Laboratory Crushers are available with four sizes of jaw openings and various capacities to suit the needs of batch laboratories and all continuous laboratory test plants and pilot test plants. Various construction features on the three types of Laboratory Jaw Crushers ensure their ruggedness and durability for constant usage over long periods of time. All units have main frame cast in one piece and reversible jaw plates cast of manganese steel. The smaller size crushers are furnished for belt drive or motor drive and with either of these drives provision is made for hand operation if desired. The larger units are available for power drive only with belt or motor. Let us makerecommendations for type and size crusher for your batchlaboratory or continuous or pilottest plant.
The (Type I) Laboratory Forced Feed Jaw Crusher is furnished in two sizes. The 5x 6 size is excellent for crushing in ore testing laboratories and continuous test plants. The 2x 3 size is ideal for assay or batch testing laboratories for such uses as sample crushing.
This crusher is the high capacity, forced feed type with a one piece cast alloy iron frame.The eccentric bumper is special nickel cast iron and mounted on two tapered roller bearings which are sealed to exclude dirt. The eccentric shaft is machined from chrome nickel. The bearings are equipped with alloy bronze cast insets. All bearings are fitted with Klean seal fittings. Jaw plates and cheek plates are reversible and are of manganese steel. The safety toggles on these units may be either long or short, the length depending on the size product desired. Both sizes of crushers are available for motor drive using V-V or flat belt drive and the 2x 3 size may be furnished for hand or belt drive. Cast steel frames can be supplied.
The 2X 3 (Type I) Laboratory Forced Feed Jaw Crusher is available incorporated into a crusher-pulverizer unit on a common base with a single driving motor. The pulverizer unit is the McCool Laboratory Pulverizer which is of the disk type, designed for grinding virtually any material, and for pulverizing to any mesh in one operation. This crusher-pulverizer unit is compact, efficient, and portable and ideal for use in laboratories.
The (Type II) Laboratory Forced Feed Jaw Crusher is available in only one size, 5x 6. This crusher issimilar to the Type I crusher but with frame and bumper made of cast steel. This construction adds considerable strength to the shock resisting parts of the crusher. The bearings are all of special design; they are bronze and will stand continuous service, such as continuous test and pilot test plants require, without danger of failure. The jaw and cheek plates are manganese steel and are completely reversible, thus adding to their wearing life. The jaw opening is controlled by the position of an adjustable wedge block. The crusher is usually driven by V-V but can be arranged for V-flat and flat belt drive.
The 3x 2 (No. 1) Laboratory Jaw Crusher will reduce hard rock from 2 inch to inch and finer at a rate of from 50 to 150 pounds per hour. This unit can be quickly and thoroughly cleaned as a safeguard against salting succeeding crushing, and provides an excellent means of reducing small quantities of ore samples quickly and efficiently, using either hand or power drive. Power driven unit is equipped with two V-belts.
The frame of this crusher is a one piece casting, fixed jaw plates are manganese steel, and movable jaw is alloy steel. Jaw plates are bolted so they may be reversed, thusdoubling their operating life, and the movable jaw is pivotedto give a forward and downward motion, greatly increasing capacity on wet, sticky ores. Toggle pin has been eliminated by a new design pitman-toggle movement. Any wear that occurs in the toggle assembly is taken up by a large coil spring. Fineness of the crushed product is controlled byreplaceable shims. Lubrication is by grease cups as standardbut Alemite fittings may be supplied.
The 4X 3 (No. 2) Laboratory Jaw Crusher is similar to the No. 1 unit but is larger and provides greatercapacity with increased strength for heavier work. Thisunit is available for power drive only and for belt drive is equipped with tight and loose pulley in addition to a heavy balance wheel. This larger unit will crush approximately 360 pounds of quartz per hour to 4 mesh. Frame is cast with heavy lugs in back for mounting electric motor. New motor support on individual motor driven units is designed to use part of the weight of the motor to maintain uniform tension on the V-belts. Three V-belts are provided on this unit for motor drive.
CRUSHER, Ore, Braun, SimplexA cast iron crusher of rigid construction.Among its important features are the ease with which it may be opened for cleaning, and thesimplicity of adjustment.One blow of a hammer loosens the wedge holding the non-vibrating jaw in place, allowing this jawto be lifted out, thereby giving sufficient access for cleaning.
The fineness of the product obtained is regulated by increasing or decreasing the size of thedischarge or lower opening of the jaws; this can be accomplished by a few turns of two regulatingscrews, which have hand wheels, obviating the necessity for use of wrench or other tools. The BraunSimplex crusher is made in one style only, for both hand and power operation. The flywheel has a handleattached for hand operation. The power pulley is 16 inches in diameter, with a 2inch face, andrequires H.P. The jaw is 63 inches, and the opening is 23 inches.
Practically of all steel construction, the frame plates being made ofsteel and all other essential parts subjected to strain being similarly made of steel. The ChipmunkCrusher has a jaw movement that insures a large capacity and impels the discharge, making itadaptable for crushing both hard and soft materials.
The vibratory jaw is mounted upon an eccentric at its upper end and rests against a toggle at its lower end.The eccentric imparts a circular or gyratory movement to the upper end, while the toggle compels the lower end to describe anarc of a small circle. This movement is both forward and downward and impels the discharge.
An adjusting screw passes through the front spacer casting and fits into the recess in the adjusting block.This block engages with a service block, which presses against the stationary jaw. This device allows close adjustment, isstrongly constructed and easily manipulated.
The Chipmunk Jaw Crushers have the greatest capacity (size of jaws considered) of any crushing device. The type VC can beoperated by either hand or power. It will reduce rock from about 214 inches down to 14 inch and smaller at a rate of 400pounds per hour. The type WC is intended for power operation, and will crush rock at a rate of 1500 pounds per hour.
The equipment illustrated above includes the Braun Chipmunk Crusher and the Braun Type UA Pulverizer, bothdirectly connected with V Belt drive to a single ball bearing enclosed type electric motor mounted on a special slidingbase with adjustments for belt tightening.The bench top is three feet deep and four feet long:
In the (Cone and Ring Typeand buck types) Laboratory Crusher the crushing of quartz from inch or inch to 20 mesh can be accomplished at the rate of 4 pounds per minute. For many years it has been standard equipment in samplers, mills and large mines where continuous or intermittent dry grinding is done.
The ore is ground between a revolving cone and a bell-shaped hopper, leaving the machine through double discharge openings. Size of product is controlled by a conveniently located handwheel. Drive is by a gear and pinion, supplied with tight and loose 18x 6 pulleys for flat belt drive, to operate about 150 R.P.M. on drive shaft. Grooved tight pulley and V-belt drive with 5 H.P. motor is also available.
(Type C) Laboratory Crushing Rolls are usually used as a secondary crusher, handling products from jaw crushers or gyratory mills and for making products for pulverizers. For certain special applications they are used as a continuous grinding unit.
The main frame and stationary roll journal boxes arecast as one piece, thereby assuring rigidity and greatest possible strength to withstand severe shocks. The roll spacing may be changed quickly and easily while rolls are in operation by means of a handwheel to control product size. Heavy compression springs protect the shells and bearings from excessive loads and shocks.
The roll shells are constructed of forged steel, and for rolls smaller than 12 diameter the rolls and shafts are constructed as a replaceable unit. In the 12 diameter size,replaceable roll shells are provided. Roll faces are groundsmooth and true for efficient fine grinding.
Various drives are available. The unit drive, with one motor and one set of double V-belts mounted with crushing rolls on a common base of welded steel, is ideal for normal laboratory crushing operations.
The (Type M) Laboratory Crushing Rolls embody the latest improvements and are constructed as a self-contained unit with proper provisions for adjustment and lubrication, and are completely housed and protected from dust.
The main frame is cast in one piece and of the best grade of gray iron. The stationary roll journal box is cast in the frame and movable roll is mounted on a sliding saddle of especially heavy design which slides on a machined surface. All bearings are outside of the housing. The shaftis of forged steel of sufficient diameter to withstand severe strainsand shocks without deflection.
All roll shells are made of heavy selected rolled steel to provide highest wearing qualities. Roll shells are bored to a straight taper corresponding to the taper of the cast iron hub and are held in place by shrinkage and reinforced by heavy lug bolts. The roll hub is securely keyed to the shaft by a full hub length key.
The movable roll is held in position by two double helical springs which are housed in main frame casting. The springs are held at any desired tension by lock nuts and the machine may be dismantled without changing adjustment of the springs.
Various drives are available. The unit drive with one motor and one set of double V-belts mounted with crushing rolls on a common base of welded steel is ideal for normal laboratory crushing operation.Let us make recommendations for your laboratory unit.
January 25, 2019, the Vale iron mine in Brazil experienced a dam break, which led to the closure of large-scale mines. At the same time, the two major mines in Australia, BHP and Rio Tinto, were affected by the hurricane to reduce their shipments.
Since the end of January this year, iron ore prices have risen sharply, far exceeding the increase in steel and other raw materials. Therefore, iron ore has become the most popular investment in the eyes of investors. In July 2019, the price of iron ore reached more than US$120 per ton.
For the time being, the investment prospect of iron ore is very bright. So what is the global reserves and distribution of iron ore? How much does it cost to build an iron ore processing line? This article will answer you in detail.
The data released by USGS in early 2005 showed that the global iron ore reserves were 160 billion tons, the reserves of mineral iron (ie, iron contained in iron ore) were 80 billion tons and the basic reserves were 180 billion tons.
The worlds iron ore is mainly reserved in Ukraine, Russia, Brazil, China and Australia. The reserves are 30 billion tons, 25 billion tons, 21 billion tons, 21 billion tons and 18 billion tons respectively, accounting for 18.8%, 15.6%, 13.1%, 13.1% and 11.3% of the worlds total reserves respectively.
In addition, Kazakhstan, the United States, India, Venezuela and Sweden also have rich iron ore resources, and their iron ore reserves are 8.3 billion tons, 6.9 billion tons, 6.6 billion tons, 4 billion tons and 3.5 billion tons, respectively accounting for 5.2%, 4.3%, 4.1%, 2.5% and 2.2% of the worlds total iron ore reserves.
The worlds mineral iron is mainly reserved in Brazil, Russia and Australia, with reserves of 14 billion tons, 14 billion tons and 11 billion tons respectively, accounting for 17.5%, 17.5% and 13.8% of the worlds total reserves. The sum of the reserves in the three countries accounts for 48.8% of the total reserves in the world.
Mineral iron reserves and basic reserves are the most representative of the richness of a countrys iron ore resources, so Brazil, Russia and Australia are the worlds richest iron ore resources. At the same time, it shows that although Ukraine and China have large reserves of iron ore, they have more lean ore and less rich ore.
Iron ore resources are mainly reserved in more than10 countries, and 90% of proven reserves are distributed in10 countries and regions. They are: CIS (proven reserves of 114 billion tons, of which Russia is more than 80 billion tons), Brazil (68 billion tons), China (50 billion tons), Canada (over 36 billion tons), Australia (35 billion tons) ), India (17.57 billion tons), the United States (17.4 billion tons), France (7 billion tons), Sweden (3.65 billion tons).
The global iron mine reserves increased from 232 billion tons in 1996 to 370 billion tons in 2006, an increase of 59.5% in 10 years. The total amount of iron ore resources in the world is estimated to exceed 800 billion tons (the amount of iron ore), and the iron content exceeds 230 billion tons and there is still great potential for future discovery.
The major countries of iron ore resources include Brazil, Australia, China, Russia, Kazakhstan, Ukraine, the United States, India, Sweden, and Venezuela. High-grade ore is widely distributed in Brazil, Australia, India and other countries. The low mining cost and relatively high grade of iron ore make these countries the major iron ore suppliers in the world.
Before dry selection, the lean iron ore requires millimeter-scale fine crushing by the fine crusher. If the particle size of the iron ore is not small enough in the crushing stage, low-grade iron ore is difficult to be selected later, which will cause serious waste of resources.
The common problem in the iron ore crushing production line is that the wear parts of the fine crusher are seriously worn out, and the repair and maintenance of the fine crusher are too frequent, which makes the production efficiency of the iron ore crushing production line lower.
Different iron ore has different features. According to these features, the crushers are made of different materials. Therefore, the prices of iron ore crusher are different. However, reasonable crushing processes and crusher can be used to save the cost investment and achieve the required crushing effect.
In the crushing process of lean iron ore, in order to obtain the best process configuration and the lowest crushing cost, it is necessary to master the relationship of particle size among the primary crushing, the secondary crushing and the fine crushing.
For medium and low hardness lean iron ore, the second crushing equipment can use the impact crusher. The iron ore impact crusher utilizes a plate hammer on a high-speed moving rotor to produce a high-speed impact on the iron ore fed into the crushing chamber. The crushed iron ore is thrown at a high speed in the tangential direction toward the counter-attack at the other end of the crushing chamber.
During this process, the iron ore will collide with each other, causing cracks and looseness. When the iron ore particle size is smaller than the gap between the counterattack plate and the plate hammer, it is discharged outside the machine.
For high-hardness iron ore, a cone crusher can be used for the secondary crushing equipment. The HXJQ short-headed cone crusher can achieve a fine crushing effect of 3 to 13mm, which can fully meet the requirements of dry selection and grinding. However, due to the high hardness of such iron ore, the impact on the wear parts is large, so ordinary crushing equipment is difficult to exert its advantage.
In areas with low power consumption, the sand making machine developed and produced by HXJQ can achieve the fine crushing effect of high hardness and high output iron ore. Not only can the iron ore particle size be reduced to improve the dry selection efficiency, but also the ball mill load and operating cost can be greatly reduced, and the ball mill production capacity can be improved.
The price of iron ore crushing production line is related to various factors such as equipment combination, output level, and quality. Of course, the quotation standards of different manufacturers will also be different. Customers also need to analyze specifically when purchasing.
The comparison found that the price of the iron ore crushing production line of HXJQ Machinery is the most economical and reasonable, ensuring that the production line has a long service life, less failure, high efficiency, good effect, energy-saving and environmental protection, and can keep its price lower than other manufacturers 6% to 7%.
At the same time, the HXJQ configuration plan is all-sided, and there is a wide variety of equipment in HXJQ Machinery. If you are interested in these crushing equipment, please submit your relevant information on the right side, we will arrange a professional engineer to answer your questions.
The crusher capacities given by manufacturers are typically in tons of 2,000 lbs. and are based on crushing limestone weighing loose about 2,700 lbs. per yard3 and having a specific gravity of 2.6. Wet, sticky and extremely hard or tough feeds will tend to reduce crusher capacities.
Selectiingwhat size a crusher needs to be is based on factors such as the F80 size of the rocks to be crushed, the production rate, and the P80 desired product output size. Primary crushers with crush run-of-mine rock from blast product size to what can be carried by the discharge conveyor or fit/math the downstream process.A typical example of primary crushing is reducing top-size from 900 to 200 mm.
Ultimately, the mining sequence will certainly impact the primary crusher selection. Where you will mine ore and where from, is a deciding factor not so much for picking between a jaw or gyratory crusher but its mobility level.
The mom and dad of primary crushers are jaw and gyratory crushers. In open-pit mines where high tonnage is required, thegyratory crushers are typically the choice as jaw crushers will not crush over 500 TPH with great ease. There are exceptions like MPI Mineral Park in AZ where 50,000 TPD was processed via 2 early century vintage jaw crushers of a:
The rated capacity at 5 closed-side setting was 490 stph based on standard 100lbs/ft3 feed material. These crushers were fed a very fine ore over a 4 grizzly which allowed the 1000 TPH the SAG mills needed.
In under-ground crushing plants where the diameter of the mine-shaft a skip forces limits on rock size, a jaw crusher will be the machine of choice. Again, if crushing on surface, both styles of stone crushing machines should be evaluated.
Well over two billion tonnes of iron ore is mined every year, often involving multiple handling stages, beneficiation, stockpiling, blending, and shipping over vast distances. How can you be certain of the value of your ore during all these processes?
You need to ensure that the samples extracted and prepared along the entire value chain are representative so that meaningful decisions can be made based on their analyses. If you get this wrong, you face the potential of losing millions of dollars in terms of:
You need analytical results that you can trust. However, with increasing demands for higher sample capacity, mass and quality, it is clear that manual sample preparation and analysis laboratory operations are falling behind, often due to the inability to rely on workers to provide a continuous, repeatable and unaffected process.
Recognising these challenges, we offer a range of automated solutions and equipment, designed to establish a standard that you can rely on. Our proven handling, sample preparation and analytical equipment, integrated with state-of-the-art software packages, is globally recognised as the most efficient solution for automating iron ore mine and port laboratories.
These systems are designed to run 24/7 for 365 days a year, immediately increasing sample capacity and improving turnaround times. Workplace ergonomics are also improved, as operators are not exposed to hazards, and the dependence on labour availability often in remote locations is reduced.
Automating these processes also delivers greater consistency, traceability and reproducibility, resulting in enhanced quality that you can trust.Our equipment can automate a range of common functions, including:
Using our automated solutions, you will see long-term benefits, placing you in an improved competitive position within the industry. This is due to reduced variability, decreased bias, full traceability, increased mine life, and greater reliability of supply.
Confidence in the value of your product from the mine to market is critical to your operations success. High quality and proven automated sampling, preparation and analysis provide that assurance.
By automating your preparation and analysis processes, productivity at your laboratory will increase, as heavy samples are not manually handled, and higher volumes can be processed in shorter turnaround times. Your operations are not exposed to fluctuating labour availability and are designed to be operated 24/7/365. The entire integrated system is programmed to minimise any delays between processes ensuring all equipment is operating at peak availability. Also, your automated laboratory requires fewer operators to function more efficiently. Integrate the laboratory to your plant control to achieve true closed-loop control of your process.
Automation can create concern for operators, such as what the impact would be for their jobs. Automating preparation and analysis processes removes the operators from the hazards of manual handling, noise, dust, heat, fumes and repetitive tasks. Even though automation has reduced many of these traditional lab roles, it has also created new ones, which we provide the training for, to ensure your staff develop the skills to manage this new technology.
For years, we have been providing iron ore laboratories with state-of-the-art semi and fully automated technologies. We often challenge conventional sample processing techniques, and we work with like-minded iron ore producers to engineer ground-breaking innovative solutions.
Based at Saldanha Port, this iron ore laboratory is a fully automated facility, capable of sample preparation and analysis without interference. Because of this, the laboratory functions 24/7, 365 days a year.
It is the worlds first sampling and analytical laboratory at an iron-ore loading port which uses the principle of the laboratory straddling the ship-loading conveyors. Due to limitations with usable land around the ship-loading area, this economical solution was formed, which has proven to be a great success.
This laboratory located in Sishen, South Africa is a fully-automated sample preparation and analytical facility. It uses robotics to receive 2 kg samples and automatically prepares and analyses these samples, reporting the results directly to the plant. This means that it requires very little input from personnel, making the process quicker and more efficient.
It consists of two automated mills, sample press, fully automated fusion apparatus, magazine rack for approximately 120 sample bottles, an automated sampleweighing and splitting station, an industrial robot, two XRF spectrometers, and software to control and monitor the process.
Located in Northern Cape, South Africa, this world-class laboratory is semi-automated, as manual intervention is required to place the samples into the processing system. However, from there, all aspects of processing and analysis are automated.
The facility includes all automated sample preparation processes, including crushing, splitting, milling, production of pressed pellets for XRF analysis, automated density measurement, and preparation of aliquots for wet chemical analysis.
Located at Mt. Webber, Australia, this fully automated sample preparation and analysis facility has been designed to utilise robotics. Because of automation, this laboratory has been able to boost its initial processing capacity of 800 samples per day to 1000 samples per day, with no human errors or intervention.
The automated system processes a mix of geochemical mining and pit control samples, metallurgical control samples and a dedicated line-to-process near mine geochemical exploration samples, which is unique to this facility.
This turnkey project located in Newman, Western Australia consists of an automated robotic sample preparation facility, which became the largest in the world. Its automated functions included drying, ISO moisture analysis, crushing, splitting, pulverising and dosing into vials.
The end-to-end automated facility receives samples up to 15 kg from the plant, which are registered and manually entered into one of the two automated sample preparation lines. The samples are then automatically dried and weighed to determine the moisture content.
This fully automated sample preparation and analysis facility was designed and supplied by FLSmidth on a turnkey basis. It is used to process mine pit and plant samples, with up to 15 kg of dry samples being entered into the automated system.
Having the automated laboratory based on the Cloud Break mine site provides FMG with the advantage of efficient turnaround times on chemical analysis. Also, access to accurate data onsite enables FMGs management to make informed decisions on sample grade, ensuring that the highest quality products are economically produced.
magazine, three automated weighing stations, six induction heating systems, an automated platinum cleaning station and an XRF interface. The system is capable of weighing, fusing and analysing close to 1000 samples per day.
FLSmidth provides sustainable productivity to the global mining and cement industries. We deliver market-leading engineering, equipment and service solutions that enable our customers to improve performance, drive down costs and reduce environmental impact. Our operations span the globe and we are close to 10,200 employees, present in more than 60 countries. In 2020, FLSmidth generated revenue of DKK 16.4 billion. MissionZero is our sustainability ambition towards zero emissions in mining and cement by 2030.