reinforced rubber belt conveyors should be
foreseen.
Pre-screening Pre-screening is often installed in order to relieve the crusher or to optimize the comminu-
tion results. The crusher itself has to handle less material and can therefore be smaller.
Depending on the particle size distribution of the feed material there is also no energy-
intensive over-crushing of the material. This additional comminution is undesirable since
further comminution during subsequent grinding is more efficient.
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5 Health and Safety Practices
The following provisions must be observed when dealing with and operating comminution
equipment:
provide protection against contact with all moving parts (drives, v-belts, drive wheels,
fly wheels)
provide protection against falling at the feed hopper and crusher inlet
provide barriers at the tipping edges of the feed bunker/crusher inlet to stop heavy duty
trucks
install cameras at the rear of the heavy duty trucks so the driver can see the tipping
area
provide protective chains at the inlet and outlet openings to protect against flying par-
ticles
provide safety devices on the transport equipment (emergency trips, emergency circuit
breakers), ensure fault-free functioning of system start-up warning signals
disconnect the plant from the power supply at all poles and secure against accidental
31
reconnection before starting any repairs
take safety precautions when carrying out major repairs in the systems (for example
prevent wearing plates from falling, etc.)
prevent rotation of the rotor e.g. when changing the discharge grate
make the operating and repair staff aware of the dangers posed by the systems during
operation and repair works
use lifting tools of suitable size for repairs
keep routes and pathways inside the system clear and safe
Personal protective equipment must be worn when working on or in any type of container, Personal Protective
silo, conveyor, fan, filter and container/silo filling and emptying equipment. Personal Equipment
protective equipment includes:

protective clothing incl. protective footwear
hard hat
protective gloves
protective goggles
protective breathing mask
safety harness
6 Operation and Quality

The design of the feed material transport system ahead of the crusher has a considerable Throughput and
influence on the throughput of a primary comminution system. The distance between the Capacity Utilization
point of material extraction and the crusher, the number and size of the vehicles (heavy-
duty trucks) and the size and type of loader have a direct influence. If, for example for
reasons of quality, material from different deposits must be loaded, a wheel loader should
be used as the loader. The use of an excavator is more economically viable for virtually
stationary operation.
The payload and number of vehicles should be selected in accordance with the length and
type of the routes so as to achieve optimal capacity utilization of the crusher. If the route
becomes too long, the crusher must be repositioned or a mobile crushing system must be
used.
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8 Environmental Protection
Primary comminution (crushing) generally makes it possible to achieve cost-effective

transport (overland belt conveyor systems) and further handling/subsequent processing of
the raw material obtained.
The energy consumption in subsequent comminution machinery like e.g. ball mills is
reduced in accordance with the degree of primary comminution achieved. There is not
normally a clear division between crushing and (subsequent) grinding with regard to a
specific particle size. The transition tends to be blurred.
Typical particle sizes of the feed material for downstream comminution equipment are:
for high-pressure roller mills: 2 x grinding gap
for ball mills: 50 mm
for vertical roller mills: 7 % of the roller diameter
Influence of the Material The quality of the raw material blend is affected already when it is loaded at the points of
material extraction. As, for example, the calcium carbonate content of a quarry face may
vary in the individual layers, attention must be paid during loading to ensure that the entire
cross-section of the quarry face is always loaded in sequence.
32 The raw material is already somewhat homogenized during primary comminution this
effect increasing with product fineness.
The maximum gap width in the primary comminution equipment determines the size of
the largest particle. With primary comminution the aim is normally to achieve particle
sizes between 20 and 80 mm. In practice, dust-like particles may also be produced during
comminution of the feed material so a particle size range from 0 to the maximum particle
size is achieved during primary comminution.
7 Maintenance and Servicing

Wearing Parts The throughput and fineness of the crushed material are also affected by the condition of
the wear parts. The wear elements are forged, cast or produced from composite materials.
Greater resistance to fracture (toughness) generally implies lower resistance to wear
(brittleness).
Weldability With hammer crushers attention should be paid to the material pairing at the eyes of the
hammer and the hammer shaft. If the working surface of the hammers has to be welded at
a later stage, the hammer material must be easy to weld. Austenitic manganese steels are
particularly suitable in this instance.
Influencing Factors A large number of factors (mineral size and type of rock, etc.) affect wear. Ultimately,
only tests on material samples provide the information required for correct system design.
Checks The condition of the wearing parts should be checked regularly. Damaged fixtures of
the crusher elements may lead to considerable damage of the machinery. When loading,
attention should always be paid as to whether all the teeth are still present on the bucket
of the loader. A steel body of this type can also causes serious mechanical damage in the
crusher and may result in long-term downtime. Of course, regular checks in accordance
with the see, hear, feel principle are essential. Regular lubrication also forms part of
system maintenance.
8 Environmental Protection
Dust and Noise As the comminution process involves the generation of dust and noise, suitable filter sys-
tems and sound insulation measures are used to reduce the emissions to an acceptable
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level. In dry weather the transport routes are sprayed with water in order to avoid the
generation of dust.
The separation and disposal of waste such as used oil, residual hydraulic oil, coolant,
etc.should be carried out in accordance with the relevant legislation.
Suitable measures should be used to keep blasting vibration to a minimum.
The state of wear of the crusher elements naturally affects energy consumption. Optimum Energy Requirement
equipment and adaptation of the loaders, heavy-duty trucks and the crusher plant are cru-
cial for the energy consumption of the entire system. Matching the type of crusher to the
type of rock also has a considerable influence on the energy consumption which increases
with increasing fine fraction in the feed material.
9 Questions on Course LB 2.1 Primary Comminution

You can test your knowledge by answering the following questions.
33
Question 9.0 A:
1. What different types of stresses are used for comminution?
2. What is the degree of comminution?
3. Name three different crusher designs.
4. Give the typical sizes of the feed material for subsequent comminution equipment.
Solutions see p. 34
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9 Questions on Course LB 2.1 Primary Comminution
Solutions
Solution for 9.0 A:
1. compression (1), shock (2), shearing (3), impact (4)
1 F 2
V v
V
F
F F
3 4
V v
34
F F
2. The ratio of the longest edge length of the feed material to the longest edge length
of the finished product
3. jaw crusher, impact crusher, hammer crusher, roller crusher
4. high pressure roller mill: 2 x grinding gap
ball mill: 50 mm
roller mill: 7 % of the roller diameter
Questions see p. 33
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Glossary
asynchronous motor
A type of electric motor
slipring motor
A type of electric motor
V-belt
Medium for transferring force from a motor to a machine.
35
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Index
A
asynchronous motor 30
S
slipring motor 30
V
V-belt 30
36
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Course 2 Raw Material Preparation

2.1 Primary Comminution

German Cement Works Association

Issued: 7th January 2013

3 Operational Configuration of Comminution Processes ................................ 3

4 Designs of Comminution Machine ................................................................. 5

5 Health and Safety Practices ............................................................................. 31

6 Operation and Quality ..................................................................................... 31

7 Maintenance and Servicing.............................................................................. 32

Figure 1.0-1: Example of a Crusher in a Quarry (Source: Polysius) .

2 Basic Principles and Types of Comminution

2 Figure 2.0-1: Types of Stressing .

3 Operational Configuration of Comminution

Figure 3.0-1: Flow Diagram of Single-Stage Comminution .

4 Designs of Comminution Machine

4.1 Jaw Crushers

4.1.1 Double-Toggle Jaw Crushers

Figure 4.1-1: Double-Toggle Jaw Crusher (SKET Magdeburg Design) .

1 housing of crushing jaw

2 oscillating element with crushing jaw

5 front toggle plate

6 rear toggle plate

7 oscillating shaft with bearing

8 drive shaft with cam

9 connecting rod element

10 connecting rod bearing

11 spring-loaded connecting rod

14 fly wheel and drive wheel

16 toggle plate bearing

17 clamping wedges for retaining the crushing jaws

Table 4.1-1: Key to Fig. 4.1-1.

Figure 4.1-2: Mode of Operation of a Double-Toggle Jaw Crusher .

4.1.2 Single-Toggle Jaw Crushers

1 crusher housing (frame)

2 housing of crushing jaw

3 drive shaft (eccentric shaft)

5 oscillating crushing jaw

9 toggle plate bearing

10 spring-loaded connecting rod

14 adjusting device (hand wheel) with spindle

16 fly wheel and drive wheel

18 belt pulley and drive motor

Table 4.1-2: Key to Fig. 4.1-3.

Figure 4.1-4: Drive Principle of the Single-Toggle Jaw Crusher .

4.1.3 Jaw Crusher Components: Crushing Plates and Overload Pro-

Figure 4.1-5: Various Crushing Plate Configurations .

4.2 Cone Crushers/Gyratory Crushers

1 crushing bowl with crushing shell

3 crushing cone shaft

6 bevel gear drive

Table 4.2-1: Key to Fig. 4.2-1.

Parameters Steep-Angle Cone Crusher Shallow-Angle Cone Crusher

Particle Size of the Feed 150 ... 1,800 25 ... 300

Final Particle Size (mm) 25 ... 250 5 ...40

Throughput (t/h) 35 ... 3,500 10 ... 600

Specific Energy Demand 0.15 ... 0.5 0.4 ... 2.2

Type of Stress compression compression/percussion

Table 4.2-2: Options forCone Crusher Use.

4.2.1 Steep-Angle Cone Crushers

Figure 4.2-2: Gyratory Crusher (Esch Werke Duisburg Design) .

1 distribution of feed material

4 outer crushing surface

9 adjusting ring nut