Crushers in Mineral
Processing
Anand Anupam
Assistant Professor
Department of Fuel and Mineral Engineering
Indian School of Mines, Dhanbad – 826004
E-mail: [email protected]; Mob: +91 9162 343434
Presentation Topics
• Jaw Crusher
• Gyratory Crusher
• Cone Crusher
• Rotary Breaker
• Sizer
• Single Roll Crusher
• Double Roll Crusher
• Impact Crusher
• Hammer Mill
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Jaw Crusher
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Jaw Crusher
• Depending upon the location of the pivot of the swing
jaw, jaw crushers can be of the following three types
• Blake crusher - the swing jaw is hinged/pivoted at the upper
position
• Dodge crusher - the swing jaw is hinged/pivoted at the lower
position
• Universal crusher - the swing jaw is hinged/pivoted at an
intermediate position
4
Jaw Crusher
• Blake crushers are of two types
• Single toggle (Blake) jaw crushers, and
• Double toggle (Blake) jaw crushers
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Jaw Crusher
• Blake crushers are of two types
• Single toggle (Blake) jaw crushers, and
• Double toggle (Blake) jaw crushers
6
Jaw Crusher
• Blake crushers are of two types
• Single toggle (Blake) jaw crushers, and
• Double toggle (Blake) jaw crushers
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Jaw Crusher
• Primary Crusher
• Hard rock and abrasive rock applications such as
• Iron ore
• Manganese ore
• Copper ore
• Lead-zinc ore, etc.
• Distinctive crushing action which is very similar to that of animal
jaws
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Jaw Crusher
• The main components of jaw crushers are listed as follows.
• Fixed Jaw
• Swing Jaw or Moveable Jaw
• Cheek plates
• Flywheel
• Toggle Plate(s)
• Pitman (in Double toggle crushers)
• Drive system
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Jaw Crusher
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Jaw Crusher
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Sub-Topics
• Crushing Action
• Arrested Crushing
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Gyratory Crushers
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Gyratory Crushers
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Gyratory Crushers
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Gyratory Crushers
• Gyratory crusher is another common primary crusher for hard
rock applications.
• The basic concept of crushing in a gyratory crusher is same as in
a jaw crusher.
• Functions as infinite number of jaw crushers.
• Operates in full cycle.
• Feeding arrangement may be disposed of.
• Chosen over jaw crushers for higher capacity requirements.
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Gyratory Crushers
• Consists of a long shaft, also called spindle, on which a steel
conical head is mounted.
• The head is covered with mantle, made of manganese steel.
• The crushing element, which is enclosed in a concave surface,
known as shell, also lined with manganese steel.
• The spindle is connected to an eccentric sleeve, which is rotated
by a drive through bevel gear, to provide an eccentric motion to
the shaft.
• The spindle is suspended from a spider and is free to rotate
about its own axis.
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Rotary Breaker
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Rotary Breaker
• Also known as Bradford Breakers
• Primary (Heavy-Duty) Crushers
• Breakage is mainly due to impact
• Lifters are provided to lift and convey the coal
across the length
• Undersize may be collected in an outer shell or
on a conveyor
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Rotary Breaker (contd.)
• Advantages
• Little Maintenance
• Ability to handle fluctuations in moisture
content, tonnage and size distribution of feed
• Better liberation
• Less fines generation
• High capacities
• Positive control on product top size
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Rotary Breaker
• Limitations
• Ineffective for plastic or clayey material
• High capital costs
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Cone Crusher
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Cone Crusher
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Cone Crusher
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Cone Crusher
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Sizer
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Sizer
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Sizer
• Can be used for underground, primary or secondary
crushing of coal
• Consists of two rolls of equal diameter, fitted with teeth,
rotating in opposite directions
• The rolls rotate with high torque but at lower speeds
• Two configurations
• Inward Rotating
• Outward Rotating
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Sizer
Inward Rotating Outward Rotating
Inward Rotating
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Roll Crushers
• Roll crushers essentially consist of one or more
cylinders, often corrugated or toothed, which rotates
against a fixed plate or another rotating cylinder
• The main size reduction phenomena are compression
and shear
• Main types are
• Single Roll Crusher
• Double Roll Crusher
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Single Roll Crushers
• Consists of a cylindrical toothed roll rotating towards a
fixed anvil
Anvil
Feed
Teeth
Product
Toothed
Roll
Anvil Toothed Roll 31
Single Roll Crushers
• Generally used as a primary or secondary crusher
• Single roll crushers are generally applied for soft, less
abrasive material like coal, as surface wear and
maintenance cost of the crusher become high
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Double Roll Crusher
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Double Roll Crusher
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Double Roll Crusher
• A double roll crusher is generally used as a secondary or
tertiary crusher. They are mostly employed for crushing
soft and less abrasive material like coal
• Roll crushers consist of two cylindrical rolls of equal
diameter separated by a small distance
• Both the rolls revolve at equal speed towards each
other and are either smooth lined or have surface
features like corrugations or teeth.
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Double Roll Crusher
• Advantages
• lesser fines generation
• least specific energy consumption
• ability to handle friable, sticky and frozen feeds.
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Impact Crusher
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Impact Crushers
Feed
① Rotor
① Rotor
② Hammer
② Hammer
③ Breaker Plates
③ Breaker Plate
④ Screen
Feed
Product Product Product
(a) Single Rotor (b) Double Rotor
Impact Crushers
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Impact Crushers
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Impact Crushers
• They use impact for carrying out comminution
• They are most suited for reducing the size of brittle,
non-abrasive materials
• Fines generation is more
• Closed circuit operation is required
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Hammer Mill
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Hammer Mill (contd.)
Feed
Feed
Product
Product
Reversible Hammer Mill
Hammer Mill
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Hammer Mill (contd.)
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Hammer Mill
• Hammer mills can be used as primary or secondary
crushers for coal.
• Hammer mills are generally used for reducing the size of
brittle, non-abrasive material in cases where generation
of fines is of little or no concern
• Reversible Hammer Mills prevent uneven hammer wear
• Feed moisture has critical effect
• Hammer wear is the major concern
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Queries ???
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