crusher plant design 7 tph

jaw crushers | mclanahan

Jaw Crushers are used to reduce the sizeof many different types of materials in many applications. The Jaw Crusher was first introduced by Eli Whitney Blake in 1858 as a double-toggle Jaw Crusher. Introduced in 1906, McLanahans Universal Jaw Crusher was one of the first modern era overhead eccentric Jaw Crushers. On the overhead eccentric style Jaw Crusher, the moving swing jaw is suspended on the eccentric shaft with heavy-duty double roll spherical roller bearings.

The swing jaw undergoes two types of motion: one is a swing motion toward the opposite chamber side (called a stationary jaw die due to theaction of a toggle plate), and the second is a vertical movement due to the rotation of the eccentric. These combined motions compress and push the material through the crushing chamber at a predetermined size.

More than 110 years of engineering and customer service experience keep customers running to McLanahan tomeet their production goals. McLanahan Jaw Crushers are proudly made in the USA and have imperial designs. With our grass roots design coupled with listening to customer needs for product enhancement over the years, McLanahan offers traditional hydraulic-shim adjustment Jaw Crushers as well asH-Series Jaw Crushers that featurehydraulic discharge setting adjustment, adjust-on-the-fly chamber clearing in the event the site loses power (once power is restored) and hydraulic relief for overload events with auto-reset.

Whether the traditional hydraulic-shim adjustment or the H-Series Jaw Crushers, both machines have an aggressive nip angle that providesconsistent crushing throughout the entire crushing chamber, which leads to increased production and less downtime on maintenance.

A Jaw Crusher uses compressive force for breaking material. This mechanical pressure is achieved by the crusher'stwo jaws dies, one of which is stationary and the other is movable. These two vertical manganese jaw dies create a V-shaped cavity called the crushing chamber, where the top of the crushing chamber is larger than the bottom. Jaw Crushers are sized by the top opening of the crushing chamber. For example, a 32 x 54 Jaw Crusher measures 32" from jaw die to jaw dieat the top opening or gape opening and54 across the width of the two jaw dies.

The narrower bottom opening of the crushing chamber is used to size the discharge material. A toggle plate and tension rods hold the pitman tight near the bottom of the moving swing jaw. The toggle plate is designed to perform like a fuse and protect the crusher in the event that an uncrushable materialenters the crushing chamber. As a rule, Jaw Crushers have a 6:1 or 8:1 ratio for crushing material. Still using the 32 x 54 Jaw Crusher example, the top size of thefeed entering the crushing chamber has to follow the F80 rule that 80% of the top size feed material is smaller than the gape opening. Using the F80 rule with the 32 x 54 Jaw Crusher, the32 gape opening equals a26 top sized feed, and with the 6:1 ratio of reduction, the discharge setting would be around 4.

Since the crushing of the material is not performed in one stroke of the eccentric shaft, massive weighted flywheels are attached to the eccentric shaft andpowered by a motor. The flywheels transfer the inertia required to crush thematerial until it passes the discharge opening.

While Jaw Crushers are mostly used as the first stage of material reduction in systems that may use several crushers to complete the circuit, the Jaw Crusher has also been used as a second-stage crushing unit. Depending on the application requirements, Jaw Crushers can be used in stationary, wheeled portable and track-mounted locations. The Jaw Crusher is well suited for a variety of applications, including rock quarries, sand and gravel, mining, construction and demolitionrecycling, construction aggregates, road and railway construction, metallurgy, water conservancy and chemical industry.

F100 is the maximum gape opening on a Jaw Crusher. F80 is the feed size to the Jaw Crusher, calculated by taking 80 times the gape opening divided by 100. P80 is the percent passing the closed side setting in tph.

A best practice, if possible, is to blend the material arriving from the source. This will ensure a constant and well-graded feed to the crushing chamber. In turn, this will produce a steady rate of tph andpromote inter-particle crushing that helps break any flat or elongated material. It also aids in equal work hardening the manganese jaw dies and prolonging the life of the jaw dies.

Usually a Jaw Crusher is in an open circuit, but it can be used in a close circuit if the return load is not greater than 20% of the total feed and the raw feed is free of fines smaller than the closed side setting.

Efficiency can be defined by the ratio of the work done by a machine to the energy supplied to it. To apply what this means to your crusher, in your reduction process you are producing exactly the sizes your market is demanding. In the past, quarries produced a range of single-size aggregate products up to 40 mm in size. However, the trend for highly specified aggregate has meant that products have become increasingly finer. Currently, many quarries do not produce significant quantities of aggregate coarser than 20 mm; it is not unusual for material coarser than 10 mm to be stockpiled for further crushing.

vibrating screen working principle

When the smaller rock has to be classified a vibrating screen will be used.The simplest Vibrating Screen Working Principle can be explained using the single deck screen and put it onto an inclined frame. The frame is mounted on springs. The vibration is generated from an unbalanced flywheel. A very erratic motion is developed when this wheel is rotated. You will find these simple screens in smaller operations and rock quarries where sizing isnt as critical. As the performance of this type of screen isnt good enough to meet the requirements of most mining operations two variations of this screen have been developed.

In the majority of cases, the types of screen decks that you will be operating will be either the horizontal screen or the inclined vibrating screen. The names of these screens do not reflect the angle that the screens are on, they reflect the direction of the motion that is creating the vibration.

An eccentric shaft is used in the inclined vibrating screen. There is an advantage of using this method of vibration generation over the unbalanced flywheel method first mentioned. The vibration of an unbalanced flywheel is very violent. This causes mechanical failure and structural damage to occur. The four-bearing system greatly reduces this problem. Why these screens are vibrated is to ensure that the ore comes into contact will the screen. By vibrating the screen the rock will be bounced around on top of it. This means, that by the time that the rock has traveled the length of the screen, it will have had the opportunity of hitting the screen mesh at just the right angle to be able to penetrate through it. If the rock is small enough it will be removed from the circuit. The large rock will, of course, be taken to the next stage in the process. Depending upon the tonnage and the size of the feed, there may be two sets of screens for each machine.

The reason for using two decks is to increase the surface area that the ore has to come into contact with. The top deck will have bigger holes in the grid of the screen. The size of the ore that it will be removed will be larger than that on the bottom. Only the small rock that is able to pass through the bottom screen will be removed from the circuit. In most cases the large rock that was on top of each screen will be mixed back together again.

The main cause of mechanical failure in screen decks is vibration. Even the frame, body, and bearings are affected by this. The larger the screen the bigger the effect. The vibration will crystallize the molecular structure of the metal causing what is known as METAL FATIGUE to develop. The first sign that an operator has indicated that the fatigue in the body of the screen deck is almost at a critical stage in its development are the hairline cracks that will appear around the vibrations point of origin. The bearings on the bigger screens have to be watched closer than most as they tend to fail suddenly. This is due to the vibration as well.

In plant design, it is usual to install a screen ahead of the secondary crusher to bypass any ore which has already been crushed small enough, and so to relieve it of unnecessary work. Very close screening is not required and some sort of moving bar or ring grizzly can well be used, but the modern method is to employ for the purpose a heavy-duty vibrating screen of the Hummer type which has no external moving parts to wear out ; the vibrator is totally enclosed and the only part subjected to wear is the surface of the screen.

The Hummer Screen, illustrated in Fig. 6, is the machine usually employed for the work, being designed for heavy and rough duty. It consists of a fixed frame, set on the slope, across which is tightly stretched a woven-wire screen composed of large diameter wires, or rods, of a special, hard-wearing alloy. A metal strip, bent over to the required angle, is fitted along the length of each side of the screen so that it can be secured to the frame at the correct tension by means of spring-loaded hook bolts. A vibrating mechanism attached to the middle of the screen imparts rapid vibrations of small amplitude to its surface, making the ore, which enters at the top, pass down it in an even mobile stream. The spring-loaded bolts, which can be seen in section in Fig. 7, movewith a hinge action, allowing unrestricted movement of the entire screening surface without transmitting the vibrations to the frame.

One, two, or three vibrators, depending on the length of the screen, are mounted across the frame and are connected through their armatures with a steel strip securely fixed down the middle of the screen. The powerful Type 50 Vibrator, used for heavy work, is shown in Fig. 7. The movement of the armature is directly controlled by the solenoid coil, which is connected by an external cable with a supply of 15-cycle single-phase alternating current ; this produces the alternating field in the coil that causes the up-and-down movement of the armature at the rate of thirty vibrations per second. At the end of every return stroke it hits a striking block and imparts to the screen a jerk which throws the larger pieces of ore to the top of the bed and gives the fine particles a better chance of passing through the meshes during the rest of the cycle. The motion can be regulated by spiral springs controlled by a handwheel, thus enabling the intensity of the vibrations to be adjusted within close limits. No lubrication is required either for the vibrating mechanism or for any other part of the screen, and the 15-cycle alternating current is usually supplied by a special motor-generator set placed somewhere where dust cannot reach it.

The Type 70 Screen is usually made 4 ft. wide and from 5 to 10 ft. in length. For the rough work described above it can be relied upon to give a capacity of 4 to 5 tons per square foot when screening to about in. and set at a slope of 25 to 30 degrees to the horizontal. The Type 50 Vibrator requires about 2 h.p. for its operation.

The determination of screen capacity is a very complex subject. There is a lot of theory on the subject that has been developed over many years of the manufacture of screens and much study of the results of their use. However, it is still necessary to test the results of a new installation to be reasonably certain of the screen capacity.

A general rule of thumb for good screening is that: The bed depth of material at the discharge end of a screen should never be over four times the size opening in the screen surface for material weighing 100 pounds per cubic foot or three times for material weighing 50 pounds per cubic foot. The feed end depth can be greater, particularly if the feed contains a large percentage of fines. Other interrelated factors are:

Vibration is produced on inclined screens by circular motion in a plane perpendicular to the screen with one-eighth to -in. amplitude at 700-1000 cycles per minute. The vibration lifts the material producing stratification. And with the screen on an incline, the material will cascade down the slope, introducing the probability that the particles will either pass through the screen openings or over their surface.

Screen capacity is dependent on the type, available area, and cleanliness of the screen and screenability of the aggregate. Belowis a general guide for determining screen capacity. The values may be used for dried aggregate where blinding (plugged screen openings), moisture build-up or other screening problems will not be encountered. In this table it is assumed that approximately 25% of the screen load is retained, for example, if the capacity of a screen is 100 tons/hr (tph) the approximate load on the screen would be 133 tph.

It is possible to not have enough material on a screen for it to be effective. For very small feed rates, the efficiency of a screen increases with increasing tonnage on the screen. The bed of oversize material on top of the marginal particlesstratification prevents them from bouncing around excessively, increases their number of attempts to get through the screen, and helps push them through. However, beyond an optimum point increasing tonnage on the screen causes a rather rapid decrease in the efficiency of the screen to serve its purpose.

Two common methods for calculating screen efficiency depend on whether the desired product is overs or throughs from the screen deck. If the oversize is considered to be the product, the screen operation should remove as much as possible of the undersize material. In that case, screen performance is based on the efficiency of undersize removal. When the throughs are considered to be the product, the operation should recover as much of the undersize material as possible. In that case, screen performance is based on the efficiency of undersize recovery.

These efficiency determinations necessitate taking a sample of the feed to the screen deck and one of the material that passes over the deck, that is, does not pass through it. These samples are subjected to sieve analysis tests to find the gradation of the materials. The results of these tests lead to the efficiencies. The equations for the screen efficiencies are as follows:

In both cases the amount of undersize material, which is included in the material that goes over the screen is relatively small. In Case 1 the undersize going over the screen is 19 10 = 9 tph, whereas in Case 2 the undersize going over is 55 50 = 5 tph. That would suggest that the efficiency of the screen in removing undersize material is nearly the same. However, it is the proportion of undersize material that is in the material going over the screen, that is, not passed through the screen, that determines the efficiency of the screen.

In the first cases the product is the oversize material fed to the screen and passed over it. And screen efficiency is based on how well the undersize material is removed from the overs. In other cases the undersize material fed to the screen, that is, the throughs, is considered the product. And the efficiency is dependent on how much of the undersize material is recovered in the throughs. This screen efficiency is determined by the Equation B above.An example using the case 1 situation for the throughs as the product gives a new case to consider for screen efficiency.

Generally, manufacturers of screening units of one, two, or three decks specify the many dimensions that may be of concern to the user, including the total headroom required for screen angles of 10-25 from the horizontal. Very few manufacturers show in their screen specifications the capacity to expect in tph per square foot of screen area. If they do indicate capacities for different screen openings, the bases are that the feed be granular free-flowing material with a unit weight of 100 lb/cu ft. Also the screen cloth will have 50% or more open area, 25% of total feed passing over the deck, 40% is half size, and screen efficiency is 90%. And all of those stipulations are for a one-deck unit with the deck at an 18 to 20 slope.

As was discussed with screen efficiencies, there will be some overs on the first passes that will contain undersize material but will not go through the screen. This material will continue recirculating until it passes through the screen. This is called the circulating load. By definition, circulating load equals the total feed to the crusher system with screens minus the new feed to the crusher. It is stated as a percentage of the new feed to the crusher. The equation for circulating load percentage is:

To help understand this determination and the equation use, take the example of 200 tph original or new material to the crusher. Assume 100% screen efficiency and 30% oversize in the crusher input. For the successive cycles of the circulating load:

The values for the circulating load percentages can be tabulated for various typical screen efficiencies and percents of oversize in the crusher product from one to 99%. This will expedite the determination for the circulating load in a closed Circuit crusher and screening system.

Among the key factors that have to be taken into account in determining the screen area required is the deck correction. A top deck should have a capacity as determined by trial and testing of the product output, but the capacity of each succeeding lower deck will be reduced by 10% because of the lower amount of oversize for stratification on the following decks. For example, the third deck would be 80% as effective as the top deck. Wash water or spray will increase the effectiveness of the screens with openings of less than 1 in. in size. In fact, a deck with water spray on 3/16 in. openings will be more than three times as effective as the same size without the water spray.

For efficient wet or dry screeningHi-capacity, 2-bearing design. Flywheel weights counterbalance eccentric shaft giving a true-circle motion to screen. Spring suspensions carry the weight. Bearings support only weight of shaft. Screen is free to float and follow positive screening motion without power-consuming friction losses. Saves up to 50% HP over4- bearing types. Sizes 1 x 2 to 6 x 14, single or double deck types, suspended or floor mounted units.Also Revolving (Trommel) Screens. For sizing, desliming or scrubbing. Sizes from 30 x 60 to 120.

TheVibrating Screen has rapidly come to the front as a leader in the sizing and dewatering of mining and industrial products. Its almost unlimited uses vary from the screening for size of crusher products to the accurate sizing of medicinal pellets. The Vibrating Screen is also used for wet sizing by operating the screen on an uphill slope, the lower end being under the surface of the liquid.

The main feature of the Vibrating Screen is the patented mechanism. In operation, the screen shaft rotates on two eccentrically mounted bearings, and this eccentric motion is transmitted into the screen body, causing a true circular throw motion, the radius of which is equivalent to the radius of eccentricity on the eccentric portion of the shaft. The simplicity of this construction allows the screen to be manufactured with a light weight but sturdy mechanism which is low in initial cost, low in maintenance and power costs, and yet has a high, positive capacity.

The Vibrating Screen is available in single and multiple deck units for floor mounting or suspension. The side panels are equipped with flanges containing precision punched bolt holes so that an additional deck may be added in the future by merely bolting the new deck either on the top or the bottom of the original deck. The advantage of this feature is that added capacity is gained without purchasing a separate mechanism, since the mechanisms originally furnished are designed for this feature. A positivemethod of maintaining proper screen tension is employed, the method depending on the wire diameter involved. Screen cloths are mounted on rubber covered camber bars, slightly arched for even distribution.

Standard screens are furnished with suspension rod or cable assemblies, or floor mounting brackets. Initial covering of standard steel screen cloth is included for separations down to 20 mesh. Suspension frame, fine mesh wire, and dust enclosure are furnished at a slight additional cost. Motor driven units include totally-enclosed, ball-bearing motors. The Vibrating Screen can be driven from either side. The driven sheave is included on units furnished without the drive.

The following table shows the many sizes available. Standard screens listed below are available in single and double deck units. The triple and quadruple deck units consist of double deck units with an additional deck or decks flanged to the original deck. Please consult our experienced staff of screening engineers for additional information and recommendations on your screening problems.

An extremely simple, positive method of imparting uniform vibration to the screen body. Using only two bearings and with no dead weight supported by them, the shaft is in effect floating on the two heavy-duty bearings.

The unit consists of the freely suspended screen body and a shaft assembly carried by the screen body. Near each end of the shaft, an eccentric portion is turned. The shaft is counterbalanced, by weighted fly-wheels, against the weight of the screen and loads that may be superimposed on it. When the shaft rotates, eccentric motion is transmitted from the eccentric portions, through the two bearings, to the screen frame.

The patented design of Dillon Vibrating Screens requires just two bearings instead of the four used in ordinary mechanical screens, resulting in simplicity of construction which cuts power cost in half for any screening job; reduces operating and maintenance costs.

With this simplified, lighter weight construction all power is put to useful work thus, the screen can operate at higher speeds when desired, giving greater screening capacity at lower power cost. The sting of the positive, high speed vibration eliminates blinding of screen openings.

The sketches below demonstrate the four standard methods of fastening a screen cloth to the Dillon Screen. The choice of method is generally dependent on screen wire diameters. It is recommended that the following guide be followed:

Before Separation can take place we need to get the fine particles to the bottom of the pile next to the screen deck openings and the coarse particles to the top. Without this phenomenon, we would have all the big particles blocking the openings with the fines resting atop of them and never going through.

We need to state that 100% efficiency, that is, putting every undersize particle through and every oversize particle over, is impossible. If you put 95% of the undersize pieces through we in the screen business call that commercially perfect.

crusher efficiency calculations

The following example demonstrates a method of selecting the components of an aggregate plant. Good component efficiency and part performance pre-evaluation is essential to a solid design. The aggregate production requires the consideration of several crushers, feeders and screens. This is not intended to be a typical situation, though it does involve common crusher and screen units often used in aggregate plants.

Quarry rock of 12 in. maximum size is to be handled in a two-stage crusher plant at the rate of 70 tons per hour. The maximum size of output is to be 1 in., and separation of materials over 1 in. size and the minus 1 in. in the output is required. Select a jaw crusher like those included in this table.

The screens to be considered are a 1-in. screen with an estimated capacity of 2.7 tph/sq ft and a 1-in. screen with a capacity of 2.1 tph/sq ft. The solution will include the selection of adequate and economical crushers for the two stages and the sizes of screens between them and below the secondary stage.

For the primary crusher a jaw crusher will probably be most economical. A jaw crusher, like 2036 in the Jaw Crusher Table here above, would be able to take the maximum 12 in. size quarry stone but it would not have the required 70 tph capacity needed. To have the needed capacity a jaw crusher like the 2042 or 2436 sizeswill have to be selected overloading the secondary crusher.

A grid chart or curve for the selected crusher shows that, for a 2-in. setting, 54% of the material will pass a 1-in. screen, or 46% will be retained (this is like Jaw Crusher capacity table abovewhere 48% passes a 1 in. screen). The 46% of 70 tph gives the 32 tph fed to the secondary crusher shown in Figure below as a roll crusher.

A twin-roll crusher is selected, like those given inthe Roll Crusher capacityTable above, to serve as the reduction crusher. The smallest, 24 x 16 roll crusher shown in theRoll Crusher capacity Table above has enough capacity with a setting of 1 in. but the maximum size feed will be too large, that is, the stage of reduction is not large enough. The maximum size of feed coming from the discharge of the primary crusher with a setting of 2 is about 3 in. as may be found in this Table.

Considering a 30-in. diameter roll crusher the maximum size particle that can be nipped with the roll crusher set at 1 in. according to this Equation is F = 0.085(15) + 1.0 = 2.28 in. <3 in. feed. It will take larger than a 40-in. diameter roll crusher. A better solution would be to use a larger jaw crusher set at 1 in., then a roll crusher from the Roll Crusher capacityTable above could be used. If the output of this crushing process should have less material of the +1-in. size, the larger crusher could be operated with a closed circuit. That is, the oversize in the output could be recirculated through the roll crusher without exceeding the rated capacity of the crusher. Then all material leaving that crusher with a 1-in. setting would be of a minus 1-in. size.

Another possible solution to this problem would be to use a gyratory crusher for the primary crushing stage. A gyratory like Telsmith model1110 could be set at 1 in. in an open circuit with a capacity for 260 tph. The maximum size of stone in the output is estimated to be approximately 2 1/8 in. Then all the output from the primary crusher could be nipped by a 40 in. diameter twin-roll crusher with a 1-in. setting according to the Roll Crusher capacityTable above. The specifications and manufactured limitations, rather than economy, generally govern the selection of crushers.

To find the required areas of screen, the rate of feed of material as well as gradation of the feed must be known. The 1-in. screen under the jaw crusher is the top deckno deck correction factor will be necessary. Therefore, the 1-in. screen will need to be at least 70/2.7 = 29.9 sq ft in area. It must be at least 36 in. wide for an 18 x 36 jaw crusher. So a 4-ft by 8-ft screen would be acceptable. The 1-in. screen is a second deck for the 38 tph from the jaw crusher, so the deck correction factor is 0.90 and that screen capacity is 2.1 x 0.9 = 1.89 tph/sq ft.

The screen area needed under the jaw crusher is 38/1.89 = 20.1 sq ft. For the 1-in. screen below the roll crusher the capacity has no correction factor and the area needed is 32/2.1 = 15.2 sq ft. To handle the output from a 40 x 24 roll crusher the screen will have to be at least 24 in. wide. Perhaps it will be more effective to use one continuous screen of at least 20.1 + 15.2 = 35.3 sq ft. A 4-ft by 10-ft 1 in. screen should be satisfactory.

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jaw crushers

The RockSizer / StoneSizer up-thrust single toggle design has specific features that benefit the user with lower manganese wear rates and power consumption per tonne of material crushed with improved product shape whilst maintaining higher outputs than old double-toggle style designs. The ten standard models in the RockSizer / StoneSizer range cover output capacities from 5tph to over 200tph.

The RockSledger down-thrust single toggle design provides a more aggressive crushing motion and subsequently higher capacities are achieved. Six standard models in the RockSledger range provide outputs from 70tph to over 850tph and are at the core of the designs used by Parker in their ranges of static, transportable and mobile jaw crushing plants.

RockSizer primary stage jaw crushers feature the upthrust toggle action which is also common to the StoneSizer range. Developed by Parker, this gives a slight downward movement to the swing jaw that promotes a forced feed and therefore increased output while at the same time minimising any rubbing action resulting in a well shaped product and reduced and even wear on the crushing jaws.

The RockRanger has a wide discharge conveyor with good clearance under the crusher. Installation is rapid and easy to set up. The feed hopper is an externally reinforced heavy-duty steel plate hopper to stand up to the toughest of jobs.

Mounted on a robust, semi-trailer chassis, a Parker RockSizer or RockSledger primary jaw is combined with a matched, high strength feeder/grizzly and integral product conveyor to give owners portable primary crushing at its best.

A fully mobile primary crushing plant complete with a Parker Rocksizer or RockSledger single toggle Jaw crusher, built around a strong straight beam chassis with standard supports for feed section, crusher, power unit and conveyor frame. The chassis is complete with access/maintenance platforms to the crusher and power unit and a main operator platform overlooks all stages of operation.

Robust fabricated chassis with all necessary operator platforms and access ladders. (the running gear for the RE1180 is quad-axle bogie and the RE1165 is a standard tri-axle bogie). Operating jacks are as standard for levelling the machine.

RockSizer (single toggle up-thrust) or RockSledger (single toggle down-thrust) design. Heavy duty reinforced fabricated welded steel plate body. High grade steel eccentric shaft. Hydraulically adjusted jaw settings.

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cone crusher manufacturer & supplier in nashik, india

The use of high quality steel components has ensured excellent reliability and safe Operations. From the extra heavy-duty main Shaft, premium roller bearings to the extremely functional Hydraulic Power pack, quality is the main focus. SINGH Cone Crushers are designed to give maximum performance in a wide variety of Crushing: from Sand Crushing to secondary Crushing: from stationary to Mobile applications. The best feature of SINGH Cone Crushers is adaptability. This is possible due to a special Crusher design that enables choice of various Crushing geometries: in the same Crusher!

Special attention has been paid to ensure a wider feed opening as compared to similar sized cone Crushers; there by permitting use of Primary Jaw Crushers at large closed side settings. This not only helps in increasing the throughput of the Crushing plant but also minimizes wear & tear.

Advanced automation, easy adjustment and minimum maintenance points have made the SINGH BULLET Cone Crushers very operator friendly. The hydraulic adjustment is very easy to use and can be conveniently adjusted during operation.

symons cone crusher

For finer crushing or reduction a Symonscone crusher the norm. Symons are commonly used for secondary, tertiary or quaternary crushing. They do this by a different chamber design which is flatter and by operating at about twice the rotational speed of a primary type gyratory crusher.

One of the first cone crushers had a direct drive vertical motor mounted above the spider with the drive shaft passing through the hollow bored main shaft. With relatively high speeds of 480 to 580 rpm and small eccentric throw, the machine produced a uniform produce with minimum fines.There are numerous Symonscone crusher manufacturers of modern crushers each promoting some unique aspect.

The Allis Chalmers Hydrocone selling point is its adjustability and tramp protection through a hydraulic support system for the headcentre. By merely adjusting the oil reservoir below the head centre the crusher setting can be changed while in full operation. Tramp metal causes a surge of pressure in this hydraulic system which is absorbed through relief valves and gas-bladder-filled accumulator bottles which allow the headcentre to momentarily drop and return to its normal operating position when the tramp has fallen through.

The Symons or Rexnord spring cone crusher is adjusted by spinning the bowl up or down manually or through hydraulic rams. A series of powerful springs give the necessary tramp protection. Several other manufacturers produce similar types and sizes of crushers but all follow the basic types described.

When the Symons brothers Invented the cone crusher, they employed the principle wherein the length of the crushing stroke was related to the free fall of material by gravity. This permitted the material being crushed to fall vertically in the crushing chamber; and in effect, caused the particles to be crushed in a series of steps or stages as the particles got smaller due to the crushing action. This also helps to reduce the rate of wear of the liners since the sliding motion of the particles is minimized.

Recognizing that the Symons principle of crushing is the most efficient means of ore and aggregate reduction in hard rock applications, the engineers used this same principle in the design on the hydrocone.

Versatility in the form of having the ability to perform in a wide range of applications without the need for a change in major assemblies was another objective in the design. Ease of maintenance and remote setting capability also were part of the design parameters the market requires.

There is no startling revelation to the fact that the mining industry as a whole is generally moving toward the use of larger equipment to process ores in quantities far greater than what was even considered a decade ago. Trucks and shovels have led the way in extra large machines and many other manufacturers have followed suit in the development of so-called supers in their line of equipment.

In order to keep pace with the industry, crusher manufacturers have also enlarged the size of their equipment. There is now on the market, a Gyratory crusher capable of accepting a 72 diameter piece of ore. Primary jaw crushers have also increased in size. It is inevitable, therefore, that larger secondary cone crushers would also be required to complement the other equipment used to process these large quantities of ore. This super-size secondary cone crusher is the SYMONS 10 Ft. Cone Crusher.

Until 1973, the largest cone crusher built was the 7 Ft. Extra Heavy Duty crusher, which is currently used in the majority of the mining operations throughout the world. The 10 Ft. crusher, when compared to the 7 Ft. Extra Heavy Duty Crusher, is approximately 1 times larger in physical dimensions; three times heavier; will accept a maximum feed size which is approximately twice as large; and will crush at approximately 2 times the rate of the 7 Ft. machine at identical closed side settings. It will be the largest cone crusher built in the world.

The conclusions of this investigation were all positive the crusher could be built and at a cost that would be in line with its size and capacity and also with other size crushers. After that preliminary study, the project became dormant for several years.

The project was reactivated and this time general assembly drawings were made which incorporated many improvements in the crusher such as pneumatic cylinders in place of the conventional, springs for tramp iron release, a two-piece main frame a dynamically balanced design of the internal moving parts of the crusher, and an automatic clearing and adjusting mechanism for the crusher. At this stage of development we felt we were ready to build a 10 Ft. crusher for any mine that was willing to try one. Unfortunately, the conservative posture of the mining industry did not exactly coincide with our sales plans. This, added to the popularity of the autogenous mill concept at the time, led to another lull in the 10 Ft. development program.

The project was reactivated again in 1970, this time primarily at the request of one of the large Minnesota Iron Range mining companies. We then undertook a comprehensive market research study to determine if there was a need for this size crusher by the mining industry in general, rather than just the iron ore industry. We talked not only to the iron ore people but to the copper people and persons connected with the other metallic ores as well. The acceptability of this large crusher was also discussed with the aggregate industry. After interviews with many of the major mining companies, the decision was made to complete the entire engineering phase of the development program and to actively solicit a customer for this new crusher. We spent approximately $85,000 on engineering work and tests on the gamble that we could find a customer. I speak of a gamble because during our market research study we continually were told my company would be very interested in buying a 10 Ft. crusher, but only after we have seen one in operation.

The actual building and test of the first prototype unit without a firm commitment for a sale was an economic impossibility. We were now at the point where we needed to sell at least one unit in order to prove not only the mechanical reliability of the machine, but the economic justification for its purchase as well. Needless to say, when the order for two SYMONS 10 Ft. cone crushers was received, we felt we were now on the way toward completion of the development program.

Perhaps at this point it might be apropos to examine the crusher itself. It will stand 15-6 above its foundation, the overall height will be 19-4-. At its greatest diameter, in the area of the adjustment ring, it will be approximately 17-6. It will weigh approximately 550,000 lbs. Under normal crushing conditions, the crusher will be connected to a 700 HP motor. A 50 ton. overhead crane is required to perform routine maintenance on this crusher.

The main shaft assembly will weigh approximately 92,000 lbs. and the bowl assembly approximately 95,000 lbs. The mantle and bowl liner, cast from manganese steel, will weigh approximately 13,000 lbs. and 25,000 lbs. respectively.

The throughput capacity of the Standard will be approximately 1300 TPH at a 1 closed side setting and 3000 TPH at a 2- closed side setting. The throughput capacity of the SHORT HEAD will be approximately 800 TPH at closed side setting and 1450 TPH at a 9/16 closed side setting.

Persons familiar with the design of a conventional 7 Ft. SYMONS cone crusher will recognize that the design of the 10 Ft. is quite similar to it. As a matter of fact, we like to say that the design of the 10 Ft. is evolutionary rather than revolutionary, because all the reliable features of the SYMONS cone crusher were retained and the only changes that were made were those that added to the convenience of the operator, such as automatic clearing and automatic adjustment. From a mechanical point of view the stresses generated due to crushing loads are less in the 10 Ft. crusher than in the existing 7 Ft. Extra Heavy Duty cone.

One of our senior engineers who has long since retired told me that he had the occasion many years ago to make a presentation of a newly designed crusher to a prospective customer. He carefully prepared a rather detailed description of the crusher which included all the features that his new machine had when compared to the customers existing machine. The presentation itself took about one hour and after that period the customer leaned back in his chair and said, Thats all well and good, but will it crush rock? In effect, the customer was; saying that all the features in the world were of no use to him if the crusher did not perform its basic function to crush rock and ultimately make profits for the owner. Using todays financial terminology he was asking the engineer to economically cost justify the purchase of the crusher.

The working day of the contemporary manager or project engineer evolves around making decisions to economically justify a piece of equipment or a new operation. In our development program of the 10 Ft. cone crusher, we felt that the economic justification, from the customers point of view, was just as important to develop as the engineering aspects of the program. So we developed a three-part program to examine the economics of installing a 10 Ft. crusher. First we talked in wide generalities concerning the use of a 10 Ft. crusher. Secondly, we discussed the ramifications of using a 10 Ft. crusher versus 7 Ft. crushers in a completely new plant being considered for the future. Thirdly, we examined how a 10 Ft. crusher could be used to its best advantage in a plant that is being expanded.

The first consideration was the economic generalities of installing the crusher, or more specifically, what questions regarding the installation are pertinent to every crushing plant. Usually, the initial comparison which is made between a 7 Ft. crusher and a 10 Ft. crusher is that of price versus capacity. Theoretically, the capacity of a 10 Ft. crusher is 2 times that of a 7 Ft. while the selling price is approximately 3 times that of the 7 Ft. On that basis alone, it would appear that the 10 Ft. could not be justified. However, this is an incomplete picture. Recent cost estimates show that considerable savings are realized when the entire physical plant structure is considered. Because fewer machines are required to crush an equivalent amount of ore, the size of the buildings can be reduced, thereby decreasing the capital investment of buildings and allied equipment used as auxiliaries for the crusher.

Total manpower requirements to operate and maintain the plant is another of the generalities which were considered. Fewer crushers normally require less personnel to operate and perform maintenance, Manpower requirements obviously play a large part in the profitability of a plant. Therefore, it follows that using a 10 Ft. in place of multiple 7 Ft. units should be more profitable from the standpoint of manpower. We should, however, clarify one point regarding normal maintenance of the 10 Ft. crusher which is commonly misunderstood; namely, the periodic changeout of manganese liners in the crusher. The normal time period between manganese changes would not be significantly different between the 7 Ft. and a 10 Ft. because the wear rate, that is, the pounds of liner worn away per ton of ore crushed, will remain the same. Consequently, if a set of liners in a 7 Ft. crusher, lasted six weeks, a 10 Ft. crusher in the same operation would also last approximately six weeks. However, since the total amount of ore crushed will be greater, the maintenance costs per liner changeout will be less on the 10 Ft. crusher.

Another point for consideration is that the 10 Ft., cone crusher is a secondary crusher and normally would be fed with the product of a gyratory crusher. Since the 10 Ft. can accept a larger feed than a 7 Ft. crusher, it is possible to increase the open side setting of a gyratory crusher, thereby, allowing a greater volume of feed to pass through the crusher. Because of this, it is conceivable that a smaller primary crusher could be used in order to obtain a given quantity of ore.

A good salesman could expound on a multitude of ideas for using 10 Ft. crushers in place of 7 Ft. crushers in a new plant, but in the final analysis, the deciding factor as to whether or not the 10 Ft. crushers should be used will be the anticipated over-all plant capacity. Several studies have indicated that as a general rule of thumb the break even point for using 10 Ft. crushers in place of 7 Ft. crushers is a plant which will have an overall ore treatment capacity of approximately 40,000 TPD or approximately 8,000,000 TPY. Anything less than that figure should indicate the use of conventional 7 Ft. crushers. Obviously a small four stage crushing plant in which the third stage crusher was a 7 Ft. Standard and the fourth stage consisted of two 7 Ft. SHORT HEAD cone crushers, would not improve economically by the use of one 10 Ft. Standard cone crusher and one 10 Ft. SHORT HEAD cone crusher in place of the 7 Ft. crushers.

A study was made which considered a plant to be built using three different approaches of a conventional crushing-grinding operation. The plant which was being considered would be crushing taconite similar to that found in the Iron Range. The end product of the crushing was 5/8 rod mill feed and in this example the plant capacity was to be approximately 13.5 million TPY of ore processed to eventually produce approximately 4 million TPY of iron ore pellets. The study arbitrarily chose a four-year period of operation so that operating costs would be included and also because a four-year period is the usual comparison basis for calculating return on investment. In this example the primary crusher as well as the fine crushing plant would be operated fourteen shifts per week.

In our economic analysis of the 10 Ft. crusher development program, we also studied how this crusher could be used to best advantage when planning expansion of an existing plant. Before delving into the actual dollars and cents of several variations of expansion plans, several preliminary questions must be answered in the affirmative:

Since each plant is unique, the relative merits of the 10 Ft. crusher must be examined on an individual plant basis. Again, as a general rule of thumb, it has been found that the most benefit can be achieved in those plants which presently contain a four-stage crushing plant in which the first two stages of crushing are gyratory crushers. Studies have shown that converting the second stage gyratory crusher to a 10 Ft. Standard crusher shows most potential because the major auxiliaries required for the crusher, such as crane, conveyors, etc., are already large enough to accommodate the increased capacity of the 10 Ft.

As one possible solution, we suggested that the two 30 x 70 secondary gyratory crushers be replaced by two 10 Ft. Standard cones. These crushers could then send approximately 3600 TPH of minus 3 material to the fine crushing plant. The two existing 7 Ft. Standard crushers could be converted easily to SHORT HEAD crushers and two new 7 Ft. SHORT HEAD crushers added to the existing vacant foundations.

In Summary, we feel that the Symons cone crusher has a very definite place in the future of the mining industry and we intend to move steadily ahead with its progress. However, we have learned a few lessons along the way.

Initially, the development of these super size machines is an extremely expensive proposition. We know that if our company alone, attempted to completely design, manufacture, erect, and test a machine in this size range, it would severely tax our financial resources.

We found that super size equipment also presents some problems for our manufacturing facilities. The manufacture of one of these units puts a large dent into the production schedule of many of the smaller conventional units. In our enthusiasm to build a bigger newer machine, we continually remind ourselves that the smaller conventional units are still our bread and butter units.

On the positive side, we found that our reputation as a crusher manufacturer was enhanced because of what our customers refer to as progressive thinking. We listened to the suggestions of the mining industry in attempting to give them what they wanted.

Perhaps you will allow me to close with a bit of philosophizing from a manufacturers point of view. The 10 Ft. crusher is here ready to go into operation. Where do we go from here? A 15 Ft. cone crusher? A 20 Ft. cone crusher? Who knows? We do know that we have reached the financial limit of a development program on a machine of this size. We also know that as the size of a machine grows larger, the developmental and manufacturing risks grow larger along with it and any allowable margin for error must be minimized. We, like you, are in business to make a profit. Since larger crushers usually mean a fewer number of crushers, we must examine the profit picture from aspects of the sale. I think I speak for other manufacturers as well when I say that bigness in machines reflects bigness in development costs as well. If the mining industry wants still larger equipment in the future, the industry should prepare itself to contribute to the development program of those machines.

A multi-cylinderHydraulic Cone Crusher, theHydrocone Cone Crushercan be used in either the second or third stage of crushing by merely changing liners and adaptors.It can produce the full product range that the combination of a comparable sized Standard and Short Head can produce. It makes the machine much more versatile. It allows for much more standardization. The value of this feature is one where spare parts investment in the form of major assemblies is minimized.

All operator controls are conveniently mounted on a remote control console to eliminate the need for an operator to approach the crusher during operation.Over a period of years we have developed a unique engineering knowledge about the effects of cone crusher design parameters such as speed, throw and cavity design on crusher productivity.

Each Hydrocone Cone Crusher features dual function hydraulic cylinders that provide overload protection and a safe and fast way to clear a jammed cavity. Should the crusher become plugged, the operator merely pushes levers on the remote control console to clear the cavity.

It can produce the full product range that the combination of a comparable sized Standard and Short Head can produce. It makes the machine much more versatile. It allows for much more standardization. The value of this feature is one where spare parts investment in the form of major assemblies is minimized.

All operator controls are conveniently mounted on a remote control console to eliminate the need for an operator to approach the crusher during operation.Over a period of years we have developed a unique engineering knowledge about the effects of cone crusher design parameters such as speed, throw and cavity design on crusher productivity.

Each Hydrocone Cone Crusher features dual function hydraulic cylinders that provide overload protection and a safe and fast way to clear a jammed cavity. Should the crusher become plugged, the operator merely pushes levers on the remote control console to clear the cavity.

TheHydraulic Cone Crusheruses hydraulic tramp release cylinders and accumulators to hold the adjustment ring against the main frame seat. There is only one angular surface between the main frame and the adjustment ring which also has a radial contact point in the lowermost area. When a piece of tramp goes through the crusher, the oil is forced into the accumulators allowing the adjustment ring to raise and pass the tramp.

The tramp release cylinders are secured to the adjustment ring and the lower portion of the main frame through clevises. This allows the crushing forces to be transferred directly from the frame arm locations to the adjustment ring. This relieves the main frame shell and upper flange from carrying heavy loads.

The Hydraulic Cone Crusher is equipped with hydraulic clearing. The tramp release cylinders which hold the adjustment ring in place are double acting cylinders. These cylinders can be pressurized in the opposite direction, after the clamping pressure has been released, to raise the adjustment ring and bowl assembly for clearing; only the weight of the adjustment ring, clamp ring, and bowl assembly, plus any residual material in the bowl hopper raises.

intelligent hst315 single cylinder cone crusher is blossoming in henan zhumadian basalt site

Material: Basalt Capacity: 450-500TPH Input Size: >750mm Mohs Hardness: 7 or above Output Size: 0-5, 5-12, 12-24, 24-31, 31-40mm Application: Mixing plant, road construction and high-speed rail construction Equipment: PE900 * 1200 jaw crusher, two sets of HST315 single cylinder hydraulic cone crusher, one ZSW420 * 110 vibrating feeders, five sets of 3Y2160 circular vibrating screen, one transfer bin, one dust removal system

The production line has run for less than 3 years. The equipment was purchased from other domestic manufacturers. Unfortunately, the equipment cannot meet the customers demand on capacity while the maintenance cost was quite high. Whats worse, within 3 years most of facilities were broken and must be replaced. In December, 2015, the customer bought from SBM 2 sets of HST315 single cylinder hydraulic cone crusher and a PE900*1200 Jaw Crusher. The cone crusher adopts advanced intelligent control method. After installation and commissioning, the production line has been put into use for 3 months. The aggregate produced was characterized by good granularity and quality, so when the aggregate was put on the market, it won favors and had a higher price. Therefore, the customer spoke highly of SBMs products and services.

Influenced by "The Belt and Road", "13th Five-Year" plan, China increases investment in infrastructure. "The Belt and Road" initiative involves more than 60 countries and total investment amounts to $6 trillion. China Railway Corporation plans to complete 800 billion yuan of investment in 2016. During "12th Five-Year", fixed assets investment on railway will achieve 3.58 trillion yuan while railway as long as 30.5 thousand kilometers will be put in operation, increasing by47.3% and 109% respectively compared with "11th Five-Year". Railway, highway and other infrastructure projects need a large number of aggregate, so high-quality sand aggregate production becomes a craze for many enterprises.

After many years of quarrying, the natural sand is reducing sharply so the quarrying cost is getting higher and higher. Because natural sand belongs to non-renewable resources, many areas start to make regulations to strictly prohibit the exploitation of natural river sand, in order to maintain the natural landscape, protect dyke dam and the ecological balance. Under the influence of policy and environmental factors, machine-made sand production is promoted for protecting ecological environment.

Basalt has the advantages of high compressive strength, low crushing value, strong corrosion resistance, good adhesion, etc. It has been recognized as the best material in the construction of highway, railway and airport runway in the world. Not only that, basalt is also widely used in lightweight concrete for high buildings because it is porous but hard. It can make concrete lighter with the admixture in concrete. Besides, it has advantages of sound insulation and heat insulation so it is popular at major building materials markets.

According to the requirements of customers, the finished materials have five kinds with different finenesses. Therefore, as for the configuration of production line, SBM engineers replaced coarse and fine crushing equipment with low capacity and efficiency and installed a multi-level screen which is equipped with PLC intelligent control and dust removal system, which ensures that the whole production line is highly efficient and environmental protection.

The production line includes PE900 * 1200 jaw crusher, two sets of HST315 single cylinder hydraulic cone crusher, one ZSW420 * 110 vibrating feeders, five sets of 3Y2160 circular vibrating screen, one transfer bin, one dust removal system and ten sets of belt conveyor.

20-750mm of basalt after separation is given into primary jaw crusher PE900 * 1200 by ZSW420*110 vibrating feeder where the basalt is crushed to 0-300mm of fine aggregate which is then transmitted to transfer bin through belt conveyor. Transfer bin is arranged below the hydraulic valve and small vibrating feeder. Passing the transfer bin, the material is then sent into two sets of HST315 single cylinder hydraulic cone crusher for secondary crushing. The broken material then enters the two sets of 3Y2160 circular vibrating screen which brings material above 40mm back to transfer bin which fine material is sieved out as finished product.

The main equipment is HST315 single cylinder hydraulic cone crusher. Apart from high efficiency, low cost and long service life, the intelligent electronic control system of the cone crusher is also a major highlight of the production line. Intelligent electronic control system can provide multiple control modes including manual control, constant feed control and constant power control mode. Users can continuously monitor actual internal load and the device can be adjusted automatically so as to optimize the utilization rate of crusher, which can make crusher play best performance at any time. Besides, intelligent electronic control system can automatically monitor and display various operating parameters to record real-time operation situation and give alarm if necessary. For example, when the lining board is too worn to be used continuously, it will automatically display and alarm in the control panel.

1. Central control system: It is designed for large crushing line or for customers having centralized control requirements. The whole system takes industrial computer as the core part. Through a variety of communication technologies, the PLC (programmable controller) is read and the status of equipment is collected. Then according to equipment status, computer furthermore sends commands to control the equipment on site, so as to realize the remote control, information record and analysis. The central control system can realize the automation, intelligence and concentration of the production line, which can meet the requirements of the customers and achieve the decentralized management, centralized control:

6). realize the monitoring visualization and individual start and stop, a key to start and stop, single control and interlock switch, automatic determination operation fault, automatic stop when in fault condition.

2. Remote monitoring and control system (IOT): This system allows all devices to be integrated into network. Wherever we are, customers will be able to view machine's availability and historical records as long as there is a device that has access to internet. The remote monitoring control system, what's more, can also provide instant warning service. Furthermore, when grinding mill is in trouble, we will promptly notify the relevant personnel and provide remote guidance service, conveniently and quickly.

This cooperation is a victory of SBM when competing with other manufacturers. The old basalt crushing line has run for 2-3 years. The customer used other manufacturer's equipment before. As a result, the capacity was unsatisfying and maintenance cost was quite high. Within 2 years the customer changed 3-4 sets of main equipment. Eventually, they chose SBM by purchasing a series of crushing equipment.

1. Company strength: SBM is a leading manufacturer of crushers and mills in the world. Our machines are widely used in mining and metallurgy, municipal engineering, high-speed railway, highway, bridges, ports, airports, water (nuclear) power plant around the world. In addition, SBMs excellent quality and perfect service are best-known all over the world.

2. Product quality: It is a key for SBM to win customers in the 30 years of development. As for this case, SBM provided HST single cylinder cone crusher for customers according to the hardness of basalt. Product quality was excellent and the final output was totally out of customer expectation.

3. Quick production: Due to the fact that the line was being in production, to avoid economic losses caused by production disruption, SBM made preparations in advance to make production as usual. The installation engineer worked overtime in 6 days on site and installed two units and solved other issues completely to let the production line keep normal production.

4. After-sale service: In the development of more than 30 years, the company's services have always had a good reputation. Under the premise of standardized service, SBM will continue to improve the service system to create a more experienced service team.

We used equipment produced by small domestic factory before. The poor quality made us crazy and we replaced the host device again within two years. Maintenance cost a lot. Then by accident we learned that SBM does well in mine crushing after the market investigation, so we bought two sets of HST single cylinder cone crusher and one jaw crusher. The whole process spent less than a month. SBM impressed me deeply by good quality and service efficiency. We will continue to cooperate with SBM later.

General layout of crushing line is as follows: (raw material bin) - feeder-jaw crusher-transit bin-cone crusherimpact crusher) - vibrating screen-storage bin. But the layout of actual production line is made in terms of scale, material property, input and output size, discharging method and other special requirements.

1. The scale of production line: The scale directly determines equipment selection, which further determines the investment of equipment. For example, as for 200t/h production line, HJ98 high-energy jaw crusher and HPT300 multi cylinder hydraulic cone crusher would be recommended; for 300t/h production line, it is better to configure PEW860 European jaw crusher, HST160 single cylinder hydraulic cone crusher and HPT300 multi-cylinder hydraulic cone crusher, etc.; for another 500t/h production line, It is a good choice to configure HJ125 high energy jaw crusher, HST250 single cylinder hydraulic cone crusher, HST315 single cylinder hydraulic cone crusher, etc.

2. Material features: The selection of equipment is decided by hardness of materials. Very often, processing of hard materials like granite, basalt, pebble can adopt cone crusher while soft materials like limestone and dolomite can use impact crusher for middle crushing.

5. Special requirements: It is necessary to make different configurations according to actual crushing needs such as installation of de-ironing separator if there is iron briquette in the raw materials; installation of the dust remover if there is a strict requirement on environment; installation of sand-washer if there is a need for sand purity and installation of electric generator if there is no electricity supply.

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Crushers are the main component of an aggregate production plant/operation. They reduce the size, or change the form, of various raw materials so they can be more easily differentiated by size and material type.

Power Equipment Company has the largest aggregate equipment product availability in the Rocky Mountain region. All of our aggregate equipment is available to buy, rent, or rent-to-purchase.With over 30 years of aggregate industry experience, no other dealership can match the solutions that we deliver to your operation.

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