Technical Learning Program

Comminution Fundamentals

Developed by:
Comminution Technology Group

Version: 2.0 4 July 2019

Copyright © 2016. Not to be reproduced without the express written permission of Weir Slurry Group, Inc..
Comminution Basics
1. General Information
2. Ores & Geology
3. Material Characteristics & Testing Methods
4. Crushing Products
5. Plant Enquiry Questionnaire
6. Developing Flow Sheets
7. Marketing Layouts

2
Comminution Basics
1. General Information
1.1 Training Objectives
1.2 General Safety Procedures

2. Ores & Geology

3. Material Characteristics & Testing Methods
4. Crushing Products
5. Plant Enquiry Questionnaire
6. Developing Flow Sheets
7. Marketing Layouts

3
1.1 – Training Objectives

Training is intended to …
 Provide process training in comminution basic information

 Provide an understanding of the principles of comminution and the equipment used in the
crushing process

Training does not …

 … make you qualified to install, operate or repair the machines (refer to product training). Only
skilled professionals who are specifically trained in installing, operating, maintaining and
repairing similar equipment and who are familiar with appropriate safety and environmental
protocols should work with the equipment.

 … define all types of crushing. This training is focused only on the comminution process, with
a focus on crushers offered by Weir.

 … provide detailed sizing requirements (refer to Aggflow training)

4
1.2 – General Safety Procedures

• These process instructions are intended to review the comminution process and the pros and cons of
the various crushing products.

• It is the responsibility of the purchaser of this product to ensure such regulations are observed by all,
including those installing the product.

• Always coordinate repair activities with operations personnel and follow all plant safety requirements,
applicable workplace health, safety, and environmental laws and regulations.

• Mandatory Personal Protective Equipment (PPE)

Safety Gloves Safety Goggles

Safety Vests Safety Helmets

Safety Shoes Hearing Protection

Dust Protection
5
Comminution Basics
1. General Information
1.1 Training Objectives
1.2 General Safety Procedures

2. Ores & Geology

2.1 Aggregates & Hard Rock Mining
2.2 The Natural Rock Cycle
2.3 Minerals

3. Material Characteristics & Testing Methods

4. Crushing Products
5. Plant Enquiry Questionnaire
6. Developing Flow Sheets
7. Marketing Layouts

6
2.1 – Aggregates & Hard Rock Mining

Material needed over a lifetime

7
2.1 – Aggregates & Hard Rock Mining

8
2.1 – Aggregates & Hard Rock Mining 9

Materials, Rock & Ores

2.1 – Aggregates & Hard Rock Mining

Materials, Rock & Ores

10
2.2 – The Natural Rock Cycle

Igneous rock:
• Granite
• Gabbro
• Basalt
• Diorit

Sedimentary rock:
• Sandstone
• Limestone
• Chalk

Metamorphic rock:
• Gneiss
• Marble
• Quarzit

11
2.2 – The Natural Rock Cycle

The relative abundance of the three rock groups in the earth’s crust

12
2.2 – The Natural Rock Cycle
Igneous Rocks

Granite

Gabbro

Basalt
13
2.2 – The Natural Rock Cycle

Metamorphic rocks

Gneiss

Marble

Quarzit

14
2.2 – The Natural Rock Cycle

Sedimentary Rocks

Sandstone

Limestone

15
2.3 – Minerals

Minerals

16
2.3 – Minerals

Man made minerals

Slag Cement Mill Scale Glass & Ceramics

17
Comminution Basics
1. General Information
1.1 Training Objectives
1.2 General Safety Procedures

2. Ores & Geology

2.1 Aggregates & Hard Rock Mining
2.2 The Natural Rock Cycle
2.3 Minerals

3. Material Characteristics & Testing Methods

3.1 Work Index
3.2 Abrasion Index
3.3 Dynamic Fragmentation
3.4 Crushability & Abrasiveness
3.5 Shape Index
3.6 Flakiness Index
3.7 Hardness
3.8 Size / Gradation

4. Crushing Products
5. Plant Enquiry Questionnaire
6. Developing Flow Sheets
18

7. Marketing Layouts
3.1 – Work Index (Wi)

Work index is useful in determining the energy required to crush the rock

A representative sample, minimum

of 10, of a size 50 to 75 mm are hit
parallel from two side with
hammers. The energy, height of
hammers, is continnuesly
increased until sample breaks.

Calculate the Work Index

19
3.1 – Work Index (Wi)

Work index is useful in determining the energy required to crush the rock

Material WI
▪ Basalt 20 +/- 4
▪ Gabbro 20 +/- 3
▪ Diabas 19 +/- 4
▪ Greywacke 18 +/-3
▪ Porphyr 18 +/- 3
▪ Granite 16 +/- 6
▪ Gneiss 16 +/- 4
▪ Quarzit 16 +/- 3
▪ Dolomite 12 +/- 3
▪ Limestone 12 +/-3
▪ Hematite 11 +/- 3
▪ Magnetite 8 +/- 3

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3.2 – Abrasion Index (Ai)

Abrasiveness of the material is useful in estimating the life of wear parts

A representative sample, 1.6 kg of

dry rock between 12.70 – 19.05 mm
size, placed within a rotating drum,
with an impact paddle mounted on a
center shaft rotating at a higher
speed than the drum. The paddle is
made from standard alloy steel
hardened to 500 Brinell.

The Abrasion Index is determined

from the weight loss of the paddle
under standard operating conditions.

21
3.2 – Abrasion Index (Ai)
Abrasiveness of the material is useful in estimating the life of wear parts and selecting
the appropriate crusher

Material AI
▪ Quarzit 0,75 +/- 0,1
▪ Granite 0,55 +/- 0,1
▪ Hematite 0,5 +/- 0,3
▪ Gneiss 0,5 +/- 0,1
▪ Gabbro 0,4 +/- 0,1
▪ Diabas 0,3 +/- 0,1
▪ Greywacke 0,3 +/- 0,1
▪ Basalt 0,2+/- 0,2
▪ Magnetite 0,2 +/- 0,1
▪ Porphyr 0,1 to 0,9
▪ Dolomite 0,015 +/-0,05
▪ Limestone 0,001 +/- 0,03

Note: Higher silica content results in higher abrasiveness 22

3.3 – Dynamic Fragmentation (DyFr)

Dynamic Fragmentation (DyFr) reflects a material‘s impact resistant

350g of dried material is placed in a

bowl. A 14kg hammer is dropped
onto the sample from 40cm height.

Depending the size fraction tested,

the hammer is dropped between 16 –
28 times. The resulting sample is
sieved on a 1.6mm sieve.

The Dynamic Fragmentation (DyFr)

% is determined by the weight ratio of
the minus 1.6mm fraction to the
original 350g sample.
Material Dynamic Fragmentation % Impact Resistance
Dolomit 20 - 38 LESS
Kalkstein 28 - 44
Gneis 12 - 42
Granit 17 - 41
Quarzit 14 - 40
Diabas 11 - 21
MORE
Basalt 11 - 32
Durchschnittswerte Dynamic Fragmentation DyFr (Metso Minerals Brechlabor) 23
3.4 – Crushability & Abrasiveness

500g of dried material is placed in a

bowl, of size fraction between 4 – 6.3
mm. A calibrated paddle is rotated
within the bowl at 4500rpm for 5
minutes.

The Abrasiveness is calculated using

the weight loss of the calibrated
paddle.

The Crushability % is determined by

the weight ratio of the minus 1.6mm
fraction to the original 350g sample

24
3.4 – Crushability & Abrasiveness

Work/power required to crush the rock

Range
Ability to Wi Crushability Dynamic Fragmentation
crush
Very easy <8 > 50 > 45
Easy 8 - 12 40 - 50 37 - 45
Medium 12 – 16 30 - 40 25 - 37
Hard 16 – 20 20 - 30 15 - 25
Very Hard 20 – 24 10 - 20 10 - 15
Extremly Hard > 24 < 10 < 10

Amount of wear / life of wear parts

Range
Abrasive Abrasion Index i Abrasiveness
Very low < 0,1 < 100
Low 0,1 - 0,4 100 - 600
Medium 0,4 - 0,6 600 - 1200
High 0,6 - 0,8 1200 - 1700
Very High > 0,8 > 1700
25
3.5 – Shape Index

Why is shape so important?

Paving roads:
+ Compaction (filled potholes)
+ Better mechanical handling
+ Higher stability
+ Less abrasive

Buildings:
+ Ease of flowability
+ Compaction
+ More tighten
+ Less cement needed (stronger)

26
3.5 – Shape Index

Shape Index – EN933-4

▪ Testing in Europe is carried out under EN933-4
▪ This method described in EN933-4 measures the ratio of length to width of individual
aggregate particles using a vernier calliper and a specially designed 3:1 length gauge.
1. Measure particle length L – the maximum dimension of the stone piece
2. Check particle thickness E – If the piece passes through E then it has failed
3. Calculate shape index - the % weight of the failed material against total sample

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3.5 – Shape Index

Flaky material
Interparticle crushing Poorly fed
Choke feed (Cone crusher) Wrong crushing chamber

28
3.6 – Flakiness Index

Flakiness index

▪ Testing in Europe is carried out under EN933-3

EN 933-3 Flakiness Sieve
for 6.3mm to 10mm product

Material sample 6.3mm to 10mm

Flaky stone % of this material against

passes through overall test sample

▪ Flakiness Index required values can vary between

10% to 35% depending on what the aggregate is
being used for.

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3.7 – Hardness

Hardness is a measure of the rock’s resistance to abrasion / scratch resistance

All deposits, rocks or ores have different hardness depending on the chemical
composition and the geological environment.

30
3.8 – Gradation

Minerals break along natural fracture lines

Minerals being crushed have the tendency to break into endless numbers of sizes and
shape every time they are introduced to energy. Be careful in overbreaking and receiving
normally the unwanted fines.

When producing high quality

products from minerals in S&G
business (fillers excepted) is to
to keep the reduction curves as
steep as possible.

To achieve that goal we need to

select the equipment for size
reduction very carefully.

31
3.8 – Importance of Size and Hardness

Size and hardness are important to the suitability of material

All operations have different process environments due to mineral hardness and size range.
It is important to know in which “range” we are operating as this will affect many process
parameters (wear rate, uptime, operation costs, etc...)

32
Comminution Basics
1. General Information
1.1 Training Objectives
1.2 General Safety Procedures

2. Ores & Geology

2.1 Aggregates & Hard Rock Mining
2.2 The Natural Rock Cycle
2.3 Minerals

3. Material Characteristics & Testing Methods

3.1

4. Crushing Products
4.1 Crushing
4.2 Jaw Crushers
4.3 Cone Crushers
4.4 Vertical Impact Crushers
4.5 Horizontal Impact Crushers
4.6 Summary

5. Plant Enquiry Questionnaire

6. Developing Flow Sheets
7. Marketing Layouts 33
4.1 – Crushing

Comminution is the reduction of solid materials from one average particle size to a smaller
average particle size, by crushing, grinding, cutting, vibrating, or other processes

Primary Secondary Tertiary

Crushing Crushing Crushing

TP Series
HPGR
Gyratory

HSI
TC Series
Jaw VSI

Feed & Product Size 34

4.1 – Crushing: Reduction Ratio

Primary F80
Crushing RR 
RR: 3 - 4
P80
RR: 3 - 6
F80 = (80 % Feed Size)
Secondary
P80 = (80 % Product Size)
RR: 7 - 12
Crushing

RR: 4 - 6

Tertiary
RR: 4 - 12 Crushing
RR: 20-25
F50/P50
4.2 – Jaw Crushers

36
4.2 – Jaw Crushers

RR: 3 - 4

RR: 2 - 4

37
4.2 – Jaw Crushers
Application Considerations – full range of CT & CTHT jaw crushers

Feed Requirements
• Max feed size: 8 – 54 inches (200 – 1370mm)
• Production capacity: 23 – 1575 STPH (20 - 1425mtph)
• Typical reduction ratio: 4:1 hard rock, 5:1 limestone
• Use grizzly to remove fines from feed
• Not ideal for “slabby” material or coal

Typical Applications
• Primary crushing, secondary crushing at
smaller jaw sizes
• Aggregate
• Small scale mining (gyratory for large scale
mining operations)

Operating Requirements
• Lower capital costs (compared to gyratory)
• Simple operation
• Wide range of cavity configurations

Product Characteristics
• Economical primary crushing
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4.3 – Cone Crushers

39
4.3 – Cone Crushers
Application Considerations – full range of TC & TP cone crushers

Feed Requirements
• Feed size: 3 – 14 inches ( 80 – 350mm)
• Production capacity: 35 - 2000 STPH (32 – 1800mpth)
• Typical reduction ratio:
• 4:1 for secondary (standard head)
• 3:1 for tertiary (short head)
• Recommend fines pre-screened
• Choke Feed – recommend TC series if intermittent feed
• Even feed distribution

Typical Applications
• Secondary, tertiary, quaternary crushing
• Mining, aggregate
• Mobile – recommend TP series (lighter, more compact)
• Pebble crushing – recommend TC (durability)

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4.3 – Cone Crushers
Application Considerations – full range of TC & TP cone crushers

Operating Requirements
• Higher capital requirements (compared to impact
crushers)
• Advanced automation and controls
• Lubrication and Hydraulic systems
• High application flexibility with various cavity
configurations crushing)

Product Characteristics
• Cubicle shape – recommend TP series (high
pivot point for more inter-particle crushing)

41
4.4 – Horizontal Impact Crushers (HSI)

42
4.4 – Horizontal Impact Crushers (HSI)
Application Considerations – full range of APP & APS

Feed Requirements
• Max feed size: 10 – 36 inches ( 250 – 900mm)
• Production capacity: 22 – 935 STPH (20 -850mpth)
• High reduction ratio: 7:1 to 10:1
• No tramp allowed in feed
• Accepts wide range of feed sizes
• Recommended for use low abrasive material

Typical Applications
• Primary (APP) & secondary (APS) crushing
• Recycling concrete and asphalt (with rebar)
• Aggregate

Operating Requirements
• Lower capital costs
• Simple operation – simple lubrication & hydraulic functions

Product Characteristics
• Good product shape for aggregate industry
• Easily adjust product size by changing curtain setting and speed
• Creates fines = lower yield of viable product 43
4.4 – Horizontal Impact Crushers (HSI)

HSI for use with materials having Low Abrasion Index and Low Work Index, in order to
reduce cost of wear parts

44
4.4 – Horizontal Impact Crushers (HSI): Blow Bar Selection

Refer below table to select blow bar material for required applications.

Blow Bar Type Martensitic Steel

Chrome Iron with
Manganese Chrome Iron with Ceramic
Feed Material Ceramic Insert
Insert
Primary Feeds
Secondary Feeds
Recycle Asphalt
Recycle Concrete
without Rebar
Recycle Concrete
with Rebar
Rubble

Acceptable but caution

Recommended Not Recommended
should be used

45
4.5 – Vertical Impact Crushers (VSI)

46
4.5 – Vertical Impact Crushers (VSI)
Application Considerations – full range of TV
Feed Requirements
• Max Feed size: 1-1/2 – 5 inches (40 – 125mm)
• Production Capacity: 140 – 600 STPH (125-550mtph)
• Typical reduction ratio: 4:1 to 6:1
• Accepts wide variation in feed conditions
• Rock moisture content has little affect on performance
(but sticky material or dust suppression may require
spray bars for routine maintenance)

Typical Applications
• Best applied in tertiary & quaternary applications
• Some secondary crushing applications
• Fully autogenous (Rock-On-Rock)
 High abrasive, high hardness material
 Lowest wear cost
• Semi autogenous (Rock-On-Steel)
 Higher reduction ratio
• Standard configuration (Steel-On-Steel)
 Larger feed size

47
4.5 – Vertical Impact Crushers (VSI)
Application Considerations – full range of TV

Operating Requirements
• Lower capital costs
• Simple operation with combined Hydraulic &
Lubrication Power Unit (HLPU)
• Easy access to wear parts
• ROR offers lowest wear costs

Product Characteristics
• Excellent product shape for aggregate
industry and concrete sand
• Cubical shape and fractured face, compliant
with Superpave specification
• Wide speed range for precise control of
product gradation
• Creates more fines (compared to HSI)

48
4.5 – Vertical Impact Crushers (VSI): Chamber Selection

Crushing Chamber Configuration

SOS ROS ROR
Abrasiveness Open Shoe Table and Enclosed Rotor and Enclosed Rotor and
Anvil Ring Anvil Ring Rock Box
Very High
>1700 (>0.8)

High
1200 – 1700 (0.6 – 0.8)

Medium
600 – 1200 (0.4 – 0.6)

Medium Low
<600 (<0.4)

49
4.6 – Summary: Crusher characteristics

Horizontal VSI with VSI with

Jaw Cone
impactor anvils rock box
reduction
3-5 5-15 2-5 2-5 1-1.5
ratio
energy
consumption low high medium high high
/ ton
production of medium / medium / medium /
low medium
fines high high high
cubical shape poor good good exellent exellent

Investment medium / low / medium / low / low /

cost high medium high medium medium
wear part
low high medium high medium
costs/ton

50
Comminution Basics
1. General Information
1.1

2. Ores & Geology

2.1

3. Material Characteristics & Testing

3.1

4. Crushing Products
4.1

5. Plant Enquiry Questionnaire

5.1 Project Details
5.2 Plant Capacity
5.3 Feed Gradation
5.4 Material Physical Properties
5.5 Moisture, Clay & Contamination
5.6 Density
5.7 End Product Requirements
5.8 Site Pictures / Videos
5.9 Other Information

6. Developing Flow Sheets

51

7. Marketing Layouts
5.1 – Project Details

Project Details
▪ Customer Name

▪ For all requests not only in the questionnaire but also the e-mails put the following
information into the subject line or respond to the same e-mail chain

▪ C4C Number
▪ Customer Name
▪ Site Name

Example : Subject : CRC 234567 – Colas – Quarry Hill

▪ For all future e-mails keep the same subject line – easier to track the history

Just because you know do not assume that anyone else knows.

52
5.2 – Plant Capacity

Plant Capacity ▪ Request for single piece of plant

▪ Initial feed, without pre-screening
▪ Machine throughput includes
▪ Customers capacity requirements anticipated recirculating load.
▪ End products (most important)
▪ Feed rate into primary crusher
excluding fines/dirty material
Initial
Feed
Initial Feed +
Recirculation

53
5.3 – Feed Gradation

Gradation, or Particle Size Distribution (PSD), is the measure of variation in product size

Sample
▪ Taken from stockpile, Testing
bins, dump trucks, ▪ Sample prep (splitting,
conveyor belt … washing, drying)
▪ Mechanical vibration
▪ Test method per
AASHTO, ASTM, etc…
Test Results

54
5.3 – Feed Gradation

Feed Gradation Curve

Particle Size Distribution

55
5.3 – Feed Gradation
Sampling
Best taken off a conveyor.
▪ If a 1m length of sample is taken from a belt you can
also tell the mtph on the belt using belt speed (m/s).

If from a stockpile
▪ Do not take sample directly below conveyor discharge
▪ Material separates on the stockpile so coarse on the
outside and fine material on the inside
▪ It is not a representative sample
▪ Use loading shovel to pull out material to be sampled.
Orange – Coarse
▪ Roll material out of the bucket, not at height and then Green - Fine
take a sample

56
5.3 – Feed Gradation

Primary Crusher feed

▪ Very few companies are able to carry out exact

gradation tests
▪ Assumptions can be taken such as if material is
fine, medium fine or coarse etc.
▪ If feed material is slabby this may cause bridging
issues with the primary crushers.
Quarry Shot Quarry Shot Med
Granite Hard Limestone

57
5.3 – Feed Gradation

Sand & Gravel, feed to secondary and tertiary crushers and screens
▪ More accurate information from site = better results.
▪ Especially critical for screen calculations to have detailed gradations
▪ Local laboratory companies can do this for low cost - important information and looks
professional

58
5.3 – Feed Gradation

Using the same as competition for sizing the plant

▪ Example below for the same feed tonnage one plant requires a CT3042 jaw and the other
a CT3648. But look at the % of +101.6mm in the feed.
▪ Most of the competition do not show what feed gradation they have used for calculations.
▪ All customer will see is that both have the same feed tonnage?

40% 24%
bypass bypass

59
5.3 – Feed Gradation

Maximum feed to primary crusher versus capacity required.

▪ A larger crusher running empty will have higher capital cost, maintenance and running costs.
▪ Example below same feed tonnage but different max feed size, allowing a smaller crusher.
▪ May be more economical for the customer to control max feed size by blasting, selective
excavating, rock breaker at primary etc.

Incorrect Correct
60
Primary crusher sized on feed size and Primary crusher sized on capacity not
not capacity feed size
5.4 – Material Physical Properties: Crushability or Hardness

Material Physical Properties

▪ Type of material
▪ Granite
▪ Limestone
▪ Sand & gravel
▪ C&DW (Construction and demolition waste)
▪ Mineral Ore

▪ Crushability or hardness Crushing Work Crushability

▪ How hard the material is to crush Index (Wi) - Kwh/t
determines crusher type, setting, discharge  Less than 10  Very easy
gradation and tonnage achievable etc.
▪ Hard materials will require more power and  10 - 14  Easy
therefore a correction factor for capacity.  14 - 18  Medium
▪ Many specialist tests available such as
Bond Crusher Work Index, Los Angles,  18 - 22  Hard
Crushability etc  22 - 26  Very hard
▪ If unknown then customer could give us an
indication , or we can assume this from the  26 and above  Extremely hard
rock type and what has been tested in the
past Most crusher manufacturers use a Wi of
12-14 as the basis for their capacity charts.
61
5.4 – Material Physical Properties : Abrasiveness

Abrasiveness

▪ How abrasive is the material?

▪ Used to determine crusher type required.
▪ Many specialist tests available such as Abrasion Index, abrasivity, silica content etc
▪ If unknown then customer could give us an indication
▪ Higher silica content usually the more abrasive the rock
▪ Or we can assume this from the rock type and what has been tested in the past

Abrasion Index (Ai) Wear Rate

 Less than 0.1  Minimal wear

 0.1 – 0.2  Low wear
 0.2 – 0.4  Normal wear
 0.4 – 0.6  Medium wear
 0.6 – 0.8  High wear
 0.8 and above  Extremely high wear

62
5.5 – Moisture Content

Moisture Content
▪ High levels of moisture will affect capacity of dry processing equipment especially if
there is a high % of fines
▪ Increased risk of blinding (sticking /covering) of material on the screen media which will
reduce performance (open area%) and require regular cleaning
▪ Increased risk of packing inside crushers which may cause mechanical damage.
▪ Will also increase wear of components

Material blinding (sticking) to the top Material packing inside a VSI crusher
deck of a screen (also clay present)

63
5.5 – Moisture Content

Moisture Content
▪ Crushers – Limit of around 3% moisture
content in the feed.
▪ Dry Screening – Limit of around 3%. See
chart 3%
▪ At 7% material is extremely difficult to 50%
screen
▪ These limits also depend on the % of fines
and clay content in the feed material.
▪ Also keep in mind that some materials are
porous and can hold a high % of water
internal which may affect crushing, but not
the screening operation

7%
Wet Screening
Normally looking to have the water content
in the feed around 50% + or the use of
spray bars to increase this.
▪ Information can come in two forms
▪ % of solids per weight
▪ % of solids per volume 64
5.5 – Clay

Clay content

▪ High levels of clay will affect ability of the

material to be screened and crushed.
▪ Same as high moisture content in the
material with blinding on screens and
packing inside crushers.

65
5.5 – Clay

Clay content
▪ Simple test on site to determine whether the clay is soluble (absorbs water) or non-
soluble (does not absorb water). This information is most important if a washer is
required in the flow.
1 – Take a sample of clay
2 – Put the clay sample in a bucket of water overnight.
3 – If the clay has broken down or if you pick it up it and it turns to slush it has
absorbed the water and clay is soluble.
4 – If the clay is still in the same shape and is only a slime on the surface then it is
non-soluble.

Sample should be taken from the extraction area (virgin material that has not weathered)
and not what is present in stockpiles

Clay sample at the start of test Clay material next day (This is soluble)

66
5.5 – Other Contaminants

▪ Is there other types of contaminates present such as wood/plastic etc or uncrushable

material such as steel in the feed material.
▪ Full details required as this can affect crushers and screens.

67
5.6 – Density

Two different types of density measurement

Specific Density
▪ Specific density or Particle density 100% Solid (No Air voids)

▪ Weight of the material as a solid block Weight = 2.65 tonnes per cubic m (t/m³)

▪ Bulk density

▪ Weight of the material with air voids included

between the particles

▪ Specific Density is always higher than Bulk

Density

Bulk Density
Solid + Air Voids
Weight = 1.6 tonnes per cubic m (t/m³)

68
5.6 – Density

Bulk Density

Bulk Density for crushers and screens

All equipment capacities are based on a material having a bulk density of 1.6 t/m3
▪ Any differences in material weight of more or less than this will have a factor on
the achievable capacity of the plant

1 m³ 1 m³

Coal Bulk Density Iron Ore Bulk Density

Weight = 0.8 tonnes per cubic Weight = 3.2 tonnes per cubic
m (t/m³) m (t/m³)

69
5.7 – End Product Requirements: Gradation

End Product
▪ What end product does the customer require?
▪ Split of end products. Which do they require
more or less of?

▪ Requirement for grading envelopes for end

products
ROAD BASE

70
5.7 – End Product Requirements: Shape

Product Shape

What does this mean?

Why is cubical shaped material required?

▪ Asphalt production – Flaky and elongation aggregate in the mix are liable to break
up and disintegrate during the pavement rolling process
▪ Concrete production – Flaky and elongation aggregate lower the workability
(ability to achieve maximum strength) of the concrete mix which may impair the
long-term durability

▪ We need exact requirement and not just a standard. Standards have many different
products listed with all different requirements. Also some customers have special 71
requirements.
5.7 – End Product Requirements: Shape
Flow Number 1 – Maximum Capacity Flow Number 2 – Better Shape
▪ High overall capacity ▪ Lower overall capacity
▪ Lower finer material produced ▪ Increased finer material produced
▪ Less cubical material in final stockpile ▪ More cubical shaped products in final stockpile

72
5.8 – Site Pictures / Videos
Pictures tell a thousand words

The more pictures the better, costs nothing.

▪ Feed and end products
▪ Existing machines

Don’t take pictures from far away

• Picture on right example of picture given for a customer
looking for a cone crusher!

73
5.8 – Site Pictures / Videos

Pick the material up in your hand to give an indication of scale

74
5.8 – Site Pictures / Videos

• Use slow motion video function on IPhone to take videos of

material on conveyors, screens etc.
• Video shown low quality for PowerPoint presentation.

75
5.9 – Other Information
Other Basic Information Required for Plant Design (abbreviated list)

• Why is the customer looking for new equipment especially if they have existing plant

• Is data available from existing machines or other equipment working in the same deposit

• Feed method and size of implement (truck/loader/excavator/dredge/etc.)

• Primary feed hopper- size required? (normally depending on loading machine size)

• Should surge piles and surge bins be designed into the plant for optimisation?

• Customer preference on screen type(s) to be used

• Special requirements on conveyors

• Special inclusions- electricals, dust suppression, dust extraction, paint, etc.

• Plant site- elevation changes or existing obstacles to be considered in the layout

76
5.9 – Other Information

Summary

• Ask questions – Looks more professional to the customer, giving them confidence.

• Use the questionnaire when speaking to the customer as a check list of what to ask

• Think through the process before sending through to applications team to ensure process
is fully understood.

• Translate key technical details and documents into English.

• Don’t just copy what everyone else is doing. Think outside the box for a better solution as
competition sometimes get it wrong. Also avoids you being used as a price check which
takes up time

• Sometimes it may be a case that optimising the plant is a better solution for the customer
rather than selling. Looks good in the customers eyes for working on future projects.
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Comminution Basics
1. General Information
1.1

2. Ores & Geology

2.1

3. Material Characteristics & Testing

3.1

4. Crushing Products
4.1

5. Plant Enquiry Questionnaire

5.1

6. Developing Flow Sheets

7. Marketing Layouts

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6.0 – Developing Flow Sheets

Bruno – Metso mass flow calculation software (propriety)

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6.0 – Developing Flow Sheets

Plant Designer – Sandvik mass flow calculation software (propriety)

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6.0 – Developing Flow Sheets

Aggflow (Bedrock Software, Seattle WA)

• Program developed in the USA since 1993

• Designed primarily to help sand & aggregate producers optimise their existing layouts
using samples taken from site

• Most manufacturers provide crusher & screen operation data to Aggflow to participate in
the software.

• Crusher gradations are based on standard information.

• Results are only as good as the application information used for the simulations.

• As well as using it as a sales promotion tool, we can analyse Bruno & Plant Designer
flow sheet for accuracy and an independent review.

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6.0 – Developing Flow Sheets
Aggflow Simulation - Example

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Comminution Basics
1. General Information
1.1

2. Ores & Geology

2.1

3. Material Characteristics & Testing

3.1

4. Crushing Products
4.1

5. Plant Enquiry Questionnaire

5.1

6. Developing Flow Sheets

6.1

7. Marketing Layouts
7.1 3D Layouts
7.2 Google Earth

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7.1 – 3D Layouts

84
7.1 – 3D Layouts

85
7.1 – 3D Layouts

86
7.1 – 3D Layouts

87
7.1 – 3D Layouts

88
7.2 – Google Earth Layouts

Advantages
• Ability to give the customer a visual representation of the plant on their site
• Image depends on the quality of picture available on Google Earth
• Remember to ask customer for site survey, google earth coordinates, take pictures,
etc… Any site information is helpful to create the 3D layout

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7.2 – Google Earth Layouts

90
Comminution Technology Group
(CTG)

Contact Information:
Martin H. Comer
Director of Comminution Technology Group

M. +1 608 509 8580

T. +1 608 308 3633
[email protected]
www.weirminerals.com

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