master your output crusher selection quick guide...manual calibration automatic calibration lost...
TRANSCRIPT
MASTER YOUR OUTPUTCRUSHER SELECTION QUICK GUIDE
A CHOICE fOR TODAY AND TOMORROwA crusher is a major investment, so it’s essential to select one with the potential to meet your needs into the future. This guide covers a few of the key points to consider before making a decision. But remember that your crusher is just one part of a wider process – always consider crushing in conjunction with screening and transport.
The process – whaT and whenThe first considerations are at what point in the process the crusher will be used, the type of material, and the output required. Use the table below as a guide.
Primary Gyratory Crusher
B G G
Primary Jaw Crusher
G B G
Primary HSI Impact Crushers
P P B
Secondary Cone Crushers S-type
B G
Secondary HSI Impact Crushers
P B P G G P
Cone Crushers H-type
B G G P B G P G G
Impact Crushers- VSI
B B G P B B B
Pri
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last
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ove
80
0 m
tph
1. 5
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Sec
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MACHINE
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N
CRUSHER SELECTION QUICK GUIDE
1. A typical example of primary crushing is reducing topsize from 900 to 300 mm.
2. A typical example of secondary crushing is reducing topsize from 300 to 100 mm.
3. a typical example of fine crushing is producing concrete aggregates in fractions below 30 mm.
4. Manufactured sand is typically smaller than 5 (often 2) mm.
5. Typical abrasive rocks are Granite, Quartzite, Diorite, Trap rock, Basalt, Gneiss - Abrasion index above 0.10
6. Typical non-abrasive rock is clean Limestone (Marble) - Abrasion Index below 0.10
7. fines or ”0-X mm” material is normally below 2 mm. -0.075 mm is called filler
Recommendations: Best (B), Good (G), Possible (P)
wHICH CRUSHER DESIGN?Is it a heavy duty application with a lot of wear and tear? Consider whether you need top and bottom mounted rather than bottom only.
wHICH CHAMBER?different materials and outputs demand different crushing chamber designs. don’t accept ‘close enough’ – select a supplier with the right match.
MAINTAINING OUTPUT OVER TIMECapacity and reduction ratio can decrease with mantle wear. for consistent production, choose a crusher with a design that delivers CLP (Constant Liner Performance) through the entire product lifetime.
CRUSHER SELECTION QUICK GUIDE
Top and bottom mounting increases robustness. The principle can be illustrated as above.
Extra coarse Coarse Medium coarse
Medium Medium fine fine extra fine
AUTOMATE!Modern automation systems constantly adjust the CSS (Closed Side Setting) with no need to shut the machine down. Compensates for variations in feed material and wear in wear parts.
Manual calibration Automatic calibration
Lost production
TIME
PR
OD
UC
TIV
ITY
160
140
120
100
80
60
40
20
00 700600500400300200100
Gain with CLP
Traditional crushing chamber designC
AP
AC
ITY
(T
ON
NE
S/H
R)
OPERATING HOURS
CRUSHER SELECTION QUICK GUIDE
PLAN YOUR OUTPUTYou can only choose the right crusher if you know exactly what you want to achieve. overall profitability depends on the balance between fractions and fines.
Consider this:higher quality means more fines – what balance will give you the best total result?
Production time, energy costs and wear and tear from recirculation all affect your bottom line.
INCREASE REDUCTION OR REDUCE fINES – consider your opTiMal ouTpuT
75 mtph
81 mtph
81 mtph
81 mtph
Feed 5–45 mm
59 mtph
6 mtph
16 mtph
19 mtph13 mtph27 mtph
19 mtph13 mtph27 mtph16 mtph
Stockpile0–2.0 mm
Stockpile2.0–4.0 mm
Stockpile4.0–8.0 mm
Stockpile8.0–11.2 mm
101 mtph
105 mtph
0 mtph 105 mtph
105 mtph
Feed 5–45 mm
82 mtph
3 mtph
19 mtph
26 mtph 19 mtph 37 mtph
26 mtph 19 mtph 37 mtph 19 mtph
Stockpile0–2.0 mm
Stockpile2.0–4.0 mm
Stockpile4.0–8.0 mm
Stockpile8.0–11.2 mm
0 mtph
CH430
Net cap. 75 mtph
Throw: 34 mm
CSS: 9 mm
80% < CSS
73% < 8 mm
92% < 11.2 mm
Reduction: 3.7
CH540
Net cap. 101 mtph
Throw: 48 mm
CSS: 10 mm
91% < CSS
78% < 8 mm
97% < 11.2 mm
Reduction: 4.2
No plastic backing
To illustrate the benefits of optimising your set-up, we compare sandvik’s CH540 and CH430 crushers.
Additional sales generated by the CH540: 26 mtph x 1500 h/year x 8 Euro/ton = €312,000/year
Additional cost CH540 vs. CH430:Investment cost approx. €40,000Cost wear and tear approx. €10,000Energy cost approx. €10,000*
The bottom line:Fast roi and a significant increase in sales. *Annual cost based on Swedish prices
CRUSHER SELECTION QUICK GUIDE
DON’T MISS HIDDEN COSTS Time spent on changing parts during service and maintenance, and the number of people it takes, also affect profitability. premium machines are often designed for easy fitting and maintenance, saving time and costs.
Energy use is also an important factor – new crushers should be equipped with IE3 motors.
PROfITABLE QUARRYING: GET THE BIG PICTUREGreat athletes never stop striving to get closer to perfection. Neither do we. we believe that there is always room for improvement – a tweak here and a tweak there. we’ve always been driven to make better and better equipment. But today, we make an even bigger difference by understanding how the entire process works together.
Time to take a fresh look at your quarry or mobile crusher operation? Contact your local representative or visit crushology.sandvik
A mantle lifting devices is one way to save time and increase safety.