The following presentation examines the adverse effect too many fines have on roller mill production and how pre-screening even small amounts of product sized particles can have a significant impact on mill capacity and ultimately on a producer’s bottom line.

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Corporate Profile
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5. The operating stages in mineral processing
have remained the same for thousands of
years.
Crushing and screening is the first controlled
size-reduction stage in the processing of
industrial minerals.

6. More often than not, size reduction of the
raw material is done in stages and the
material is crushed several times

7. JAW CRUSHER GYRATORY CRUSHER CONE CRUSHER IMPACT CRUSHER
Typical 3-Stage Crushing
Primary/Secondary/Tertiary

8. Primary Circuit:
This is the first crusher in the circuit. It is designed to
reduce the largest particle size received at the highest
capacity.
Secondary Circuit:
This is the second stage crusher which typically has a
primary function of reducing the material for the next
stage of crushing.
Tertiary Circuit:
This is the third stage in crushing. Because gradations are
finer at this stage, the crusher must be more accurate to
settings and screens must be capable of finer screening.

9. Screens are
used at each
step to
separate the
undersized
material from
the oversized
material

10. Size reduction below 5-20 mm moves into a
different category of size reduction referred
to as the grinding stage. Grinding is the
pulverizing or powdering of a mineral.
Quaternary Circuit:
This is the 4th stage of crushing. At this stage, the type of crushers
used in the previous three stages give way to grinding mills.
Examples of this type of mill includes air-swept roller mills,
hammer-mills, and various types of ball mills

11. Crushing of the material over and
over can result in too many fines for
certain types of grinding mills.

12. Roller mills
are
considered
the
industry
standard
for mineral
processing

13. • Soft to medium hard minerals
(typically 5 or less on Mohs scale)
• Typical feed size range of ¼” minus to
1” minus
• Typical product range of 325 mesh to
100 mesh

14. WAYS TO INCREASE ROLLER MILL
CAPACITY
•Improve air classification efficiency
(vertical blade over whizzer)
•Improve feed control system
(keep mill under a constant load)
•Reduce number of rolls in mill
(only an option if you have even number of rolls)
•Increase air flow
(if out of fan rpm’s, tipping fan blades may be an option)
•Reduce amount of fines in roller mill feed

15. The MAX3 Screener
MAXimum Capacity/MAXimum Efficiency/MAXimum Performance
How to cost-effectively reduce
the amount of fines in your feed?

16. APPLICATION
•Grinding Mill – Air-swept Roller Mill
•Material – Soft Mineral
•Product Spec – 97% minus 200 mesh
•Current Capacity – 20 TPH
Existing Problem
•Needed 25% more production from mill
•Already have vertical blade high efficiency classifier
•Already have adequate feed controller
•Fan is already sized correctly
•Mill is a 5 roll (odd number of rolls)

17. SOLUTION
•Remove existing 20 percent of minus 200 mesh from feed
•Install a MAX3 Fine Mesh Screener ahead of roller mill
•Increase material flow in circuit from 20 to 26 TPH
•MAX3 screens out 4 TPH of finished product before it goes to
roller mill
•Roller mill production is increased (minus fines) from 20 to 22
TPH
•Net result - Increased circuit production by 6 TPH (30 percent)

18. Economic Viability
8,760 Operating hours in a year
80% run time –7,008 hours a year
19.2 operating hours per day
Production Increase of 6 tons per hour

19. Simple ROI = Amount of Financial Gain
Total Investment Amount

20. ROI Analysis – Total cost vs. benefit analysis
Direct Costs
Direct – One Time Expenses Costs
1) Testing (travel/expenses)
2) Engineering (40 hrs. @ $125/hr)
3) Procurement (8 hrs. @ $50/hr.)
4) Equipment - MAX3 Screener
5) Additional Equipment needed
6) Shipping (all equipment)
7) Installation Cost (all equipment incl. modifications)
8) Start-Up Assistance (travel/expenses)
TOTAL COST
$1,200.00
$5,000.00
$400.00
$40,000.00
$17,000.00
$5,800.00
$59,500.00
$1,500.00
$130,400.00

21. Increased Capacity Increased Revenue
6 Tons Per Hour $1,800.00 Per Hour
115.2 Tons Per Day $34,560.00 Per Day
3,504 Tons Per Month $1,051,200.00 Per Month
42,048 Tons Per Year $12,614,400.00 Per Year
PRODUCT VALUE- $300/TON
$130,400.00 (Equipment Cost)
$34,560.00 (Revenue Increase Per Day)
$130,400.00 / $34,560.00 = 3.77 days

22. Hypothetical APPLICATION
•Grinding Mill – Air-swept Roller Mill
•Material – Soft Mineral
•Product Spec – 90% minus 100 mesh
•Current Capacity – 30 TPH
Existing Problem
•Need more production from mill
•Already have vertical blade high efficiency classifier
•Already have adequate feed controller
•Fan is already maxed out
•Mill is a 5 roll (odd number of rolls)

23. Hypothetical ROI Analysis
Projected Costs
Direct – One Time Expenses Costs
1) Testing (travel/expenses)
2) Engineering (40 hrs. @ $125/hr)
3) Procurement (8 hrs. @ $50/hr.)
4) Equipment – MAX3
5) Additional Equipment needed
6) Shipping (all equipment)
7) Insallation Costs (all equipment incl. modifications)
8) Start-Up Assistance (travel/expenses)
TOTAL COST
$1,200.00
$5,000.00
$400.00
$55,000.00
$17,000.00
$5,800.00
$59,500.00
$1,500.00
$145,400.00

24. Increased Capacity Increased Revenue
3 Tons Per Hour $240.00 Per Hour
57.6 Tons Per Day $4,608.00 Per Day
1,752 Tons Per Month $140,160.00 Per Month
21,024 Tons Per Year $1,681,920.00 Per Year
PRODUCT VALUE- $80/TON
$145,400.00 (Equipment Cost)
$4,608.00 (Revenue Increase Per Day)
$145,400.00 / $4,608.00 = 31.55 days

25. Efficient fine size reduction
which is often aided through
efficient size separation is
one of the most effective
investments to reduce cost
per ton and increase revenue.

26. Thank you for attending our presentation.