documents.in_general-design-and-sizing-crushers-upc.pdf

5/20/2018 General Design and Sizing Crushers UPC - slidepdf.com
http://slidepdf.com/reader/full/general-design-and-sizing-crushers-upc 1/71

General Design and Sizing of
Comminution Equipment


© Metso
Mining mineral processing circuits and trends
• Presentation Overview:
- Common mining circuits
- Mill designs and their application
- Mining industry trends
- Current mining circuits
- Crushers in future market trends
- What is next?
2
INTERNAL
…….


© Metso
Comminution
Product role
3
- Grinding materials
in horizontal mills
with or without
media dates back
to the late 1800's
- Since that time,
Metso has designed
and manufactured
more than 12,000
grinding mills
1 m 100 mm 10 mm 1 mm 100
micron
10
micron
1
micron
• Crushing and grinding processes liberate valuable minerals
from ores through a series of size reductions


© Metso
Crushing and grinding of ore and minerals
• Rock crushing and grinding is accomplished in stages:
4
–First Stage  Primary Stage of Crushing
–Second Stage Secondary Stage of Crushing / Grinding
–Third Stage Tertiary Stage of Crushing / Grinding
–Fourth Stage Grinding / Finishing Stage
INTERNAL


© Metso
Common mineral processing circuits
• 2 or 3 stage crushing  Rod Mill  Ball Mill  Flotation
• 3 Stage crushing  Ball Mill  Flotation
• Primary Gyratory  Cone  HPGR  Ball Mill  Flotation
• Primary Gyratory  AG Mill  Ball Mill Flotation
• Primary Gyratory  AG Mill  Pebble Mill  Pebble crusher 
Flotation
• Primary Gyratory  AG Mill  Ball Mill Flotation
• Primary Gyratory  SAG Mill  Pebble Mill  Pebble crusher 
Flotation
• Primary Gyratory  Pre- Crusher  SAG Mill  Ball Mill  Pebble
crusher  Flotation
• 3 stage crushing  Heap Leach
5
INTERNAL


© Metso
Application of State of the Art Comminution
Circuit Selection
6
Non Abrasive Abrasive
Fine Coarse Fine Coarse
< 4Mtpa SS SAG
SS AG
3C Ball
SABC
SS SAG/C
SS AG/C
3C Ball
SABC
2C SS SAG
Rod
SS AG
AB
3C Ball
SABC
ABC
APC
SS SAG/C
SS AG/C
2C SS SAG
SABC
2C SABC
ABC
4 < Mtpa <8 SABC
HPGR Ball
2C SABC
SABC
HPGR Ball
2C SABC
SABC
HPGR Ball
2C SABC
ABC
APC
HPGR Peb
SABC
HPGR Ball
2C SABC
ABC
APC
HPGR Peb
> 8Mtpa SABC
HPGR Ball
SABC
HPGR Ball
2C SABC
SABC
HPGR Ball
2C SABC
ABC
HPGR Peb
SABC
HPGR Ball
2C SABC
ABC
HPGR Peb
Source: Putland, B. (2006) “Comminution Circuit Selection – Key Drivers and Circuit Limitations”, SAG 2006, Vol 2. pp 342-355

© Metso
Application of State of the Art Comminution
Circuit Selection
7
Non Abrasive Abrasive
Fine Coarse Fine Coarse
< 4Mtpa SS SAG
SS AG
3C Ball
SABC
SS SAG/C
SS AG/C
3C Ball
SABC
2C SS SAG
Rod
SS AG
AB
3C Ball
SABC
ABC
APC
SS SAG/C
SS AG/C
2C SS SAG
SABC
2C SABC
ABC
4 < Mtpa <8 SABC
HPGR Ball
2C SABC
SABC
HPGR Ball
2C SABC
SABC
HPGR Ball
2C SABC
ABC
APC
HPGR Peb
SABC
HPGR Ball
2C SABC
ABC
APC
HPGR Peb
> 8Mtpa SABC
HPGR Ball
SABC
HPGR Ball
2C SABC
SABC
HPGR Ball
2C SABC
ABC
HPGR Peb
SABC
HPGR Ball
2C SAG + VTM
ABC
HPGR Peb
Source: Putland, B. (2006) “Comminution Circuit Selection – Key Drivers and Circuit Limitations”, SAG 2006, Vol 2. pp 342-355

© Metso
8
HP or MP cones
depending on capacity
BALL MILL
TYPICAL FLOWSHEET
F80 10 – 13mm
Jaw or PG

© Metso
9
Pebble crusher
HP or MP
SAG MILL
TYPICAL FLOWSHEET
SAG
screen
SAG Mill
80%<100 – 150mm
80%<13mm
SAG screen
Typical configuration
• 2 decks
• 2nd deck opening
10 – 13mm
SAG Mill: with/without trommel
Pebble -90+10mm

© Metso
13/09/20
14
10
PEBBLE CRUSHER
Collahausi – Chile
Copper Ore

© Metso
Barrick Veladero and Alto Chicama
Heap Leaching of 2 stages (open circuit)
11
2x XH-2473-2
For 1100t/h each
Open circuit
Recently, we sold a
MF2473-2 for
Veladero plant

© Metso
Cerro Verde, Peru
Flowsheet - Oxides Plant, 3 stages in close circuit
Date Author Title
INTERNAL
12
Allis Chalmers 6089 Nordberg
BS 12’x27’DD
Feed rate: 2000t/h
Nordberg
BS 12’x27’DD
Feed rate: 2000t/h

© Metso
Cerro Verde, Peru
Oxides Plant – BS 12’x27’DD (Banana 1)
Date Author Title
INTERNAL
13
Screen live weight = 26.800kg
Isolation Frame weight = 13.000kg
Total weight = 39.800kg

© Metso
Codelco Gaby, Chile
Flowsheet – Copper Ore
Date Author Title
INTERNAL
14
2x Metso
BS 12’x24’DD
Feed rate: 2150 t/h (each)
4x Metso
BS 12’x24’DD
Feed rate: 1100 t/h
(each)
PG Metso
60110
2x MP100

© Metso
13/09/20
14
15
PROCESOS DE CONCENTRACIÓN
To be possible to the valuable minerals it is necessary that the its
particles are liberated from waste particles. For this liberation
process, crushing and/or grinding processes are utilized.

© Metso
Overview - Crushing
• Primary Mining Crushers
• Secondary Mining Crushers
• Tertiary Mining Crushers
• Application Group Sizing
Techniques
Date Author Title
INTERNAL
16

© Metso
Crusher Examples per Stage
PRI M ARY - 1st Stage
SECONDARY - 2nd Stage
è Jaw Crusher
è Gyratory Crusher
è Horizontal Shaft Impact Crusher
è Twin Shaft Sizer
è Secondary Gyratory Crusher
è Symons Cone Crusher - Standard
è Omnicone Cone Crusher - Standard
è HP Series Cone Crusher – Standard
è MP Series Cone Crusher – Standard
è GP Series Secondary/Tertiary Cone
Crusher
TERTI ARY - 3rd Stage
QUATERNARY - 4th Stage
è Symons Cone Crusher - Short Head
è Omnicone Cone Crusher - Short Head
è HP Series Cone Crusher - Short Head
è MP Series Cone Crusher - Short Head
è GP Series Cone Crusher
è Vertical Shaft Impact Crusher
è Gyradisc Cone Crusher
è HP or MP Series Cone Crusher - Short
Head
è Vertical Shaft Impact Crusher
3

© Metso
Primary Crushers
Date Author Title
INTERNAL
18

© Metso
Required Sizing Information
• Feed Gradation
- Material Top Size or F80 at a Minimum
• Feeding Method
- What type of Feeder if there is one
• Material Information
- Abrasion Index
- Work Index
- Moisture Index
- Clay Content Percentage
• Tonnage
- Instantaneous vs. Average
- Design vs. Nominal
• Product Requirements
- P80
- maximum topsize
Date Author Title
INTERNAL
19

© Metso
Primary Jaw Crusher (Feed Gradation)
• If “Feed Gradation” is not known, then you will need to assume
one.
• Feed “Top Size” will determine the smallest Jaw Crusher that can
be used for the application.
• The gradation will be used to determine how much of the Feed will
need to be crushed by Jaw Crusher and how much will be scalped
before Jaw Crusher.
• Rule of Thumb: Generally you scalp the feed to a Jaw Crusher at
the Closed Side Setting (CSS).
Date Author Title
INTERNAL
20

© Metso
Primary Jaw Crusher (Feed Method)
• Rule of Thumb: Feed to a Jaw Crusher is generally scalped by
removing the “Fines”
- Fines are generally defined as the material less than the CSS
• A vibrating Grizzly Feeder is most often used to scalp material
before the Jaw.
- Pan Feeders and Scalping Screens can also be used
• Rule of Thumb: Feed size approximately 80% of the Gape
- Gape is the distance between jaw dies at the point of entrance of jaw
crusher.
Date Author Title
INTERNAL
21
Gape

© Metso
Primary Jaw Crusher (Material Information)
• Abrasion Index:
- Abrasion Index has no impact on the Jaw Crusher Selection. It is only
used to determine “Liner Life”.
• Work Index:
- Work Index is used to determine the minimum CSS. If compressive
strength of material is over 60,000 PSI (415 MPa) Consult Factory to
determine if a jaw can be used.
• Moisture / Clay content
- Effect of moisture is usually minimal up to 5-8%.
- Clay in conjunction with moisture can affect the crusher throughput
Date Author Title
INTERNAL
22

© Metso
Primary Jaw Crusher (Tonnage)
• Instantaneous Tonnage:
- Instantaneous tonnage is the theoretical maximum tonnage that the crusher
can handle
• Average Tonnage:
- Average Tonnage is the tonnage that the crusher can handle over a long
period of time.
• The instantaneous tonnage is always higher than the Average
tonnage.
- AVERAGE TONNAGE = (0.8) x Instantaneous Tonnage
• Design Tonnage = Instantaneous Tonnage
• Average Tonnage = Nominal Tonnage
Date Author Title
INTERNAL
23

© Metso
Primary Jaw Crusher (Product Size)
• Rule of Thumb: The “Top Size of the product from a Jaw Crusher
is generally 1.6 times the CSS.
- i.e. CSS of Jaw Crusher is 100mm -> TopSize of Product = approx. 160mm
• Rule of Thumb: Depending on material a jaw will produce about
70% passing the CSS on average.
• Typically the CSS will depend on the opening of the following
crusher and Reduction Ratio (RR).
- Maximum RR for Jaw Crusher is 10:1
Date Author Title
INTERNAL
24
80
80
R P
F
Ratio
eduction 

© Metso
Primary Jaw Crusher
Sizes, Feed Openings, Capacities and Settings
A
B
Crusher
Feed Opening
(A x B)
maxstone Capacities Settings
mm mm MTPH mm
C80 510 x 800 410 55 - 335 40 - 175
C100 760 x 1000 610 125 - 490 70 - 200
C96 580 x 930 465 105 - 390 60 - 175
C106 700 x 1060 560 150 - 500 70 - 200
C116 800 x 1150 640 165 - 520 70 - 200
C3054 760 x 1375 608 210 - 670 70 - 200
C110 850 x 1100 680 160 - 555 70 - 200
C125
950 x 1250 760 245 - 755 100 - 250
C140 1070 x 1400 860 325 - 840 125 - 250
C145 1100 x 1400 900 335 - 950 125 - 275
C160 1200 x 1600 960 430 - 1145 150 - 300
C200 1500 x 2000 1200 630 - 1435 150 - 300

© Metso
Primary Jaw Crusher Sizing Example
Date Author Title
INTERNAL
26
•
Information from Customer
- 900 MTPH Design into Primary Station
- Top Size: 700mm Medium Gradation
- Using Vibrating Grizzly Feeder
• Crusher’s CSS = Primary Scalper Cut Size
• 440 MTPH go to crusher
- Very Abrasive
- Minus 240mm product
- Bulk Density = 1.6 mt/ m3
• WHAT SIZE JAW CRUSHER TO APPLY?
• WHAT SETTING IS THE JAW SET AT?
• WHAT IS THE REDUCTION RATIO?

© Metso
Primary Gyratory Crusher – Required Sizing
Information
• Feed Gradation
- Topsize determines feed opening required
- Feed topsize should be maximum of approximately 80% of feed opening
- F80 is a feed parameter that determines the fines correction factor
- Percentage of material in feed less than ½ the CSS is a feed parameter that
determines the “fines correction factor”
• Bulk Density
- TPH throughput is directly proportional to bulk density
• Work Index
- Power draw directly proportional to work index and this could dictate machine
selection if Work Index is high
- High Work Index materials may require special chamber design to limit power
draw.
Date Author Title
INTERNAL
27

© Metso
28
SUPERIOR
Product Line
Current MK-II Model Sizes
• 42-65 and 50-65 = 375kW
• 54-75 and 62-75 = 450kW
• 60-89 = 600kW
• 60-110 = 1000kW
• 60-110E = 1200kW
• Basically 4 head sizes, with SUPER SPIDER
upgrades creating the other 2 increased feed
opening versions.
• Product Naming
- 1st number = feed opening in inches
- 2nd number = mantle diameter in inches

© Metso
29
Primary Gyratory Crusher Application
• Material flows through chamber because of effect of gravity
• The geometry of the mantle and concave determine the volume of
material that will flow through the chamber
• The larger the diameter of the machine (mantle diameter) the more
volume of material will flow through the chamber
• Volumetric throughput is also directly proportional to operating speed
(gyrations per minute)
• Volumetric throughput varies with the throw of the crusher (a larger
throw allows a larger volume of material to flow through the chamber)
• Volumetric throughput varies with discharge opening (a larger OSS
results in a larger volume of material flowing through the crushing
chamber)
GYRATORY crusher is a “volumetric” machine

© Metso
30
Primary Gyratory Crusher Application
• Feed gradation
- Topsize determines size of feed opening required
- Feed topsize should be maximum of approximately 80% of feed
opening
- F80 is a feed parameter that determines the “fines correction factor”
- Percentage of material in feed less than 1/2 the CSS is a feed
parameter that determines the “fines correction factor”
• Bulk Density
- TPH throughput is directly proportional to bulk density
• Work Index
- Power draw directly proportional to work index and this could dictate
machine selection if Work Index is high
- High Work Index materials may require special chamber design to limit
power draw
Information needed to properly select a gyratory
crusher for a specific application

© Metso
Primary Gyratory Power Calculation
• Standard Bond Power Calculation used for Gyratory Crusher
Date Author Title
INTERNAL
31






















80
1
80
1
10
F
P
WI
W
Where:
W = Specific Energy Consumption (kW-hr/MT)
WI = Metric Bond Work Index (kW-hr/MT)
P80 = Square opening through which 80% of the product will pass (microns)
F80 = Square opening through which 80% of the feed will pass (microns)
75
.
0
Re 

 VC
W
kW
quired
Where:
W = Specific Energy Consumption
VC = Volumetric Capacity of Crushing Chamber
0.75 = Correction Factor Used for Primary Crushing

© Metso
Primary Gryatory (Volumetric Capacities)
Date Author Title
INTERNAL
32
MACHINE 140 150 165 175 190 200 215 230 240 255
42-65 1110 1254 1315 1467
50-65 1238 1342 1520 1568
54-75 1501 1669 1720 1786 1831
62-75 1499 1864 1953 2136 2186
60-89 2421 2560 2807 2869 2941 3035
60-110E 3157 3876 4011 4062 4300 4458 4500
SUPERIOR MK-II PRIMARY GYRATORY CRUSHER
VOLUMETRIC CAPACITIES (MTPH)
OPEN SIDE SETTING (mm)

© Metso
Primary Gyratory Power Example
• PG 54-75 with a 150mm OSS
• Work Index = 22.5 kW-hr/mt
• F80 = 500mm = 500000 microns
• P80 = 133 mm =133000 microns
Date Author Title
INTERNAL
33





 















80
1
80
1
10
F
P
WI
W























500000
1
133000
1
5
.
22
10
3
.
0 tonne
hr
kW
75
.
0
Re 

 VC
W
kW
quired
75
.
0
1501
3
.
0
338 


 MTPH
tonne
hr
kW
kW

© Metso
Primary Gyratory Additional Variables
• Moisture / Clay content
- Effect of moisture is usually minimal up to 5-8%.
- Clay in conjunction with moisture can affect the crusher throughput
• Desired Product Size
- Determines the required operating OSS and therefore affects the size of the
crusher selected.
• Desired Capacity
- In conjunction with product size will determine the crusher size and throw
required
• Abrasion Index
- Will not directly affect crusher size selection but may affect wear life of liners
- Will also affect the material selection of concaves. (Manganese vs. Alloy)
Date Author Title
INTERNAL
34

© Metso
Primary Gyratory
• Rule of Thumb: Depending on the material, a gyratory will
produce about 85% passing the OSS.
• Rule of Thumb: With a project lifetime of 10+ years and an
instantaneous design tonnage of greater than 1200 mtph a
primary gyratory is generally more.
• Rule of Thumb: Generally, the topsize of the product out of a
Primary Gyratory is twice the OSS.
Date Author Title
INTERNAL
35

© Metso
Primary Gyratory Settings and Capacities
Date Author Title
INTERNAL
36
Size
Feed
Opening
mm (in.)
Max
Stone mm
Max kW
(HP)
125mm 140mm 150mm 165mm 175mm 190mm 200mm 215mm 230mm 240mm 250mm
42-65 1065 852 375 2010 2335 2515 2870
50-65 1270 1016 375 2395 2780 2935
54-75 1370 1096 450 2885 2985 3145 3335 3485
62-75 1575 1260 450 2890 3615 3815 4205 4330
60-89 1525 1220 600 4195 4540 5080 5295 5530 5805
60-110 1525 1220 1000 4730 5935 6270 6470 7075 7345 7595
60-110E 1525 1220 1200 5535 6945 7335 7570 8280 8595 8890
Open Side Settings of Discharge Opening - Millimeters
The above capacities are based on an assumed feed where 100% of the feed passes
80% of the feed opening, 80% of the feed passes 60% of the feed topsize, and 50%
of the feed passes a sieve size that is 10% of the feed topsize. Capacities are for
feed materials with a bulk density of 1.6 metric tons per cubic meter. All capacities
are calculated at maximum throw. Material characteristics, feed size distrib ution ,
wo rk index, percent m oistu re, and feed m ethod are all factors wh en
con sidering total crush er capacity.

© Metso
Primary Gyratory Crusher Sizing Example
Date Author Title
INTERNAL
37
• Information from Customer
- 3680 MTPH Nominal into Primary Station
- Top Size: 1150mm Fine Gradation
- Method of Feeding: Truck Dump
- Very Abrasive
- P100 = 360 mm
- 3% moisture
- WI: 15 kW-hr/metric tonne
- Bulk Density = 1.7 mt/ m3
• WHAT SIZE PG CRUSHER TO APPLY?
• WHAT SETTING IS THE PG SET AT?
• WHAT IS THE REDUCTION RATIO?

© Metso
Secondary Mining Crusher
Date Author Title
INTERNAL
38

© Metso
Secondary Required Sizing Information
• Feed Gradation
- Material Top Size along with Feed Gradation
- Type of Material
- Bulk Density or Specific Gravity
- Abrasion Index
-
Work Index
- Moisture Content Percentage
• Tonnage
- P80
- maximum topsize
Date Author Title
INTERNAL
39

© Metso
Feed Gradation
• What is the maximum average feed
size of the material that is supposed to
be crushed?
- c x b x a. Middle dimension is the size used
to size crushers.
- Generally if a rock is classified as a 25mm
rock the dimensions are: 40mm x 25mm x
15mm
• The maximum average feed size sets
limits to the cone crushers that can be
used.
Date Author Title
INTERNAL
40

© Metso
Material Information
• What are the material characteristics, crushability,
abrasiveness, density.
• Red Book correction figures needs to be used if the material
characteristics differ from the material used in the
calculations.
- Clean, medium hard granite, bulk density 1.6 t/m^3
• Material Tests can be performed to define Work Index,
Abrasion Index, Bulk Density, or crushability.
• These material characteristics set limits to the settings that
can be used.
• The material characteristics, especially feed gradation, have a
significant effect on capacity and product gradation
Date Author Title
INTERNAL
41

© Metso
Product Requirements
• What is the desired product size and capacity?
• The closed side setting is determined by the product size.
- Rule of Thumb: For cones the topsize of the product is approximately twice
the CSS.
• The product size percentages with a certain CSS can be
estimated from your Bruno software or product gradation table
• Many times the crusher and crusher’s setting are based off the
product being sent “As Feed” to the next stage of crushing or
grinding.
Date Author Title
INTERNAL
42

© Metso
Secondary
HPX00’s Settings
Date Author Title
INTERNAL
43
Note:
The minimum setting is that
at which the crusher will
operate without causing
ring bounce. Depending on
the crusher characteristics
of the rock, this can
change.

© Metso
Secondary HPX00 Capacities
Date Author Title
INTERNAL
44
Represents capacity through crusher based on instantaneous product sample

© Metso
Secondary HPX Settings and Capacities
Date Author Title
INTERNAL
45
NOTE: Closed Side Feed Opening = Maximum stone size into crusher.

© Metso
Secondary GPX00S Settings and Capacities
Date Author Title
INTERNAL
46
   G
   P
   5
   0
   0
   S
   G
   P
   3
   0
   0
   S
   G
   P
   2
   0
   0
   S
   G
   P
   1
   0
   0
   S
Capacity and minimum setting figures are indicative for materials with bulk density of 1.6t/m3. Actual results will vary
depending on feed grading, rock type, moisture, etc.

© Metso
Secondary GP’s Nominal Feed Opening
Date Author Title
INTERNAL
47
Cavities: M = medium, C = Coarse, EC = Extra Course

© Metso
MP’s Settings and Feed Size Restrictions
Date Author Title
INTERNAL
48
Notes:
• Maximum Stone the crusher is able to accept = 80% of Maximum Feed Opening (B)
• MP1250 has same Settings and Feed Restrictions as the MP1000 in Standard Configuration.

© Metso
MP Gradation and Capacity Charts
Date Author Title
INTERNAL
49
The capacity figures above apply to material with a bulk density of 1.6 mt/m3. Factors that will detract from
capacity are: Sticky Material, Excessive Fines, Excessive Moisture, Feed Segregation, Improper Feed
Distribution, Lack of Feed Control, Insufficient Crusher Discharge Area, Extremely High Crushing Work Index.

INTERNAL

© Metso
Secondary Cone Crushers - MP / HP
• Rule of Thumb: Approximately 65% - 80% of the material coming
out of an MP or HP Series Standard Cavity will be passing its
CSS dimensions
- Note: As long as the Cone Crusher is Choke Fed.
• Reduction Ratio: In a secondary application or in a Standard
Crusher configuration the maximum Ratio of Reduction should
not exceed 6:1 to 8:1.
• Normally this Secondary Crusher produces products larger than
1” and prepared material for the next stage of crushing.
• For HP4 and HP5 there is no Standard and Shorthead
Differentiation.
- Closed Side Feed Opening = Maximum stone size into crusher.
Date Author Title
51

INTERNAL

© Metso
Secondary Cone Crusher Sizing Example
• Design Parameters
- Design Capacity: 2200 MTPH
- Feedsize:
• F100 = 300 mm, F80 = 185 mm
- A Bulk Density of 1.70 t/m3
- Assumed Crushing Work Index of 19.0 kW-hr/mt
- Moisture = 3%
- Product:
• P100 = 135 mm
• P80 = 75 mm
• What is the Size of the Secondary Crusher?
• What is the Setting the Crusher is Operating?
• What is the Reduction Ratio?
• What Liner Configuration is in this Crusher?
Date Author Title
52

INTERNAL

© Metso
Tertiary Required Sizing Information
Date Author Title
54
• Feed Gradation
- Material Top Size along with Feed Gradation
- Type of Material
- Bulk Density or Specific Gravity
- Abrasion Index
- Work Index
- Moisture Content Percentage
• Tonnage
- P80
- maximum topsize
Note: Same as Secondary

INTERNAL

© Metso Date Author Title
55
Note:
The minimum setting is that
at which the crusher will
operate without causing
ring bounce. Depending on
the crusher characteristics
of the rock, this can
change.
Tertiary
HPX00’s Settings

INTERNAL

© Metso
Tertiary HPX00 Capacities
Date Author Title
56
Represents capacity through crusher based on instantaneous product sample

INTERNAL

© Metso
Tertiary HPX Settings and Capacities
Date Author Title
57
NOTE: Closed Side Feed Opening = Maximum stone size into crusher.

INTERNAL

© Metso
MPX00 Settings and Feed Size Restrictions
Date Author Title
58
Notes:
• Maximum Stone the crusher is able to accept = The Closed Feed Opening (A)
• MP1250 has same Settings and Feed Restrictions as the MP1000 in Shorthead Configuration.

INTERNAL

© Metso
MP Gradation and Capacity Charts
Date Author Title
59
The capacity figures above apply to material with a bulk density of 1.6 mt/m3. Factors that will detract from
capacity are: Sticky Material, Excessive Fines, Excessive Moisture, Feed Segregation, Improper Feed
Distribution, Lack of Feed Control, Insufficient Crusher Discharge Area, Extremely High Crushing Work Index.

INTERNAL

© Metso
Tertiary Cone Crushers
• Rule of Thumb: Approximately 75% - 85% of the material coming
out of an MP or HP Series Short Head Cavity will be passing its
CSS dimensions
- Note: As long as the Cone Crusher is Choke Fed.
• Reduction Ratio: In a tertiary application or in a Shorthead Crusher
configuration the maximum Ratio of Reduction should not exceed
4:1 to 6:1
• Normally this Tertiary Cone Crusher produces products smaller
than 1” and generally produces the desired end product.
• For HP4 and HP5 there is no Standard and Shorthead
Differentiation.
- Closed Side Feed Opening = Maximum stone size into crusher.
Date Author Title
61

INTERNAL

© Metso
Tertiary Cone Crusher Sizing Example
• Design Parameters
-
Design Capacity: 400 MTPH
- Feedsize: Copper Ore
• F100 = 102 mm, F80 = 39 mm
- A Specific Gravity of 2.70 t/m3
- Assumed Crushing Work Index of 14.5 kW-hr/mt
- Moisture = 3%
- Product:
• P100 = 28 mm
• P80 = 14 mm
• What is the Size of the Shorthead Crusher?
• Determine the operating CSS?
• What is the Reduction Ratio?
• What Liner Configuration is in this Crusher?
Date Author Title
62

INTERNAL

© Metso
Applications Group Sizing Techniques
• Bruno for initial Design requirements and general outputs
• Gyratory Sizing Spreadsheet
• Empirical Crusher Database for Confirmation
Date Author Title
63

INTERNAL

© Metso
Bruno
• Crushers based off of crushing models developed.
• Screen models based off of basic VSMA (Vibrating Screen
Mechanism) calculations
• Flow sheet is all calculated off of mass flow balance
• Standard Inputs
- Feed Gradation
- Material Properties
• Standard Outputs
- Equipment Loads
-
Product Gradations
- Mass Flow Rates
Date Author Title
64

INTERNAL

© Metso
Bruno Updates
• Gyratory 110E is now in Bruno and we’re continually updating
Bruno to accurately forecast its capacities and gradations
• MP1250 will be in the next update of Bruno.
• We are continually updating Bruno to accurately forecast the MP
product lines capacities and capabilities.
• Mining Screen calculations are currently being updated to more
accurately represent VSMA calculations (MF, RF, LH)
Date Author Title
65

INTERNAL

© Metso
Gyratory Sizing Spreadsheet
Date Author Title
66
Consists of a number of
dropdown menus and
numerical inputs.
Actual Inputs into
Spreadsheet are:
1. Superior Crusher Type
2. Throw
3. Setting
4. Material Type
5. % Passing ½ of CSS
6. F80
7. Moisture Content
8. Bond Crushing WI
9. Bulk Density
10. Abrasion Index

INTERNAL

© Metso
Empirical Database
• Looks up empirical values by applying filters to distinct sets of
criteria. (Access Based Application)
- Primary, Secondary, Tertiary
- Crusher Type (i.e. MP, HP, Gyratory)
- Crusher Size (i.e. MP800 vs. MP1000)
- Settings
• CSS or OSS
• Throw
- Capacities
- Material Characteristics
• Material Type
• Moisture Content
• IC Work Index
• Cavity Level: (Choked, Low, Full, Medium)
• Bulk Density or Specific Gravity
• Feed Gradation and Product Gradation
Date Author Title
68

INTERNAL

© Metso
• Every Line item has an Application Data Sheet that the Database
was developed from. These sheets are linked to each Application.
Empirical Database - Cont
Date Author Title
69

INTERNAL

Questions? Comments?
Thank You!

documents.in_general-design-and-sizing-crushers-upc.pdf

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to documents.in_general-design-and-sizing-crushers-upc.pdf

Similar to documents.in_general-design-and-sizing-crushers-upc.pdf (20)

More from JeanClaudeEid1

More from JeanClaudeEid1 (6)

Recently uploaded

Recently uploaded (20)

documents.in_general-design-and-sizing-crushers-upc.pdf