Sandvik 12WET 25-04-2012

Mobile Crushing and Screening
g
Sales Training
Raw Materials
Sandvik Construction
Sales Training
Raw Materials
Raw Materials
General Types
Raw Materials
Species of Rock - Sedimentary
Raw Materials
Species of Rock - Igneous
Surface – fine grained Basalt
Intrusive – medium grained Diabase
Deep – coarse grained Gabbro
Raw Materials
Species of Rock - Metamorphic
Metamorphic are rocks that are transformed in the Earth
Earth’ss crust due to
increased pressure and temperature
Limestone Marble
Granite Gneiss
Raw material
Classification of Rocks
Sedimentary Igneous Metamorphic
Clastic Chemical Biologic Intrusive Extrusive Foliated Non-Foliated
Limestone
Dolostone
Evaporites Gabbro Basalt Slate Quartzite
Diorite Andesite Schist Marble
Conglomerate Coal Grandiorite Dacite Gneiss
Breccia Chert Granite Rhyolite
Sandstone
Siltstone
M d
Mudstone
Shale
Raw Materials
Impact Work Index Wi
Raw Materials
Impact work Index, Wi
I
Impact
t Work
W k Index
I d (WI) Description
D i ti off C
Crushability
h bilit
<10 Very Soft
10-14 Soft
14-18 Medium
18-22 Hard
22-26 Very Hard
>26 Extremely Hard
Raw Material
Abrasion index, Ai
Raw Material
Abrasion index, Ai
Abrasion Index (AI) Description of the Wear
< 0.1 Very low wear
0.1 – 0.2 Low wear
0.2 – 0.4 Intermediate wear
0.4 – 0.6 Normal medium wear
0 6 – 0.8
0.6 08 High wear
> 0.8 Extremely high wear
Raw Material
Average Results
Compressive
Material WI AI
strength (Mpa)
Amphibolites 16 0.4 200 - 300
Andesite 16 0.5 170 - 300
Basalt 20 0.25 300 - 400
Diabase 18 0.28 250 - 350
Dolomite 12 < 0.02 50 - 150
Diorite 19 0.4 170 - 300
Gabbro 21 0.4 200 - 350
Geywacke 18 03
0.3 150 - 300
Raw Material
Average Results
Compressive
W
Material AI strength
I
(Mpa)
Gneiss 16 0.48 200 - 300
Granite 16 0.46 200 - 300
Limestone 11 < 0.01 80 – 180
Marble 12 < 0.02 100 - 200
Quartzite 16 0.75 150 - 300
Sandstone 10 0.75 30 - 150
Iron ore (Hematite) 11 0.5 100 - 200
Iron ore
8 0.2 50 - 150
(Magnetite)
Art of Crushing
Reduction Ratio
Normal reduction (average):
− Jaw crusher 2- 4
− Gyratory crusher 3- 4
− Cone crusher 3- 5
− Impact crusher (VSI) 4- 6
− Impact crusher (HSI) 7- 10
Art of Crushing
Reduction Ratio
2-Stage Impact Plant:
10 x 7 = 70
Ok, Only for Ai <0.15
Using reduction ratio to predict
the amount of crushing stages
− Feed = 600mm 2-Stage Jaw / Cone Plant:
− Product = 22mm 3 x 4 = 12
NOT OK
− Min required plant reduction
ratio: 600/22 = 27
3-Stage Jaw / Cone Plant:
3 x 4 x 4 = 48
OK
Mobile crushing and screening
P d t Training
Product T i i
Jaw Crusher
Working Model
Jaw Crushers
Sizes
UJ640 - 1500 x 1100mm

− CJ615
UJ540
J - 1200 x 1100mm
− CJ612
UJ440 - 1200 x 800mm
− CJ412
QJ341 - 1200 x 750mm
− C12+
QJ331 - 1100 x 700mm
− CJ211
QJ241 - 1000 x 650mm
− C10+
Jaw Crushers
Capacities MTPH
CSS (mm) 125 150 175 200 225

UJ640 385-495 445-590 505-665 570-745 630-825
CSS (mm) 125 150 175 200
UJ540 300-395 355-465 405-530 455-595
CSS (mm) 75 100 125 150 175 200
UJ440 165-220 220-290 270-355 325-430 385-505 445-580
CSS (mm) 50 75 100 125 150 175
QJ341 95-140 120-190 160-265 195-325 230-390 265-450
CSS (mm) 40 50 75 100 125 150 175
QJ331 80-110
80 110 95 135 120-180
95-135 120 180 160 250
160-250 195 310
195-310 230 370
230-370 265 430
265-430
CSS (mm) 50 75 100 125
QJ241 85-115 110-160 140-215 170-270
Jaw Crushers
Features
Nipp Angle
g
Width
Gape
Heavy Duty Deflector Plate
Flywheel
Jaw Crushers
F t
Features
Hydraulic Setting Regulation

Wedge System
Depth of Jaw Box
Jaw Crushers
Features
Heavy Duty Cartridge style

bearing arrangement
Eccentric Shaft
P d t Training
Product T i i
Cone Crushers
Working Model
Cone Crushers
Sizes
UH640 - 500mtph
− CH660
US440i - 500mtph
− CS440
UH440i - 350mtph
− CH440
QH440 - 388mtph
- CH440
QH331 - 220mtph
− CH430
Sandvik Cone Crusher
Features
Spider Bearing
Top Shell
Crusher Liners
Main Shaft
D t SSeall Ring
Dust Ri
Bottom Shell
Eccentric Assembly
Pinion Shaft
Step Washer Assembly
Hydroset
y Piston
CH430 Cone Crusher
Top Shell Breakdown
Spider Cap Top Bushing
Arm Shield
Top
p Shell
Ring
Air Filter
Grease Nipples
Filler Ring
Sealing Compound
Concave Ringg
CH430 Cone Crusher
Filler Ring
There aare two different
filler rings available
depending on the type of
concave liner fitted
An “M” filler ring is used
on the F,MF and M
concave liner
An “C” filler ring is used
on a MC and d C concave,
For the EC concave
there is no filler ring
fitted
Reduction 4:1
CH430 Cone Crusher
Maximum Feed Size
The EExtra
Th t C Course The Medium Course
manganese can manganese can
accept a feed size of accept a feed size of
160 - 185mm 105 - 115mm
Product size 40- Product size 26-
EC MC
47mm 29mm
The Course The Medium

manganese can manganese can
accept a feed size of accept a feed size of
130 - 145mm 80 - 90mm
C M
Product size 32- Product size 20-
36mm 22mm
CH430 Cone Crusher
Maximum Feed Size
The M
Th Medium
di Fine
Fi
manganese can accept
a feed size of 70 -
75mm
MF Product size 17-19mm
The Fine manganese

can accept a feed size
of 45 - 50mm
P d t size
Product i 11-13mm
11 13
F
Sandvik Cone Crushers
CLP
CL P
Constant Liner Performance
Ch b
Chambers by
b Sandvik
S d ik
CLP
Sandvik Cone vs Spiderless Design
new liner worn: 50mm new liner worn: 50mm

opening: 385mm opening: 380mm opening: 335mm opening: 235mm
css: 40mm css: 40mm css: 40mm css: 40mm
Change in opening: -5mm Change in opening: -100mm

9Smaller intake 9Working Pressure Increases
9Lower capacity 9Restricted CSS Ability
9Shorter mantle life
Production Gains
CLP
(Tonnes/Hr) 160
140
Gain with
120
CLP
100
80
Capacity
60
40
C
20
0 With CLP Chamber

0
100 Without CLP Chamber
200
300
400
500
600
700
Operating hours
CH430 Cone Crusher
Throw Adjustment
The QH331 will be fitted as standard Throw Recess
with a bush that has the following throws
available
22/29
22/29mm with
ith a EC chamber
h b
29/32/36 with a MF chamber
Throw Indicator Location Key
To change the throw remove the bush

by lifting it out then moving location
key to the corresponding throw mark
on the
h bush
b h
Throws Then lower the bush back down lining
Available the keyy upp with the recess
Cone Crusher
CSS Adjustment
CSS is controlled by the Hydroset

To close the CSS oil is pumped under
the piston
To open the CSS oil is returned to the
tank
Cone Crusher
Over Load Protect
When an uncrushable piece of

material enters the crushing chamber,
an increase in pressure causes the
shaft to drop increasing the CSS and
automaticallyy allows the material to
pass through. Once the pressure has
equalised then the shaft will return to
the original
g position.
p
P d t Training
Product T i i
Impactor
Working Model
Impact Crushers
Sizes
QI440 - 500mtph
− CI322
QI340 - 200mtph
− Hazemag
QI240 - 300mtph
− CI411
Impactor
F t
Features
Pivot Frame
First Curtain
Curtain Liners
Second Curtain
Frame Liners
Hammer
Rotor
Fixed Frame
HSI
Product Control
Positioning of the first curtain depends
upon the maximum feed size of the
feed material (larger feed size =
larger opening).
opening)
Positioning of the second curtain,
depends upon the P80 / P90
requirement of the crusher
discharge.
P80 / P90 refers
to the crusher dischargeg
gradation having 80 / 90%
below the required product top size.
Adjust the feed material flow to
maintain even feed (across the whole width of the rotor) into the crusher and
ensure that maximum power available is not exceeded.
HSI Primary Curtain
Adjustment
HSI Primary Curtain
Adjustment
HSI Secondary Curtain
Adjustment
HSI Secondary Curtain
Adjustment
HSI Curtains
Movement during crushing
HSI
General points
Both the first and second curtain should only lift (release
pressure) intermittently during normal operation.
If the
th first
fi t and
d second
d curtains
t i are lifting
lifti regularly
l l (often),
( ft )
then check the power draw of the motor. If excessive, slow
the feed rate to the crusher.
P d t Training
Product T i i
Choose the right crusher
Applications
Feed
Points to Consider
Feed
− Top size
− Throughput Machines
Machines and processes
&
− What machines
− What processes
Processes
Products
− Required output
Products
JAW
Advantages
− Low fuel consumption,
consumption
− Large feed size
− Overload system,
− Excepts all types of feed material,
− Low wear rate
IMPACTOR
Advantages
− High production
− High reduction ratio
− Quality product
− Large amount of fines
− Good wear rates on non-abrasive
materials
CONE
Advantages
− Good Product Quality (Shape)
− Overload System
− Can accept
acce t most feed material
− Good reduction ratio
− Large range of feed openings
− H hl flexible
Highly fl bl machine
h
− Automation enables the crusher
performance to be maximised
Basic Crushing and Screening
General Comparison
Impact Crusher
− High
g reduction ratio
− Low Investment
− Higher wear cost
− Max AI = 0.15
0 15
ent + Wear)
al Cost
JJaw/Cone Crusher
(Investme
− Low reduction ratio Tota
− Larger Investment
− Low
L wear cost
Production (tons)
P d t Training
Product T i i
Sizing Screen
Video
Vid
Scalping Screen
Video
Vid
Scalping Screens
Sizes
QE140 - 2.5m x 3.5m

QE340 - 1.4m x 4.2m
QE440 - 1.75m x 5.5m
Sizing Screens
Sizes
QA140 - 1.5m x 3.0m

QA331 - 1.5m x 4.2m
QA340 - 1 5 x 55.0m
1.5m 0
QA430 - 1.5m x 5.45m
QA440 - 1.5m x 6.0m
QA450 - 1.5m x 6.0m TD
Screening
g
Examples
Open
p Circuit Close Circuit
Screening Examples
Open Circuit
Open Circuit
− Screening ahead of crusher avoids
packing
− Less wear
ear in crusher
cr sher
− Higher total capacity
− The product is controlled by the
screening cloth and the setting of
the crusher
Screening Examples
Close Circuit
Closed Circuit
− Calibrated product
− Higher reduction ratio
− Better cubical shape
− More machines
− L
Lower capacity
i
P d t Training
Product T i i
Screening Media
Selection
H
How do
d we chose
h the
h correct screen media
di
Firstly we need to know what types of media their are and
how do then work?
Secondly we have to know what type of material we must
screen, sandy?
y Sticky?
y Wet? Clay?
y Or?
Thirdly we need to know of any impurities or foreign
objects in the material (recycling)
Fourthly the moisture content in the material.
Fifthly what production is required and how much
percentage is need in which fractions?
Types
p of Screeningg Media
Piano wire, harp
The piano wire also know as the

h
harp screen is the
h best
b type off media
d
for fine material like sand, also good
when the material is very damp. Its
not good when you are trying to
produce high quality products like
chips, edle split. Has a good screen
thorughput
g p due to around 85%
screening area and 15% screening
media area.
Types
S Harp or diamond
S harp media, or diamond media is good

for fine and high quality materials like
chippings or edle split. They are better
than square mesh as they do not blind
so qquickly,
y, the material can have a
certain amount of moisture and they are
self cleaning screens. Good production
due to 70% screeningg area, are more
expensive.
Types
p of Screening
g Media
Elongated mesh
Elongated Mesh.
Mesh This media is good in
fine to medium fine types of material
that have a medium to high content of
moisture, ggood for earth, compost
p or
sticky types of material. They are a good
option but not for the high quality types
of materials, like chippings or close
graded
d d types
t off products
d t
Types
p of Screening
g Media
Square mesh
Woven mesh or square mesh. Very

good for high quality types of material
chippings edle split or top deck
protection screen. Big problems with
sticky wet material in bottom deck area
size less than 15mm. On bottom deck
small sizes 15mm and below low screen
throughput
g p onlyy around 40 to 50%
screening area.
Types
p of Screening
g Media
Punch plate
Punch pplate made of hardox,, good

g on
scalping screens on the top deck, good
for water protection stone production,
veryy strong.
g Can have problems
p on
material pegging and when there are a
lot of fines are in the feed material.
Types
p of Screening
g Media
Rubber screens
Rubber screens, usually the same as

square mesh are good for top deck and
on high abrasion types of material 10 x
life time compared to metal screens but
are also more expensive. Good on
washing
h off sandd & gravel,l not good
d on
bottom deck fine material, loss of
screening area due to more rubber
b i needed,
being d d only
l 40% off screen area
available, good in same material type of
application.
Types
p of Screening g Media
Finger or cascade
Finger screens, or cascade screens are

normally in the bottom deck, of
scalpers, also known as self cleaning
screens. Very good for very sticky
materials with low qqualityy needs and
size, compost, earth, clays and also in
recycling where foreign objects are
found like pplastics and other items. We
have not fitted this media to other
machines so far.
Types
Heavy duty tines
These types of screens are found on the

top deck scalping units, they are very
good for handling large and heavy object
up to 500mm and very good in recycling
and very sticky materials. Excellent
production due to very much open area.
Types
Polyurethane
These types off screens are very

Th
good in washing applications also
very good on high abrasion types of
material due to long wear life.
material, life Not
good in bottom deck when dry
screening 15mm and less size
material due to the less than 50%
open screening area.
Screening
g Media
Selection Issues
Woven wire or square mesh blocking up and blinding, better would

be a piano wire of maybe elongated. Problem is if we are making
chippings we would not get the quality needed, in this case try S.
harp or diamond screen
Screening
g Media
Selection Issues
This is showing what happens when a screen starts to blind, in this case we
can try a non stick type of material like stainless steel screens or use a
hitting system, this a cage under the screen cloth with rubber balls that hit
the piano wires cleaning them, this is not available from Sandvik but can be
retro fitted by a service company who offer this.
Screening Media
S l i Issues
Selection I
Over loaded screen mesh no productivity and over run into the next
material, this can be due to damp and sticky material, in this case try Piano
wire or elongated, also slow down the feed to the screen and try to put
the screen into a steeper angle, this will help on piano wire as the steeper
angel will make the screen cut into the material.
P d t Training
Product T i i
Examples of Application
Single Stage Jaw Crushing
Examples of Applications
Two Stage Jaw / Cone Crushing
Three Stage Jaw / Cone Crushing
Single Stage Impactor Crushing
Application Examples
Open Circuit Screening
Closed Circuit Screening
Your p
partner in
construction
96 Sandvik Construction

Sandvik 12WET 25-04-2012

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Mobile Crushing and Screening

 Surface – fine grained Basalt

 Intrusive – medium grained Diabase

 Deep – coarse grained Gabbro

Sedimentary Igneous Metamorphic

Clastic Chemical Biologic Intrusive Extrusive Foliated Non-Foliated

<10 Very Soft

22-26 Very Hard

>26 Extremely Hard

< 0.1 Very low wear

0.1 – 0.2 Low wear

0.2 – 0.4 Intermediate wear

0.4 – 0.6 Normal medium wear

> 0.8 Extremely high wear

Amphibolites 16 0.4 200 - 300

Andesite 16 0.5 170 - 300

Basalt 20 0.25 300 - 400

Diabase 18 0.28 250 - 350

Dolomite 12 < 0.02 50 - 150

Diorite 19 0.4 170 - 300

Gabbro 21 0.4 200 - 350

Granite 16 0.46 200 - 300

Limestone 11 < 0.01 80 – 180

Marble 12 < 0.02 100 - 200

Quartzite 16 0.75 150 - 300

Sandstone 10 0.75 30 - 150

Iron ore (Hematite) 11 0.5 100 - 200

 UJ640 - 1500 x 1100mm

CSS (mm) 125 150 175 200 225

 Hydraulic Setting Regulation

 Heavy Duty Cartridge style

The Course The Medium

MF Product size 17-19mm

The Fine manganese

new liner worn: 50mm new liner worn: 50mm

Change in opening: -5mm Change in opening: -100mm

0 With CLP Chamber

To change the throw remove the bush

 CSS is controlled by the Hydroset

 When an uncrushable piece of

 QE140 - 2.5m x 3.5m

 QA140 - 1.5m x 3.0m

 The piano wire also know as the

 S harp media, or diamond media is good

 Woven mesh or square mesh. Very

 Punch pplate made of hardox,, good

 Rubber screens, usually the same as

 Finger screens, or cascade screens are

 These types of screens are found on the

 These types off screens are very

 Woven wire or square mesh blocking up and blinding, better would

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Surface – fine grained Basalt

Intrusive – medium grained Diabase

Deep – coarse grained Gabbro

UJ640 - 1500 x 1100mm

Hydraulic Setting Regulation

Heavy Duty Cartridge style

CSS is controlled by the Hydroset

When an uncrushable piece of

QE140 - 2.5m x 3.5m

QA140 - 1.5m x 3.0m

The piano wire also know as the

S harp media, or diamond media is good

Woven mesh or square mesh. Very

Punch pplate made of hardox,, good

Rubber screens, usually the same as

Finger screens, or cascade screens are

These types of screens are found on the

These types off screens are very

Woven wire or square mesh blocking up and blinding, better would