Transcription of Crushing and Screening Handbook
1 Crushing and Screening HandbookPREFACEP reface to the Fifth EditionRock is the most used natural resource in the world. The two main types of natural aggregates are 1) crushed rock and 2) sand and gravel. As a main ingredient in asphalt and concrete, these aggregates are used in the construction of highways and bridges, as well as in both residential and nonresidential buildings. The widespread use of aggregates results not only from its general availability but also from economic considerations. The cost of aggregate is not, in itself, a major factor in most applications, but its impact on the use of more expensive components, such as cement in concrete or bitumen in asphalt, is quite essential. For that reason, it is important to understand those factors in aggregate processing that have the greatest impact on quality and costs. This calls for an understanding of the entire process, from solid rock to its fi nal s Mining and Construction Technology has published this book in order to help those involved in the quarrying business.
2 The main target group is quarry managers, but we hope the book will be a valuable source of information for all who deal with the quarrying industry or who are studying these subjects. Of course, the book also contributes to mining, especially in terms of Crushing and Screening , and for those seeking a greater focus on mining, Metso s minerals processing Handbook is also is an updated version of the Metso Crushing and Screening Handbook , the fi rst edition of which was published a couple of years ago. The changes in this 5th edition involve only minor updates and corrections. The content is almost identical to the 4th at Metso s Mining and Construction Technology hope that this book contributes to an improved understanding of quarrying operations and thus helps us all to achieve profi table business. Quite a few people have contributed to the book, and I wish to express my thanks to these Viilo Editor-in-chiefResearch Director Copyright 2011 Metso. All rights reserved.
3 Technical information and illustrations related to the structure of the Crushing & Screening equipment and processes presented in this Handbook are not binding or conclusive. Due to the continuous product development we reserve the right to make changes to the Handbook without prior OF CONTENTSTABLE OF CONTENTSC hapterSubject / section namePrefaceTable of ContentsMetso s Mining and Construction Technology1 Quarry Process + Process Integration and Optimization (PIO) 2 Feeders 3 Crushing Equipment 3C-Series Jaw Crushers3 Superior MK-II Primary Gyratory Crushers3GP Series Cone Crushers3MP Series Cone Crushers3HP Series Cone Crushers3NP Series Impact Crushers3 Barmac VSI Impact Crushers4 Screening 4 Screening Media4 Wet Screening 5 Wet Equipment 5 Conveyors 6 Process Planning and Examples6 Metso Sand Solution6 Cost per Ton6 Process Simulation 7 Complete Systems 8 Mobile Equipment8 Quarry Lokotracks 8LL Series Mobile Conveyors8 Contractor Lokotracks 8 Mobile Screens 8 Mobile Process Examples 8 Portable Plants 9 Automation and Electrical Components 9 Crusher Automation 9 Visiorock 10 Wear Parts - Crushers11 Customer Service 12 Standards and Technical Infromation 13 Minerology and Testing Editor in chief Keijo ViiloProduction Eero H m l inen Lay-outTarja SalonenContentsGreg AlbertClaes LarssonDenis PradonDwayne BarlowTommi LehtonenSaku PursioJerome Bernigaud Tuomas Lehtonen Mika Sepp Arnaud BertucatKing LimIlkka SomeroAlain
4 Broussaud Jorma MannonenScot SzalanskiJarmo ElorantaJouni M h nenIlpo TeittinenJouni HulttinenMikko M kinenTimo Timperi Eero H m l inen Timo NakariHannu VakkuriAndreas KanterShane OmundsenKeijo Viilo Jorma KempasTero OnnelaAdrian WoodKari KokkonenCarlos PadinMETSO S MINING AND CONSTRUCTION TECHNOLOGYM etso s Mining and Construction Technology in briefTo be successful in today s quarry and sand and gravel operations, you need a partner to sup-ply competitiveness, not just equipment. This translates into a comprehensive source of glo-bal knowledge, fi nancial resources, innovative technologies and systems, and skilled people in worldwide locations. Only one organization in the world has the resources to bring you all these capabilities for effi cient aggregates proc-ess 10,000 Metso s Mining and Construc-tion Technology people operate in sales and manufacturing facilities and service shops in over 100 countries, covering all continents.
5 They supply you with world-class equipment, complemented by comprehensive service so-lutions aimed at increasing your operational reliability. In short, we do everything possible to help ensure your trusted partnerYour partner of choice, Metso is the trusted and preferred supplier in the rock processing indus-try. Our highest priority and personal commit-ment is to provide lifetime support and service for your aggregates processing you need a single crusher, a multi-stage process or a complete plant, we assist you with the right design for the most cost-eff ective Crushing process. We are the world s leading supplier of both unit machines and complete aggregates processing process solutionsYour system may involve a whole series of proc-esses, such as Crushing and Screening , conveying, classifying, washing and pretreatment, stockpil-ing, storage, loading and unloading, automation, environmental control and wear sophisticated project tools, our experi-enced engineers will arrange the appropriate equipment into a balanced system to provide you the high quality end-products you require, at the lowest cost per ton.
6 We also provide site preparation, structural design, and supply and erection designing a new plant, we balance raw material characteristics with the required pro-duction rate and the size and shape of the fi n-ished product. After careful selection of each piece of equipment from fi nal Screening to pri-mary Crushing your process characteristics are optimum quality, productivity and S MINING AND CONSTRUCTION TECHNOLOGYt/hHard GabbroSD t/m3700mm coarseAbr 1227 g/tCr 20 %450B13-50-3 VLoad 75 %Opening 100 mm450305145 Setting 150 mmC11068 % 32 mmGP300S91 % 43 mm484484 CVB1845-3#50 mm/E93 %#20 mm/E87 %#5 mm/E83 %484164200903010 m3244244 CVB2050-3#25 mm/E97 %#13 mm/E86 %#7 mm/E84 %3634412978112 Flexstroke 40 mmGP30095 % 16 mm24424440 %10/20mm12925 %5/10mm7835 %0/5mm112100 %0/20mm53 Process simulation technologyThe computerized Bruno process calcula-tion system has already become the proven standard in the Crushing industry.
7 Rock qual-ity, feed grading and selected machines are entered to simulate the expected produc-tion capacities and product gradings. Contact for more stationary or mobile plantsBesides off ering complete stationary instal-lations, Metso is the pioneer in fully mobile in-pit Crushing operation. Integrating two or three mobile Crushing plants combined with a mobile screen and a mobile conveying system results in improved effi ciency and end-product S MINING AND CONSTRUCTION TECHNOLOGYWe have the expertise to build a fl eet of track mounted Crushing and Screening plants for pri-mary, secondary and tertiary stages according to your application. Moving along the quarry face the track-mounted units replace dump truck haulage, thus achieving substantial sav-ings. The whole mobile plant can be moved from site to site on standard trailers. This is one example of how our worldwide process know-how can serve your Crushing , Screening and conveying product rangeFeeders a wide range of heavy duty feeders designed to absorb impact, meter material to the crusher and scalp out fi gyratory crushers ideally suited to all high-capacity primary hard rock Crushing crushers we have more installed jaw crushers than anyone in the world.
8 The lead-ing choice due to their high reduction ratio and heavy duty crushers capacities available to suit all secondary, tertiary or quarternary Crushing ap-plications. High performance crushers primary and secondary machines for soft and medium-hard materials. High reduction ratios. Can eliminate need for a tertiary Crushing and wear parts genuine parts always close to you, no matter where you are located shaft impactors helps shape the rock to high-quality aggregates. Rock on rock screens an extensive range of complete Screening solutions for scalping, closed circuit Screening , fi nal sizing and de-watering. Single inclination, double, triple and horizontal and gravel washing to produce special quality rock materials for demanding construc-tion projects, such as automation ensures consistent and effi cient operation. Improves productivity and product quality while reducing maintenance costs by preventing overload conveyors a complete range of belt conveyors.
9 Wide variety of widths, lengths, accessories and options. Various models incor-porate truss frames that are simple, compact and fast to dismantle, transport and Crushing plants fully mo-bile jaw, cone or impact Crushing plants, with or without screens, and equipped with open or closed circuit and discharge conveyors. Easily transportable on standard S MINING AND CONSTRUCTION TECHNOLOGYP ortable Crushing plants excellent trans-portability between sites and fast installation, in addition to high Crushing capacities. Can be fi tted with jaw, cone or impact crushers, with or without screens, and equipped with open or closed circuit and discharge screens track-mounted units for ex-cellent mobility and high performance on-site. Ideal for a wide range of applications. Also mobile screens on wheels which incorporate on-board conveyors and travel over roadways without special conveyors mobile conveyors link a Lokotrack primary mobile Crushing plant to fur-ther processing stages.
10 They are able to follow the primary unit as it moves along the quarry face, replacing costly dump truck automation systems monitor and control all Crushing , Screening , storing and con-veying with real-time accuracy. Maintain maxi-mum production capacity by adjusting process parameters wear and spare parts using origi-nal Metso wear parts is the key to a successful Crushing process. The design of our certifi ed wear parts starts with CAD simulations of the crusher cavity, which is the heart of the crush-ing process. By computer based planning and continuous quality control of the casting we can guarantee premium material quality, which translates into improved wear life and a higher operational capacity and Service Products Metso s Mining and Construction Technology, using its long-term experience of Crushing equipment and crush-ing processes, has developed an expert service off ering aimed at improving the reliability and productivity of customer operations.
