portable rock crusher for sale 100tph

what's the difference between sag mill and ball mill - jxsc machine

A mill is a grinder used to grind and blend solid or hard materials into smaller pieces by means of shear, impact and compression methods. Grinding mill machine is an essential part of many industrial processes, there are mainly five types of mills to cover more than 90% materials size-reduction applications.

Do you the difference between the ball mill, rod mills, SAG mill, tube mill, pebble mill? In the previous article, I made a comparison of ball mill and rod mill. Today, we will learn about the difference between SAG mill vs ball mill.

AG/SAG is short for autogenous mill and semi-autogenous mill, it combines with two functions of crushing and grinding, uses the ground material itself as the grinding media, through the mutual impact and grinding action to gradually reduce the material size. SAG mill is usually used to grind large pieces into small pieces, especially for the pre-processing of grinding circuits, thus also known as primary stage grinding machine. Based on the high throughput and coarse grind, AG mills produce coarse grinds often classify mill discharge with screens and trommel. SAG mills grinding media includes some large and hard rocks, filled rate of 9% 20%. SAG mill grind ores through impact, attrition, abrasion forces. In practice, for a given ore and equal processing conditions, the AG milling has a finer grind than SAG mills.

The working principle of the self-grinding machine is basically the same as the ball mill, the biggest difference is that the sag grinding machine uses the crushed material inside the cylinder as the grinding medium, the material constantly impacts and grinding to gradually pulverize. Sometimes, in order to improve the processing capacity of the mill, a small amount of steel balls be added appropriately, usually occupying 2-3% of the volume of the mill (that is semi-autogenous grinding).

High capacity Ability to grind multiple types of ore in various circuit configurations, reduces the complexity of maintenance and coordination. Compared with the traditional tumbling mill, the autogenous mill reduces the consumption of lining plates and grinding media, thus have a lower operation cost. The self-grinding machine can grind the material to 0.074mm in one time, and its content accounts for 20% ~ 50% of the total amount of the product. Grinding ratio can reach 4000 ~ 5000, more than ten times higher than ball, rod mill.

Ball mills are fine grinders, have horizontal ball mill and vertical ball mill, their cylinders are partially filled with steel balls, manganese balls, or ceramic balls. The material is ground to the required fineness by rotating the cylinder causing friction and impact. The internal machinery of the ball mill grinds the material into powder and continues to rotate if extremely high precision and precision is required.

The ball mill can be applied in the cement production plants, mineral processing plants and where the fine grinding of raw material is required. From the volume, the ball mill divide into industrial ball mill and laboratory use the small ball mill, sample grinding test. In addition, these mills also play an important role in cold welding, alloy production, and thermal power plant power production.

The biggest characteristic of the sag mill is that the crushing ratio is large. The particle size of the materials to be ground is 300 ~ 400mm, sometimes even larger, and the minimum particle size of the materials to be discharged can reach 0.1 mm. The calculation shows that the crushing ratio can reach 3000 ~ 4000, while the ball mills crushing ratio is smaller. The feed size is usually between 20-30mm and the product size is 0-3mm.

Both the autogenous grinding mill and the ball mill feed parts are welded with groove and embedded inner wear-resistant lining plate. As the sag mill does not contain grinding medium, the abrasion and impact on the equipment are relatively small.

The feed of the ball mill contains grinding balls. In order to effectively reduce the direct impact of materials on the ball mill feed bushing and improve the service life of the ball mill feed bushing, the feeding point of the groove in the feeding part of the ball mill must be as close to the side of the mill barrel as possible. And because the ball mill feed grain size is larger, ball mill feeding groove must have a larger slope and height, so that feed smooth.

Since the power of the autogenous tumbling mill is relatively small, it is appropriate to choose dynamic and static pressure bearing. The ball bearing liner is made of lead-based bearing alloy, and the back of the bearing is formed with a waist drum to form a contact centering structure, with the advantages of flexible movement. The bearing housing is lubricated by high pressure during start-up and stop-up, and the oil film is formed by static pressure. The journal is lifted up to prevent dry friction on the sliding surface, and the starting energy moment is reduced. The bearing lining is provided with a snake-shaped cooling water pipe, which can supply cooling water when necessary to reduce the temperature of the bearing bush. The cooling water pipe is made of red copper which has certain corrosion resistance.

Ball mill power is relatively large, the appropriate choice of hydrostatic sliding bearing. The main bearing bush is lined with babbitt alloy bush, each bush has two high-pressure oil chambers, high-pressure oil has been supplied to the oil chamber before and during the operation of the mill, the high-pressure oil enters the oil chamber through the shunting motor, and the static pressure oil film is compensated automatically to ensure the same oil film thickness To provide a continuous static pressure oil film for mill operation, to ensure that the journal and the bearing Bush are completely out of contact, thus greatly reducing the mill start-up load, and can reduce the impact on the mill transmission part, but also can avoid the abrasion of the bearing Bush, the service life of the bearing Bush is prolonged. The pressure indication of the high pressure oil circuit can be used to reflect the load of the mill indirectly. When the mill stops running, the high pressure oil will float the Journal, and the Journal will stop gradually in the bush, so that the Bush will not be abraded. Each main bearing is equipped with two temperature probe, dynamic monitoring of the bearing Bush temperature, when the temperature is greater than the specified temperature value, it can automatically alarm and stop grinding. In order to compensate for the change of the mill length due to temperature, there is a gap between the hollow journal at the feeding end and the bearing Bush width, which allows the journal to move axially on the bearing Bush. The two ends of the main bearing are sealed in an annular way and filled with grease through the lubricating oil pipe to prevent the leakage of the lubricating oil and the entry of dust.

The end cover of the autogenous mill is made of steel plate and welded into one body; the structure is simple, but the rigidity and strength are low; the liner of the autogenous mill is made of high manganese steel.

The end cover and the hollow shaft can be made into an integral or split type according to the actual situation of the project. No matter the integral or split type structure, the end cover and the hollow shaft are all made of Casting After rough machining, the key parts are detected by ultrasonic, and after finishing, the surface is detected by magnetic particle. The surface of the hollow shaft journal is Polished after machining. The end cover and the cylinder body are all connected by high-strength bolts. Strict process measures to control the machining accuracy of the joint surface stop, to ensure reliable connection and the concentricity of the two end journal after final assembly. According to the actual situation of the project, the cylinder can be made as a whole or divided, with a flanged connection and stop positioning. All welds are penetration welds, and all welds are inspected by ultrasonic nondestructive testing After welding, the whole Shell is returned to the furnace for tempering stress relief treatment, and after heat treatment, the shell surface is shot-peened. The lining plate of the ball mill is usually made of alloy material.

The transmission part comprises a gear and a gear, a gear housing, a gear housing and an accessory thereof. The big gear of the transmission part of the self-grinding machine fits on the hollow shaft of the discharge material, which is smaller in size, but the seal of the gear cover is not good, and the ore slurry easily enters the hollow shaft of the discharge material, causing the hollow shaft to wear.

The big gear of the ball mill fits on the mill shell, the size is bigger, the big gear is divided into half structure, the radial and axial run-out of the big gear are controlled within the national standard, the aging treatment is up to the standard, and the stress and deformation after processing are prevented. The big gear seal adopts the radial seal and the reinforced big gear shield. It is welded and manufactured in the workshop. The geometric size is controlled, the deformation is prevented and the sealing effect is ensured. The small gear transmission device adopts the cast iron base, the bearing base and the bearing cap are processed at the same time to reduce the vibration in operation. Large and small gear lubrication: The use of spray lubrication device timing quantitative forced spray lubrication, automatic control, no manual operation. The gear cover is welded by profile steel and high-quality steel plate. In order to enhance the stiffness of the gear cover, the finite element analysis is carried out, and the supporting structure is added in the weak part according to the analysis results.

The self-mill adopts the self-return device to realize the discharge of the mill. The self-returning device is located in the revolving part of the mill, and the material forms a self-circulation in the revolving part of the mill through the self-returning device, discharging the qualified material from the mill, leading the unqualified material back into the revolving part to participate in the grinding operation.

The ball mill adopts a discharge screen similar to the ball mill, and the function of blocking the internal medium of the overflow ball mill is accomplished inside the rotary part of the ball mill. The discharge screen is only responsible for forcing out a small amount of the medium that overflows into the discharge screen through the internal welding reverse spiral, to achieve forced discharge mill.

The slow drive consists of a brake motor, a coupling, a planetary reducer and a claw-type clutch. The device is connected to a pinion shaft and is used for mill maintenance and replacement of liners. In addition, after the mill is shut down for a long time, the slow-speed transmission device before starting the main motor can eliminate the eccentric load of the steel ball, loosen the consolidation of the steel ball and materials, ensure safe start, avoid overloading of the air clutch, and play a protective role. The slow-speed transmission device can realize the point-to-point reverse in the electronic control design. When connecting the main motor drive, the claw-type Clutch automatically disengages, the maintenance personnel should pay attention to the safety.

The slow drive device of the ball mill is provided with a rack and pinion structure, and the operating handle is moved to the side away from the cylinder body The utility model not only reduces the labor intensity but also ensures the safety of the operators.

portable rock crusher / aggregate crushing plant for sale - new & used crushers | at

Used 2000 TRIO 3242 Portable Jaw Crushing Plant, SN: C0000265701, mounted on three axle carrier with fifth wheel, air brakes, running lights, with a TRIO 40" X 16' Vibrating Grizzly Feeder with a 25 HP electric motor drive, a TRIO 3242 Jaw Crusher with a 200 HP electric motor drive, a 36" X 30' product discharge conveyor with a 15 HP electric motor, we have all electrical switching equipment located with plant, F.O.B. South Carolina, $POR, Electrical compontants add $POR ...

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mobile rock crusher for quarrying & mining - jxsc machine

Feeding size: <800mm Capacity: 100-300T/H Types of mobile crusher: wheel type mobile crusher and crawler type mobile crusher Main equipment: a highly customizable combination of feeder, rock crusher, vibrating screen, conveyor, etc. Applications: aggregate, quarrying, mining, construction waste recycling, etc.

A complete mobile breaking production line is classically equipped with mobile jaw crusher and mobile impact crusher to achieve coarse and fine crushing operations such as stone and construction waste. It took only a few days to set up the entire production line without pile driving, which was nearly thirty days faster than the fixed crushing production line.

The mobile crusher is mainly used for metallurgy, chemical industry, building materials, highways, railways, and other materials that often need to be moved and processed, such as construction waste, river pebbles, granite, basalt, limestone, quartz stone and other materials. Customers can produce materials according to the processing scale. , Product quality and other requirements, select the most suitable configuration. How to recycle construction waste with a mobile crusher? A complete set of construction waste disposal production line is composed of mobile jaw crusher, impact crusher, vibrating screen, sand washing machine, etc., which can sort and crush construction waste and obtain a variety of high-quality sand and gravel aggregates with different specifications, widely used in roads, buildings and other fields to achieve recycling of construction waste.

Mobile crusher equipment is divided into two categories: tire type and crawler type according to the bearing method. In addition, each different type of crusher can also be freely assembled according to customer needs, mainly including jaw tire mobile crushing station, impact tire mobile crushing station, cone tire mobile crusher, impact tire mobile crushing station, heavy hammer type The combination of tire mobile crushing station and crawler mobile crushing station is simple and convenient. It can effectively realize the integration of the unit and the diversity of configuration. The scope of application is more extensive and flexible. 1. The mobile crusher can be moved to the operation site to start the operation quickly, saving the construction planning time. 2. The compact structure reduces the area occupied, and is especially suitable for the small crushing site. 3. The modularized and automated operation design of the mobile crusher reduces labor costs. 4. The intelligent PLC automatic monitoring system can predict the failure of machine equipment, effectively avoiding the occurrence of major accidents.

100tph capacity stone crusher production plant complete rock stone crushing line - mining & construction solutions from henan dewo machinery

Dewo machinery can provides complete set of crushing and screening line, including Hydraulic Cone Crusher, Jaw Crusher, Impact Crusher, Vertical Shaft Impact Crusher (Sand Making Machine), fixed and movable rock crushing line, but also provides turnkey project for cement production line, ore beneficiation production line and drying production line. Dewo Machinery can provide high quality products, as well as customized optimized technical proposal and one station after- sales service.

SMC750 mobile crushing plant and SMC1010PFS mobile crushing plant are scientific integration of 100 ton per hour mobile crushing and screening plant. After serveral days install and debug on site, this complete mobile stone crusher plant is running suceessfully. Clients are so happy with the machine working status and final products size.

China 100tph Coral Portable Crusher Complete Stone Crushing Plant, Find details about China Portable Crushing Plant, Portable Stone Crusher Plant from 100tph Coral Portable Crusher Complete Stone Crushing Plant - Shanghai DingBo Heavy Industry Machinery Co., Ltd.

The Stone Crushing Plant mainly consists of Vibrating Feeder, Jaw Crusher, Cone Crusher or Impact Crusher, Vibrating Screen, Belt Conveyors and Control System, etc. It is capable to crush and screen limestone, marble, granite, basalt, river stone and so on to produce sand & gravels with various granularities for construction and building industry.

Stone Crushing Plant Project Report. Project Case:Limestone 80-100tph Stone Crushing Plant. Country:South Africa. Materials:Limestone. Discharge: 1", 7/8", 1/4" Capacity: 80-100t/h. Max feeding: 11" inches. Zenith as the largest gravel crushing production line of the company, in the construction of production line put forward two ideas: saving ...

Dewo machinery can provides complete set of crushing and screening line, including Hydraulic Cone Crusher, Jaw Crusher, Impact Crusher, Vertical Shaft Impact Crusher (Sand Making Machine), fixed and movable rock crushing line, but also provides turnkey project for cement production line, ore beneficiation production line and drying production line.

Stone Jaw Crusher Machine at Rs 600000/piece . Established in the year 2013 as a Sole Proprietorship firm at Sabarkantha (Gujarat, India), we Ajit Stone Crusher are engaged in manufacturing an extensive range of Crusher Machine, Shaft Impact, Industrial Flywheel, Jaw Crusher Machine, Vibrating Screen Machines etc.Using high-quality raw material and latest techniques, these products are ...

Hard rock stone crusher plant can choose the jaw crusher and cone crusher like the river stone crushing plant. The soft rocks crushing plant can choose the jaw crusher and impact crusher,like the limestone crushing plant.According to the specific production requirements, CFTC can offer you the comprehensive production line solution and ...

100t h river stone crusher line high wear resistance. 100th River Stone Crusher Plant in MINDANAO PHILIPPINES 100th River Stone Crusher Plant in MINDANAO PHILIPPINES Capacity 100TPH Materialsriver stone Complete basalt stone crushing production line manufacturersWe have a wealth of experience and the most advanced technology

Dewo machinery can provides complete set of crushing and screening line, including Hydraulic Cone Crusher, Jaw Crusher, Impact Crusher, Vertical Shaft Impact Crusher (Sand Making Machine), fixed and movable rock crushing line, but also provides turnkey project for cement production line, ore beneficiation production line and drying production line.

mighty mill portable mini rock crusher for gold prospecting, sampling, frit new

Make sure to WATCH this item so you can check back later when more will be available! Only available in hammered black, but more color choices will be available soon, including silver , green , red , blue , and more! WHAT FEATURES MAKE THIS CRUSHER SO UNIQUE? Fits with any brand grinder, battery or 110v (6 washers included for adjustments).

Solid 1 piece 3/4 axle with 3 stainless steel strikers (shackles). Heavy Duty 4 bolt 3/4 pillow block bearing that is greasable. Comfortable built in Snappy Grip handle for easy carrying. 7" long, 2" x 2" feed tube with 1-1/2" grizzly plate to reduce the chance of the feed tube getting clogged.

I also built this unit with you the customer in mind. I made it so that it will last long, and you can get most consumable parts at a regular hardware store, such as standard SAE bolts and washers, easily replaceable shackles (strikers), replaceable Snappy Grip handle, dust seal, and Rustoleum hammered finish paint. I have researched all of the other portable mini rock crushers on the market, and I believe the MIGHTY MILL provides you with a superior performing product at a mid range price. With the MIGHTY MILL's unique features and heavy duty quality, I chose to also make it AFFORDABLE FOR EVERYONE by pricing it in the middle of the other units.

1 cover plate with 4 bolts and 1 hole plug installed-1 hole plug removal tool (not pictured). 2 grinder mounting brackets with hardware (2 bolts, 6 washers, 2 wing nuts). 2 feet of sticky back foam to seal the cover plate. Warning sticker you can apply yourself if desired. This is a small unit, so it will not be good for high volume production needs.

mobile crusher - eastman rock crusher

Mobile crusher is often referred to as mobile crushing plant, is a wheel or crawler rock crushing plant that innovatively designed for unfixed production sites, it easily movable in a varieties of rock crusher applications like aggregate production, construction waste recycling, quarrying, mining industry.The greatest advantage of mobile crushers is the flexibility, both tracked and wheeled versions, greatly shoot the trouble of hauling and thus maximise productivity reduces the operation costs.

In fact, the concept of mobile and semi-mobile crushing plants has arouse for a long time, but it has not been realized until recent years, mainly because most machines are very heavy, it is not easy to move them. Therefore, most crushers are permanent facilities and rarely relocated. Now, the mobile crusher can replace the stationary crushing system.

If youre looking for a heavy duty primary crushers rugged using in heavy mining, recycling and quarried materials, the mobile jaw crushers are right for these tough operations to reduce the material to smaller sized for further processing. Theres a sturdy tracked mobile jaw crusher with capability ranging from 50 450 tons to meet your specific requirements.Features: Remote control to clear the blockage and adjust jaw gap, automatic iron removal. It is ideal for quarrying and the like industries.

Mobile impact crushers are divided into two categories: mobile horizontal shaft impactor (HSI) and mobile vertical shaft impactor (VSI).The mobile horizontal shaft impact crusher generally used in the primary, secondary or tertiary stage of crushing process. Mobile VSI crusher, or called as mobile sand making machine, is equipped with vertical shaft impact crushing device, usually used in fine crushing and particle shaping process, can produce more uniform cubic end products desirable in the aggregate industry.

Our range of mobile cone crushers meet any size reduction challenge in secondary and tertiary crushing process, provide you with high quality materials and good shape. If the particle size of the processed material is small enough, they can also be operated as the primary crusher.Our hydraulic cone crushers are versatile & intelligent, with a compact design, minimal manual operation, wide range of chamber options and eccentric throw adjustments, making this cone crusher plant one of the most trusted cone crusher in applications.

Mobile construction waste crusher can sort, remove iron, crush, and screen various construction waste (waste concrete, bricks, slag, etc.), and produce finished aggregates of various sizes.After being crushed, construction waste can be used to produce environmentally friendly bricks, non-fired bricks, waterproof bricks, etc., which greatly improves the utilization rate of construction waste and truly realizes resources recycling. Get a price!

Yes, of course, and its complete free of charge.Eastman service: Quality guarantee; Timely delivery; Free design; Installation, debugging, operation training. If you have other questions, just let me know.

china small rock crusher price chinese jaw crusher price list jaw crusher 50-100tph for sale line - best stone crusher plant solution from henan dewo

Dewo machinery can provides complete set of crushing and screening line, including Hydraulic Cone Crusher, Jaw Crusher, Impact Crusher, Vertical Shaft Impact Crusher (Sand Making Machine), fixed and movable rock crushing line, but also provides turnkey project for cement production line, ore beneficiation production line and drying production line. Dewo Machinery can provide high quality products, as well as customized optimized technical proposal and one station after- sales service.

You can also choose from stainless steel, steel. As well as from decoiling, bending, and cutting. And whether jaw crusher steel is coated. There are 10,203 jaw crusher steel suppliers, mainly located in Asia. The top supplying country or region is China, which supply 100% of jaw crusher steel respectively.

China jaw crusher catalog of High Quality Stone Jaw Crusher for Mountain Rock, Single Toggle Jaw Crusher (PE500*750/600*900, 750*1060, 900*1200) with Competitive Price provided by China manufacturer - Zhengzhou Hengxing Heavy Equipment Co., Ltd., page1.

CGE series jaw crushers are single toggle jaw crushers.It is one of the most commonly used crushers in industrial production. They are widely applied in coarse and medium reduction of various kinds of ores and rocks with compressive strength under 350 MPa.

China Impact Crusher/Jaw Crusher / Cone Crusher supplier, Rock Crusher/Stone Crusher/Hammer Crusher, Mobile Crusher/Mobile Jaw Crusher Manufacturers/ Suppliers - Shibang Industry & Technology Group Co., Ltd.

Cone Crusher, Jaw Crusher, Stone Crusher manufacturer / supplier in China, offering 2lsx915 Fine Material Sand Screw Sand Washer, Fine Jaw Crusher Pex-1047 for America Market, Iron Ore 4.5 Feet Hydraulic Symons Cone Crusher Kl1380 in Malaysia and so on.

Jaw Crusher, Cone Crusher, Impact Crusher manufacturer / supplier in China, offering Competitive Price Horizontal Shaft Impact Crusher PF1007 PF1010, Fine impact shaft rotary crusher PF1214 PF1210, Large capacity impact hammer shan bao crusher with cheap price and so on.

Jaw Crusher, Ball Mill, Shaking Table manufacturer / supplier in China, offering Gold Mining Equipment Small Scale Gold Ore Processing Gold Rock Breaking Machine Diesel Jaw Crusher, 5 Tph Rock Hammer Mill for Gold Minerals in Peru with Spare Parts, Small Scale Gold Mining Equipment Diesel Engine Rock Hammer Mill and so on.

Technical data of Joyal telsmith jaw crusher for sale Jaw Crusher , jaw crusher price list Model Feed Opening Size (mm) Max. Jiangxi supplier quarry rock stone jaw crusher price list US $1000-$2000 / Set

portable rock crushers

As it relates to portable crushers, the basic portability concept under investigation here might better be described by the phrase decentralized crushing to allow automated ore haulage. Clearly this means more and smaller crushers exhibiting some degree of mobility, and automated ore haulage usually means belt conveyors. The trade-off is a necessarily more costly crushing system against a more efficient and productive ore handling system. From the crusher manufacturers point of view the challenge is to achieve small size and portability without sacrificing too much in the important areas of feed opening, throughput, system availability, and capital and operation costs.

Portable in Portable Rock Crushers simply means that the crusher is moved periodically in order to be close to production, thus minimizing costly haulage of run of mine material. Within this simplified definition however, portability has quite different meanings in mines of widely varying ore bodies and mining plans. We shall further assume that a portable crusher is one that can be moved through standard mine passageways with minimal dismantling, and can be set up with little or no site excavation.

Underground is obvious, and when taken with portable brings to mind such terms as low, narrow, horizontal, light, serviceable, and mobile. This study may define a machine that is also applicable to some above ground installations but no attempt will be made to enhance such applicability at the expense of underground performance.

Hard-rock is sometimes taken to mean non-coal, but this broad definition would include many weaker mineral mines not in need of the fundamentally new equipment that is the subject of this study. Many of these non-coal mines have, however, developed highly efficient and mechanized coal-like mining methods that would be applicable to hard-rock mines if suitable equipment (crushers) were available. We have therefore gained valuable information by studying these mines, but the intended beneficiary of this investigation is the underground hard-rock industry, defined as those mines that cannot economically make use of presently available portable underground crushers.

To begin, let us attempt to define approximate requirements in order to establish a background for further specification of performance parameters, and to form the basis for a critical examination of existing crusher designs. In fact, it seems clear that no single optimum set of parameters can ever be sharply defined. However, with adequate documentation and an appreciation of likely individual case variations, such an approximate set of parameters can serve as the basis for new concept generation and further development work.

Before defining what a portable rock crusher is, we need to know how it will be used. Fortunately for the purposes of this study, portable underground crusher applications may be divided into two rather distinct categories, and one of these, though worthy of further thoughts and development, does not require fundamentally new hardware development. The distinction, perhaps predictably, is primarily one of physical machine size, although, to a lesser degree, distinctions can also be made in the desired degree of portability within a given size category.

The first category, which we shall dismiss for the moment, is one in which machine size, per se, is not limiting. Applications in this category are high head-room room and pillar mines, such as large limestone mines having 35 foot backs , and, in the future, oil shale mines having even higher backs. While significant portability improvements can be made in assembly methods and general layout, as discussed in Section 9, this category of applications ran in general be satisfied by existing manufacturers through modification of essentially standard machine components.

The second category is that in which machine size is very much a limiting factorso much so that todays standard hard rock primaries are simply not applicable. The two general mine types falling in this category include, obviously, low head room room and pillar mines and, perhaps not so obviously, most mines with vertically oriented ore bodies. The latter include caving mines, whatever the caving mechanism (block caving, sub-level caving, etc.), and other generally vertical mine plans such as open stope, shrinkage stoping, cut and fill, etc. . For purposes of this study, these mines are collectively characterized by gravity delivery of ore to a stationary or nearly stationary, draw point or chute from which the ore is handled (and often rehandled) by a variety of means in both the horizontal and vertical directions. Even though massive ore bodies may be involved, typical drift dimensions in such mines are not large, on the order of 8 to 12 feet high by not much greater widths.

Both mine types in this category of small applications suggest maximum installed crusher sizes of 7 to 9 feet high, 8-10 feet wide, and any reasonable length (the latter determined by transport conditions rather than installed dimensions. It is important to note that this height includes whatever overhead feed components (and dump space) may be required by vertical feed crushersthus standard top fed jaw crushers, which would normally be selected for hard rock, are much too tall.

Portable crushers will receive run of mine material from the face regardless of the mining method or the primary haulage system used, and then crush this ore and feed it into a more continuous and efficient ore haulage system. Within these applications it appears that for a decentralised crusher arrangement a throughput of 100 to 800 tons per hour will suffice. Although there is no clear-cut limit, this throughput is obviously a function of the size of the mining unit it services, and the ability, within the stated drift dimensions, of the primary haulage system to deliver material to the crusher. Thus it is not surprising that a limited range of throughputs will serve a wide variety of mining operations.

Just like the very large central crusher located (probably) at the shaft, the proposed decentralised portable crusher system must handle ROM (run of mine) ore. This fact, when taken with the low headroom restrictions, will continually challenge the would be portable crusher designer.

A study by the U. S. Bureau of Mines in five underground mines, utilising five different mining methods, in extremely different types of rocks, showed a striking similarity of over-size ore, not only in mean size but in shape as well. Table I presents these results. The indicated size uniformity is considered misleading, particularly in view of the fact that the study did not attempt to

determine the percentage of ore exceeding the stated oversize. The shape trend of this data (3:2:1) is more interesting, indicating a condition somewhere between block and slabby. Larger variations in size of oversize are supported by another study which was concerned with block caving mines. Results of this study, also presented in Table I, characterize the block cave mine of the preceding study as having fine ore. There is clearly no single optimum crusher feed opening for these, let alone all, block caving mines, although it is probably safe to say that block caving permits the least control of fragment size and can thus be expected to present highly variable conditions.

Mining plans relying on drilling and blasting for fragmentation control will, no doubt, show greater uniformity in size of oversize, but great variations are to be expected in the size distribution of ROM ore from mine to mine. Assuming a successful crusher can avoid direct attack of the three-to-five font major fragment dimension indicated in Table I, and assuming some form of control over occasional abnormal oversize, it is likely that minimum or critical feed openings in the 30-36 inch range will satisfy a very large percentage of mines.

To establish approximate product size, let us assume that the product is to be belt conveyed. In most cases this will be true, and it is expected that maximum economic benefit will occur in this combination. The feeder-breaker, so successfully used on coal mine section belts, is generally set to produce nine inch maximum lumps for 36 inch belts. For first-cost and other reasons, this belt width appears to be very common for section and feeder applications, and for the denser-than-coal ores found in the hard rock industry, a maximum product size in the range of 6-8 inches is appropriate, it is interesting to note that even for very large oil shale installations (very wide belts) a six inch product is recommended.

It appears that there is relatively little need to simultaneously develop a range of machinery between these small units and the large central primaries now being used. Ultimately a range of intermediate sizes will be desirable, of course, but this can easily be developed from low head room equipment meeting the above specifications.

As will be illustrated in the following section, these requirements cannot be met by existing hard rock crushing equipment. In fact, noting that the desired dimensions include whatever overhead clearance is needed to load the crusher proper, and space underneath to deliver its product (assuming a typical vertical jaw or gyratory design), it is obvious that standard machines are far from satisfactory. It follows, then, that satisfactory new concepts cannot be found among minor variations of standard concepts: the sought after design will differ substantially from present designs. At the same time, it would be comforting if a new concept did not depart substantially from the basic comminution means of proven designs. Economical crushing of hard rock, day in and day out, through many millions of tons, is, after all, a rather difficult task, even without severe space limitations, and proven means should not be so quickly discarded.

The inventors task is not quite so formidable as the proceeding may suggest. In comparison to a typical aggregate production application for example, some aspects of the portable application actually ease the design problems: The crusher is needed only for oversize (unbeltable) material. Thus, while the crusher should avoid fines, it has no rigid product size requirement other than maximum size, and essentially no product shape requirement (a requirement that justifies some rather subtle variations of crusher geometry in many conventional applications). Furthermore, if the crusher is designed to pass undersize material freely, or if its feed mechanism provides scalping to bypass smaller material, much of the throughput will be free, a provision which will also reduce the production of fines, and, more importantly, dust.

Many manufacturers were contacted in an extensive effort to include all available equipment and manufacturing capability in this study. Appendix A is a list containing the names and (if available) addresses of those manufacturers who were contacted. Although not all were responsive, many were quite helpful and the majority expresses the opinion that they would need the results of this study if the industry or any single manufacturer were to consider the development of portable, underground, hardrock crushers.

This study was neither intended, nor will it attempt, to instruct the reader in the complete art of primary rock crushing. There are many good references in this area; notable among these is McGrew. Our goal is to define the optimum parameters for the design of a portable, underground, hard rock crusher in order to insure that future development will lead to maximum utilization by the industry.

In summary then, we want to study present crusher types with an eye toward moving them around in hard-rock mines. Though small, these units will handle essentially as mined or ROM material, and should rightfully be called primary crushers.

This class of crusher historically has been used on the strongest ores. Crushing is accomplished by relatively slow moving members exerting very high force levels. Understandably, these crushers are typically very big, very strong, and heavy.

Figure 1 shows a simplified section of a typical gravity fed gyratory crusher. Clearly the typical portable underground crusher requirements presented in Section 2 cannot be met by a standard gyratory. However, because the crushing action of the gyratory works well on hard rock, the portable crusher designer should be aware of the favorable features exhibited by this important member of the primary field:

Single and double toggle jaw crushers differ in the motion characteristics of the moving jaw, which results in somewhat different operating characteristics. Jaw action in the Blake (double toggle) type is a simple pivoting motion about a stationary bearing near the receiving opening. Displacement is thus a maximum at the discharge, tapering to zero at the pivot.

Because of its simplicity, the overhead eccentric (single toggle type) exhibits lighter weight, much lower cost, and a greater potential for portability, although it is not significantly shorter thanthe Blake (double toggle type). Due to the pronounced vertical components of motion from the overhead eccentric, it elliptical wiping motion provides good feeding action, and hence capacity. The price for this action is, of course, accelerated wear of the jaw plates in addition to increased shock loading on the eccentric and shaft bearings caused by the large jaw motion relative to Blake type machines at the receiving opening. Consequently, Blake types, with their low scrubbing motion and great leverage on larger feed, tend to be favoured for highly abrasive or very hard, tough rock.

The basic overhead eccentric jaw motion has been built in a vertical double-eccentric version (both jaws moving in unison), with the intention of providing more capacity for a given feed opening and longer jaw life due to reduced scrubbing provided by lower relative jaw velocity. The Eimco Division of Knvirotech, and the Westfalia Company of Germany, have tipped this arrangement on edge (eccentrics vertical), thereby changing the feed direction from vertical to horizontal and greatly reducing machine height.

Little is known about the German machines, as none are in use in North America and none are believed to be handling predominately hard rock. Eimco, on the other hand, has built two prototypes which have been tested in medium and hard rock in low headroom conditions. The Eimco crusher, shown in Figure 4, utilizes a feeder-breaker style chain flite conveyor which pulls material from the bottom of the surge pile and stuffs it into the jaw region. Discharge occurs immediately after the choke region of the jaws, onto a customer supplied conveying means. The chain conveyor obviously must pass beneath the active region between the jaws, severely diminishing or eliminating its feeding ability, particularly during the crushing stroke. To achieve better feeding in the crushing zone, Eimco has modified the common overhead eccentric toggle geometry so that both jaws close every where at the same time, with the crushing stroke strongly oriented in the feed direction. These measures enable a second generation machine to achieve throughputs approaching (perhaps 80%) the capacity of a vertical, single overhead eccentric crusher of comparable inlet dimensions. The Eimco inlet is approximately 40 x 40 inches.

Both prototypes were tested at White Pine Copper in White Pine, Michigan. Problems were encountered and changes were made, as with most prototypes, but large blocks of 20-28,000 psi sandstone were successfully handled on a regular basis. Since Dial time, mining

at White Pine has been concentrated in medium strength shale, where the horizontal jaw is not sufficiently perfected to be competitive with heavy duty feeder-breakers, about which more is presented in subsequent sections. Very strong ores have not been tried on a significant scale in the horizontal jaw.

Though low in profile, this crusher design utilizes a feed means that tends to orient slabby material horizontally, hence the wide, square jaw opening. Slabs that do get fed on edge can be passed untouched through the jaws, a common problem with vertically fed jaw crushers as well. Dimensionally, horizontal jaw crushers are quite acceptable, though they could use elevating discharge means to reduce site excavation requirements, and with more development in hard rock applications, this concept may become an economical alternative candidate for the subject application.

True impact crushers for primary crushing are limited to hammer types. They are included here only because there may be a specialized situation justifying their unique characteristics. Figure 5 shows a section of a typical hammermill; Figure 6 shows an Impactor.

Impact type crushers are high reduction machines (up to 40:1 vs. 8:1 for a jaw). In part because of this, they produce a considerably finer product than is necessary to achieve mechanized underground haulage. Very large feed, as is common with ROM material, is not easily handled by the hammer mill because of its impact principle of operation. Crushing is accomplished by the high velocity impact (5000 fpm) between the hammers (and liners) and individual pieces of rock in the feed, with the only means of support of rock fragments being the inertia of the rock itself. Under these conditions the rock fragments should not only be less massive than the hammer, but also quite friable. Abrasive feeds cannot be economically handled by hammermills or by impactors.

Impactors, as Figure 6 indicates, are better suited to large feeds than is the hammermill. This type uses fewer and stouter hammers, but, like the hammermill, relies on the inertia of the feed to hold the rock while it is chipped away. Primary crushing, even of non-abrasive and friable material, and particularly underground, is better handled by other machines unless very special conditions exist. An admittedly unlikely example of a situation in which an impact type crusher could be successfully employed as a portable underground primary crusher might be described by thefollowing conditions:

(a) abnormally small ROM material suitable for impactor feed but too big to be conveyed. (b) very friable, non-abrasive feed, material. (c) fine product allows less expensive form of mechanized haulage and eliminates the need for secondary crushing equipment.

Roll crushers is a term sometimes used to describe the combination (impact & pressure) class of crushers. Sledging roll crushers is a more suitable name, since it is distinguishing from the impact and pressure terminology and, in fact, the rotor in a roll crusher is frequently called a sledging roll. Sledging roll crushers are characterized by a medium velocity impact (500 fpm or less) between a rotor protrusion and the feed material while the feed is supported in the crusher, hence the term sledging.

The term roll is used in a wide variety of non-sledging equipment types and needs clarification here. Crushing rolls, two-roll feed-pinching machines, are really a high speed continuous pressure class of crusher used for secondary and tertiary crushing. Sometimes they are confusingly called two-roll crushers, or double roll crushers, or four-roll crushers. The roll surfaces are usually smooth or nearly so and impact or even sledging does not play a significant part in the comminution process. Roll crusher may also be used to describe a high speed machine in which the feed is neither supported by the crusher nor nipped by the roll protrusions. As described in the previous section, this is a high reduction pure impact class crusher sometimes used to avoid secondary crushing.

Sledging roll crushers may be of the single- or double-roll type, the latter being distinguishable from smooth pressure class crushing rolls by the characteristic protrusions (sledges) which work on the feed material. Double-roll sledging crushers usually employ more impact and less sledging by virtue of higher tip speeds, and are principally used for secondary crushing. Figure 7 shows a typical single-roll sledging crusher. There are several features of this type of crusher worthy of mention.

The feeder-breaker is an adaptation of the single roll-sledging crusher developed specifically for portability and use in low headroom coal mines. Since it has found successful use in a number of non-coal mines it is therefore worthy of mention. Figure 8 shows a typical feeder breaker.

To achieve low profile, this specialized machine passes material horizontally under the roll, or breaker shaft as it is usually called. The anvil (or bed in this configuration) is flat, and feed is accomplished by a chain-flite conveyor which pulls feed from under the pile of material in the attached surge hopper, and, after passing through the breaking zone, continues on to feed at a relatively controlled rate over the conveyor head pulley, hence the name feeder-breaker. Another characteristic of this single-roll sledging crusher is the shape of the breaker teeth, or picks, as they are generally called. They are relatively few in number (particularly for weak material), replaceable, and pointed, generally being carbide tipped.

Feeder breakers have greatly advanced the practice of conveyorized haulage in coal mines, and during recent years beefed-up versions, pioneered by the W. R. Stamler Corporation, have been successfully employed in a variety of non-coal mines. Among these are underground salt, potash, trona, iron, copper mines, and some open pit mines. These mines use a wide variety of primary short haulage means, but they all make use of low labor, high capacity conveyor systems made possible by the feeder-breaker.

When applied to stronger and/or more abrasive ores, feeder breaker crushing costs naturally escalate to levels well above those of conventional hard rock (i. e., jaw) crushers. In fact it appears that feeder-breakers are used, in some applications, solely because of their low headroom characteristics, and despite crushing costs from 3 to 5 times what could be expected of a jaw crusher in the same material. However, sufficient savings are achieved elsewhere in the haulage system, so that feeder-breakers are the economic choice in one copper mine where the ore is routinely between 12-20,000 psi compressive strength, and also abrasive. That mine also uses feeder-breakers in sandstone sections where ore strength runs to 28,000 psi. Maintenance and rebuild costs are higher in such areas, and this is considered by many to be about the hard rock limit of feeder breakers as a class of crusher.

A narrow version of the feeder-breaker has been developed by a German company for use on longwall systems. Various sledge configurations (not sharp picks) are used, and the unit is generally incorporated in a chain-flite bridge conveyor between the longwall system and a headgate conveyor. Two such units are in use on longwalls in U.S. trona mines (7000 psi max.), which accounts in part for their mention here. The concept (sizing of longwall discharge) is worth noting, in view of U.S. research efforts to apply new technology and longwall methods to hard rock mines.

There are many other comminution processes that one could bring to mind. Among these would be all the primary and secondary breakage methods, grinding and milling methods, thermomechanical, and even ballistic and nuclear concepts. These are not considered here because there are no presently available machines using these processes. Other comminution methods in general will be considered in the concepts section (Section 9) after the problem statement has been fully developed and conclusions drawn.

Having discussed the various classes and types of hard rock primary crushers, we can examine their potential for meeting the general requirements previewed in Section 2. Those requirements call for a crusher of low height, large feed opening, and modest throughput. Since multiple small crushers will be less efficient to operate and more costly to purchase than one central crusher, we must also consider cost as a factor in suitability.

The one mining parameter that is least controllable in a given mine and has the greatest influence on crusher selection is size of feed. Although drift dimensions obviously cannot be specified by the crusher designer, machine height, to some extent, is in his hands. Accordingly, machine height, throughput, and cost will be examined with respect to the common parameter, feed opening. Since feed opening implies a two dimensional passageway for material, the smaller or Critical Input Dimension (CID) will be used where appropriate. The implication is that most any crusher can (and should) be fed so as to avoid direct attack of the largest dimension of the feed material. Also implied, but perhaps less obvious, is the desire and intention to feed material so as to attack the smallest dimension of the feed, not the middle dimension.

Figure 9 presents representative manufacturers throughput data as a function of CID for 3 classes of crushers totalling six different types. Capacities have been normalized on medium limestone and minus 6 inch product in most cases. Gyratories are clearly high capacity machines at any feed size, and they tend to he applied to very large material. The Blake type jaw crushers are considerably lower in capacity, reflecting to some extent their application to very hard and abrasive feeds. Also noticeable is the range of capacities available for a given CID, a favorable feature afforded by variable jaw or rotor width. The tremendous forces encountered in crushing very large feed tend to leave the stronger Blake as the only jaw type in this region.

Getting down into the throughputs of most concern (400 tph and less), both Blake and overhead eccentric types appear, with the edge in capacity going to the overhead eccentrics. Also appearing are the horizontal jaw crushers and the sledging class, both single roll and feeder-breaker types. Maximum feed size for a given CID will be somewhat less in the case of horizontal jaws because the feed mechanism for this type tends to cause attack of the middle, rather than the smallest dimension of the feed material.

Figure 10 is a plot of bare machine height as a function of CIB for the same six types of crushers. Keeping in mind that bare height is exclusive of any foundations if required) or feeding and discharge means, all conventional gyratory and vertical jaw types are clearly beyond our need for 7-9 foot installed height at 30-36 inch CID. Nor can these standard machines be significantly shortened, as an examination of earlier figures will reveal.

We are left, at present, with horizontal jaws and the sledging class of crusher. But sledging roll crushers and to a lesser extent, feeder breakers, reach their economic limit at medium strength ore, characterized by (among other things) compressive strengths

in the 12-20,000 psi range and, even then, only under specialized conditions. The horizontal jaw crusher would appear to be the lone contestant, but it is relatively new and little can be learned about its economic performance at this time. Westfalia, a German manufacturer of longwall and other mining equipment, developed the concept, and, although machines are in use in Europe, no information is available regarding hard or very strong ore applications, and none are in service in North America. Eimco Division of Envirotech is the U.S. pioneer of horizontal jaw crushers, having built two generations of machines. These machines were technically successful in crushing a regular diet of stronger ore (20-28,000 psi) but could not compete economically in the medium strength range against the then highly developed heavy duty feeder-breakers, a statement which most certainly would apply to weaker ores as well. Dimensionally, the horizontal jaw is virtually identical to the successful feeder-breaker (Eimco data is plotted) and with further experience this basic concept may prove to he one answer to low profile hard-rock crushing.

Figure 11 shows the bare cost (no drives, hoppers, feeders, etc. ) of the various crushers under discussion. Some of the data are approximations, but the plot is useful in several respects. It shows, for instance, that something must be sacrificed to get low profile. In the case of horizontal jaws, increased initial cost is the penalty. Feeder-breakers, the low profile member of the sledging class, cannot economically handle the stronger ores. To work on the very hard or abrasive ores, machine height aside, requires that one choose the more expensive Blake type vertical jaw instead of the lighter overhead eccentric. Gyratories having the required CID again are inherently much too much machine for this application.

Using the larger Blake type or gyratories as an example (they dominate as centralized crushers in hard-rock mines) we can get an idea of the capital investment against which a multiplicity of portable crushers must inevitably be judged. Suppose a 7000 tpd mine would need a 4860 Blake type jaw crushing 500 tph of minus 6 inch product. Such a crusher would cost perhaps $350,000 including significant installation costs. An equivalent portable crusher system might involve five machines, four of which would be in service, with each capable of 250 tph. The greater total crushing capacity of the portable system is necessitated by its need to keep moving up, and by its vulnerability to downstream haulage interruptions. If these five portables cost in the vicinity of $200,000

each (a reasonable assumption for hard rock), the capital investment for portables becomes one million dollars versus $350,000 for a fixed installation. In addition, since the operating and maintenance costs of the two crusher systems are likely to be in about the same ratio, it is clear that the portable system must achieve great savings in other categories. These would likely include primary and secondary haulage costs (capital and labor) find productivity.

The primary use of a portable crusher, i.e., a crusher mounted on crawlers or tires, in the rock and mining industries is to reduce costs by permitting the substitution of conveyor belt haulage for truck or track haulage. The usual sequence of operations in surface mining is drilling, blasting, loading, haulage, and crushing. Haulage is normally accomplished by truck or track-mounted cars, the latter method being used for the longer distances.

In addition to potential cost savings in haulage procedures, a portable crusher would allow better utilization and performance of shovels. Loading operations would not be interrupted as often by the necessity of waiting for cars or trucks. Unfortunately, the application of belts in open pits for haulage from bench sites is generally not practical under existing conditions because a belt fed directly by a mechanical shovel can be torn, damaged, or worn out quickly by the large rock fragments falling on it during loading.

As previously noted, the use of a portable crusher would increase the performance of a loading shovel and thereby decrease the number of shovels required to maintain the same rate of production. However, there are quarries where rock must be taken from different parts of the pit and mixed together in order to get a desirable composition. This is usually done in cement quarries. For such cases, storage of material at the end of the stationary conveyor or along its route is suggested, where the desirable mixture of product could be achieved.

Quarries or open pits using track haulage often require a large number of workers to move the track after blasting as well as to operate the railroad switches. The use of a long-boom shovel would make it possible to increase the distance between the bench face and the track. It would also aid in reducing the amount of time now consumed in moving the track and the number of workers to do the job, but such a shovel is more expensive and slower.

Application of the portable crusher might encourage the use of higher benches with the commensurate less blasting that would be required. Domestic practice, however, does not favor the use of high bench faces, partly for safety reasons during loading and partly because higher benches usually require a large borehole diam, larger drill, etc. Inclined drilling might solve such blasting problems because it reduces the resistance of the rock to blasting at the toe of the bench.

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