Experiment # 02: Reduction Ratio of Jaw Crusher

2.1. Objectives:

1. To study the various parts of Laboratory Jaw crusher with special emphasis on their
functions to perform a crushing test on a given sample
2. To analyze the product by sieve analysis
3. To calculate reduction ratio

2.2. Apparatus/Materials:
• Laboratory Jaw Crusher
• Vernier Caliper
• Rock sample for crushing
• Sieve set (26.67, 18.85, 13.33, 6.70, 2.36 and 0.85 mm)
• Sieve Shaker
• Balance

2.3. Related Theory:

[References: Mineral Processing Technology by B. A. Wills (7 th Edition-2005) & Mineral Processing
Design and Operation by A. Gupta and D. S. Yan (1st Edition-2006)]

2.3.1 Introduction:
Jaw crushers are used as primary crushers, or the first step in the process of reducing rock.
They crush primarily by using compression.

The distinctive feature of this class of crusher is the two plates which open and shut like
animal jaws. The jaws are set at an acute angle to each other and one jaw is pivoted so that it
swings relative to the other fixed jaw. Material fed into the jaws is alternately nipped and
released to fall further into the crushing chamber. Eventually it falls from the discharge
aperture.

2.3.2. Types:

There are three basic types of jaw crusher as shown in Figure 2.1.

Figure 2.1: Types of Jaw Crushers

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2.3.2.1. Blake Type Jaw Crusher

The Blake crusher was patented by Eli Whitney Blake in 1858. The swing jaw is fixed at the
upper position. The Blake type jaw crusher has a fixed feed area and a variable discharge
area.

A. Double Toggle Blake Crusher

In the double toggle jaw crushers, the oscillating motion of the swing jaw is caused by the
vertical motion of the pitman. The pitman moves up and down. The swing jaw closes, i.e., it
moves towards the fixed jaw when the pitman moves upward and opens during the
downward motion of the pitman. This type is commonly used in mines due to its ability to
crush tough and abrasive materials.

B. Single Toggle Blake Crusher

In the single toggle jaw crushers, the swing jaw is suspended on the eccentric shaft which
leads to a much more compact design. The swing jaw, suspended on the eccentric, undergoes
two types of motion- swing motion towards the fixed jaw due to the action of toggle plate and
vertical movement due the rotation of the eccentric. These two motions, when combined, lead
to an elliptical jaw motion. This motion is useful as it assists in pushing the particles through
the crushing chamber. This phenomena leads to higher capacity of the single toggle jaw
crushers but it also results in higher wear of the crushing jaws. These type of jaw crushers are
preferred for the crushing of softer particles. A comparison between two can also be seen in
Figure 2.2 It shows the difference in the movement and the method of operation.

Figure 2.2: Comparison between Single and Double Toggle Blake Type

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2.3.2.2. Dodge Type Jaw Crusher

In the Dodge type jaw crushers, the jaws are farther apart at the top than at the bottom, forming a
tapered chute so that the material is crushed progressively smaller and smaller as it travels
downward until it is small enough to escape from the bottom opening. The Dodge jaw crusher
has a variable feed area and a fixed discharge area which leads to choking of the crusher and
hence is used only for laboratory purposes and not for heavy duty operations.

2.3.2.3. Universal Jaw Crusher

This jaw crusher continuously reduces material as it passes through the crushing chamber with
its aggressive force feed action as the moveable jaw compresses inward and downward. The
sharp primary blow at the top of the chamber reduces material instantly, while a secondary
crushing action at the bottom further reduces material to the predetermined output size.
Universal Jaw Crushers offer a compressive stroke that is nearly equal at both the top and bottom
of the chamber, producing more spec material at a lower cost per ton.

2.3.3. Construction:

Main Frame

The main frame is often made from cast iron or steel, connected with tie-bolts.

It is often made in sections so that it can be transported underground for installation.

Fully stress relieved after fabrication.

Jaws

The jaws are usually constructed from cast steel and are fitted with replaceable manganese steel
liners, which are bolted in sections on to the jaws so that they can be removed easily and
reversed periodically to equalize wear. One jaw is move able and other one is fixed.

Cheek Plates

These are fitted to the sides of the crushing chamber to protect the side main frame from wear.
These are also made from manganese steel and have the similar life to the jaw plates.

Flywheel

Rotational energy is fed into the jaw crusher eccentric shaft by means of a sheave pulley which
usually has multiple v-belt grooves.

Heavy fly wheel attached to the drive which is necessary to store energy on the idling half of the
stroke and deliver it on the crushing half. And maintain inertia.

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Toggle

The toggle rolls across the flat pressure face of the toggle seat. No rubbing or scuffing takes

place and friction is kept to a minimum. This type of toggle system has the following advantages
over the socket end type toggle and seat:

No lubrication whatsoever is required

The system can handle far greater crushing pressures.

The life factor of toggle and seats is many times greater.

Jaw-holder & Main Bearing Housings

Can be removed from the frame as an assembly. The jaw-holder is a robust box construction
with a fully machined face to support the moving jaw.

Spring Load

It is a safety device and in the event of an uncrushable lump entering the gape. The movable jaw
is pushed to the limit by compressing the spring and the un-crushable lump is passed out

without causing mechanical damage to the machine. In industry we use greening screen to
prevent sticky and wet material.

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 Figure 2.3: Labelled Diagram of Jaw Crusher

2.3.4. Working

A ‘Toggle and Pitman’ is the popular mechanism, driving the Blake jaw crusher. It normally
comprises of a pitman working on an eccentric on the crusher shaft and two toggles travelling
and traversing like a ‘birds wings’, one between the main frame and the pitman and the other
between the pitman and the moveable jaw, so that with the rotation of the shaft the pitman is
translated up and down whereby the distance between the two jaws is increased intermittently
and crushing effected. But our laboratory model,

which is typically a Blake jaw crusher, has a modified drive mechanism called ‘single toggle
mechanism’; it has no pitman separately but the purpose of pitman is served by the moveable
jaw itself.
Instead of the two long toggles it has one small toggle which rests on steel bearings, at one end
on back body of the moveable jaw and at the other end on a vertically slid able wedge block
beside the main frame.

It can be moved back & forward depending upon product required (e.g. if moved back then the
product will be coarser). The feed opening of the jaw crusher is called the ‘gape’ and the
discharge opening is called ‘set’. The moveable jaw is spring loaded and connected to a screw
mechanism which helps in adjusting the set. Spring loading is a safety device and in the event of
an uncrushable lump entering the gape. The moveable jaw is pushed to the limit by compressing
the spring and the uncrushable lump is passed out without causing mechanical damage to the
machine. The image of jaw crusher is shown in Figure 2.4.

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 Figure 2. 4: Jaw Crusher present in Mineral Processing Lab

2.3.5. Related Terminology

Gape: The feed opening of the jaw crusher is called gape, which is the distance between the
jaws at the feed opening & which is given as 5'' × 6'' (Max size of feed)

Set: The maximum opening of the jaws at the discharge end is called set. The discharge size of
the material from the crusher is controlled by set. This can be adjusted by using toggle plates of
the required length.

Throw: The jaw is pivoted from above; it moves a minimum distance at the entry point and a
maximum distance at the delivery. This maximum distance is called the throw of the crusher.

Free Crushing: In free crushing, no accumulation of the material takes place in the crusher.

Choke Crushing: In choke crushing, accumulation of the material takes place in the crusher.

Reduction Ratio: Ratio of Size of Feed to Size of Output.

Feed Material: Such a material which is introduced in the crusher for crushing purpose is called
the feed material. It should be 80% to 90% of the gape and it should also be a uniform size.

Product Material: Such material which is discharge from the set after crushing is called
product. The size of the product can be adjusted by adjusting the size of the set.

2.3.6. Parameters
Capacity:
The capacity of the jaw crusher available in the laboratory is 725 t/h. Jaw crushers range in size
up to 1680 mm gape by 2130 mm width. This size machine will handle ore with a maximum size
of 1.22 m at a crushing rate of approximately 725th -~ with a 203mm set. However, at crushing
rates above 545th -1 the economic advantage of the jaw crusher over the gyratory diminishes;
and above 725th -1 jaw crushers cannot compete with gyratory crushers.

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Speed:

The speed of jaw crushers varies inversely with the size, and usually lies in the range of 100-
350revmin -1. The main criterion in determining the optimum speed is that particles must be
given sufficient time to move down the crusher throat into a new position before being nipped
again.

Amplitude:

The maximum amplitude of swing of the jaw, or "throw", is determined by the type of material
being crushed and is usually adjusted by changing the eccentric. It varies from 1 to 7 cm
depending on the machine size, and is highest for tough, plastic material and lowest for hard,
brittle ore. The greater the throw, the less danger is there of chokage, as material is removed
more quickly.

2.3.6. Applications

Jaw crusher perform better on clayey, plastic material: due to their greater throw. Jaw Crusher is
used in Cement Raw Crushing. It can also be used in Mining industry along with recycling of the
concrete.

2.3.7. Limitations

Jaw crusher is applicable to feed size up to 1m & giving a product of about 10-20 cm in size

o
Jaw crusher is not suitable for hard and abrasive material. It is an 180 machine which means
o o
that it works 90 and rests 90 . Some of the lumps can pass without being crushed. Sticky
material cannot be crushed in this crusher.

2.3.8. Specifications of Industrial Models

The industrial model of jaw crushers are more powerful and of larger dimensions than the
laboratory scale and therefore Table 2.1., expresses the specifications of the industrial model of
Jaw Crushers.

Table 2.1: Yuhong Jaw Crusher Specification

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2.4. Procedure
• Study each part of the machine and know the function of every component
• Switch on the machine and study the movement of the moving jaw and the
variation of set with motion.
• Measure the side of the gape and adjust the set with the help of a lead lump and
meter rod or coarse sieve and record measurements.
• Examine the feed, measure the largest lump either with a meter rod or coarse
sieve as the case may be and record it.
• Feed the machine and crush the entire sample.
• Perform sieve analysis on the product by using coarse sieve set as given in 1.2.
• Calculate the reduction ratio of the machine.

2.5. Observations and Calculations

Feed Size
Sr. No. Length (mm) Width (mm) Height (mm)

Product Sieve Analysis

Sieve Size in µm

Sieve Fraction

Undersize %
Retained kg

Cumulative

Cumulative
Oversize %
Apparatus
Weight %

Nominal
Weight
S.No

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 2.5.1. Reduction ratio
Determine the reduction ratio by the following relation:

Reduction Ratio80: 80% passing feed size/80% passing product size

80%

2.6. Graphs
1. Draw graph of cumulative passing and retaining mass percentage against
aperture size (geometric mean) and determine cut size, d10, d25, d50, and d75.
2. Draw log-normal plot between aperture size (geometric mean) and cumulative
passing mass percentage and determine the standard deviation.
3. Express Gaudin-Schuhmann distribution on graph and determine the constants
involved.
4. Express Rosin-Rammler distribution on graph and determine the constants involved.
*Note: Read Topic 2.2. “Particle Size Distribution” in “Mineral Processing Design and Operation” by A. Gupta
and D. S. Yan

2.7. Discussions
Discuss the results and the information deducted from sieve analysis in details.

2.8. Conclusions
Give concluding remarks about the experiment and its results.