Particle technology lab report

Experiment 1
Jaw crusher
2019-CH-35
Submitted to : SIR MUHAMMAD SHAZAD
SHAHZAD

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1.1) Abstract……………………………....................................................3
1.2) Apparatus ……………………………………………………………3

1.3.1) Introduction……………………………………………………………3
1.3.2) Types of crushing circuit ……………………………………………...3
1.3.3) Types of crushers ……………………………………………………..3
1.3.4) Jaw crusher…………………………………………………………5
1.3.5) Principle of jaw crusher ……………………………………………..5
1.3.6) Types of jaw crusher……………………………………………………5
1.3.7) Construction of the Blake …………………………………………7
elk type jaw crusher
1.3) Theory

1.4) Performance indicator…………………………………………8

1.5) Performing parameters………………… .....…………………9
1.6) Observation and calculation………………………………….10
1.7) Graphs…………………………………………………………11
1.8) Conclusion……………………………………..………………13
1.9) Applications of Jaw Crusher………………………….13

1.10) ) Limitations of Jaw Crusher…………………………….13

1.11) References…………………………………………………14

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 Experiment #1
Jaw crusher
2019-CH-35
1.1) Abstract
The purpose of this experiment was to understand the working principle of the primary crusher.
Perform crushing by jaw crusher, a sieve analysis by ro-tap sieve shaker, and to resolve mixture
in several fractions which is, then, followed by statistical analysis of data, further calculate the
reduction ratio.

1.2) Apparatus
 Laboratory Jaw crusher
 Vernier caliper
 Rock sample for crushing
 Ro tap sieve shaker
 Sieves set
 Torsion Balance

1.3) Theory

1.3.1) Introduction
The first stage of size reduction of hard and large lumps of run-of-mine (ROM) ore is to crush
and reduce their size. Crushing is the first mechanical stage in the process of comminution in
which a principal objective is the liberation of the valuable minerals from the gangue. Other
purposes include; reducing the particle size for increasing surface area, managing the size of feed
for the next operation, and preparing feed for the separation process. The mechanism of crushing
is either by applying impact force, pressure or a combination of both

1.3.2) Types of crushing circuit

Crushing may be in open- or closed-circuit, depending on the required product size distribution

a) Open circuit b) Close circuit

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1.3.3) Types of crushers
Crushing is typically a dry operation that is performed in two- or three-stages
 Primary crushing
 Secondary crushing
 tertiary crushing

a) Primary crusher
Primary crushers are heavy-duty machines, used to reduce ROM ore down to a size suitable for
transport and for feeding the secondary crushers. There are two main types of primary crushers
in metalliferous operations: jaw and gyratory crushers, although impact crushers have limited use
as primaries and will be considered separately. Primary crusher deals with a feed size of 1 or
more than 1 m , producing product size till 15-25cm. However, Lewis et al. (1976) estimated that
the economic advantage of using a jaw crusher over a gyratory diminishes at crushing rates
above 545 t h21 , and above 725 t h21 jaw crushers cannot compete.

a) jaw crusher b) gyratory crusher

b) Secondary crusher
Secondary crushers are lighter than the heavy-duty, rugged primary machines. Secondary
crushers also operate with dry feeds, and their purpose is to reduce the ore to a size suitable for
grinding. There are two main types of secondary crushers: cone and roll crushers. Secondary
crusher deals with a feed size of less than 25 cm, producing product size till 2-5 cm.

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a) Cone crusher b) roll crusher

c)Tertiary crusher
They are, to all intents and purposes, of the same design as secondaries, except that they have a
closer set. They deals with a feed size of less than 5 cm, producing product size till 0.5-2 cm

1.3.4) Jaw crusher

Jaw crushers are designed to impart an impact on a rock particle placed between a fixed and a
moving plate (jaw). The faces of the plates are made of hardened steel. Both plates could be flat
or the fixed plate flat and the moving plate convex. The surfaces of both plates could be plain or
corrugated. The moving plate applies the force of impact on the particles held against the
stationary plate. Both plates are bolted onto a heavy block

1.3.5) Principle of jaw crusher

This jaw crusher uses motor as its power. Through the motor's wheels, the eccentric shaft is
driven by the triangle belt and slot wheel to make the movable jaw plate move by a regulated
track. Therefore, the materials in the crushing cavity composed of fixed jaw plate, movable jaw
plate and side-lee board can be crushed and discharged through the discharging opening

1.3.6) Types of jaw crusher

Jaw crushers are classified by the method of pivoting the swing jaw
 Blake type
 Dodge type
 Universal type

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a) Blake type crusher

In the Blake crusher, the jaw is pivoted at the top and thus has a fixed receiving area and a
variable discharge opening. Therefor the feed size is fixed but the product size is variable. Feed
size must not be larger than the gape. Blake type is widely used in industry because of its feature
of no choking.

i) Double-toggle Blake crushers

In double-toggle Blake crushers, the oscillating movement of the swinging jaw is effected by
vertical movement of the pitman, which moves up and down under the influence of the
eccentric . The back toggle plate causes the pitman to move sideways as it is pushed upward.
This motion is transferred to the front toggle plate, which in turn causes the swing jaw to close
on the fixed jaw, this minimum separation distance being the closed set (or closed side setting).
Similarly, downward movement of the pitman allows the swing jaw to open, defining the open
set (or open side setting)

ii)Single-toggle jaw crushers

In single-toggle jaw crushers the swing jaw is suspended on the eccentric shaft, which allows a
lighter, more compact design than with the double-toggle machine. The motion of the swing jaw
also differs from that of the double-toggle design. Not only does the swing jaw move toward the
fixed jaw under the action of the toggle plate, but it also moves vertically as the eccentric rotates.
This elliptical jaw motion assists in pushing rock through the crushing chamber

a) Schematic diagram of double-toggle Blake b) Schematic diagram of single-toggle jaw

crushers crushers

The single-toggle machine therefore has a somewhat higher capacity than the double-toggle
machine of the same gape. The eccentric movement, however, increases the rate of wear on the
jaw plates. Direct attachment of the swing jaw to the eccentric imposes a high degree of strain on

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the drive shaft, and as such maintenance costs tend to be higher than with the double-toggle
machine

b) Dodge type

In the Dodge crusher, the jaw is pivoted at the bottom, giving it a variable feed area but fixed
delivery area. The Dodge crusher is restricted to laboratory use, where close sizing is required. It
face choking therefore despite having an advantage of producing uniform product size it’s not
used in industries.

c) Universal type

The Universal crusher is pivoted in an intermediate position, and thus has a variable delivery and
receiving area.

1.3.7) Construction of the Blake type jaw crusher

Jaw crushers are heavy-duty machines and hence must be robustly constructed

 Main frame:
It is made of cast iron or steel, connected with tie-bolts. It is commonly made in sections so that
it can be transported underground for installation. Modern jaw crushers may have a main frame
of welded mild steel plate

 Cheek plates :
Cheek plates are fitted to the sides of the crushing chamber to protect the main frame from wear.
These are also made from hard alloy steel and have similar lives to the jaw plates

 Jaws plates
Jaw crushers are designed to impart an impact on a rock particle placed between a fixed and a
moving plate (jaw). The faces of the plates are made of hardened steel. Both plates could be flat
or the fixed plate flat and the moving plate convex. The surfaces of both plates could be plain or
corrugated. The moving plate applies the force of impact on the particles held against the
stationary plate. Both plates are bolted onto a heavy block

 Retraction spring

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In order to overcome problems of choking near the discharge of the crusher , a spring is used that
pull back the moving plate increasing set if a hard material enters the feed .

 Fly wheel
Jaw cause vibration so fly wheel store the moment of inertia .

1.4) Performance indicator

1. Capacity
Amount of material treated in tons per hour

2. Energy consumption
How much energy in kilowatt hour is required for one ton of material to be crushed in one hour
defines energy consumption for jaw crushers

3. Reduction ratio
It is the ratio of 80% feed size to the 80%product size

1.5) Performing parameters

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❑ Feed Characteristics
Solid Density
As the density of solid increase the volume of solid decreases thus increasing the capacity of the
machine more material treated per hour thus increasing the energy consumption

❑ Design Parameters
Angle between jaws
The angle between the jaws can be changed by moving the pivoted end close or away from the
fixed jaw, hence increasing or decreasing gape . Increasing gape will increase the slippage of
particle. Decreasing gape reduce the reduction ration

Width and length of jaw plates

Increasing with and length of plate increase the contact area thus increasing capacity ;
simultaneously escalating the cost as well as energy consumption.

Throw
The throw (maximum amplitude of swing of the jaw) 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.
Greater the throw is in crusher, lesser the danger of choking, as material is removed more
quickly. This is offset by the fact that a large throw tends to produce more fines, which inhibits
arrested crushing. Large throws also impart higher working stresses to the machine. Thus
increasing the capacity and reduction reduction ratio

❑ Operating Parameters
RPM
The speed of jaw crushers varies inversely with the size, and usually lies in the range of 100-350
rpm. Higher the rpm more is the capacity

Set
In Blake type jaw crusher, increasing set means increasing the product size thus reducing the
reduction ratio.

Specifications of jaw crusher

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 Name of machine Denver jaw crusher

Motor power 5hp

Motor rpm 1440
Crusher rpm 325-375
Moveable jaw depth 14 inches
Fix jaw depth 12 inches
Capacity 60t/hr.
Size of set 0.5 inch
Size of gape 6 inches

1.6) Observation and calculation

Sr. Sieve Aperture Size Individual Mass Cumulative Mass

No mm g Percentage
Passing Retaining Geometric Measured Percentage Passing Retaining
mean
1 31.75 26.61 29.07 1030 37.87 62.13 37.87
2 26.61 13.33 18.83 1027 37.76 24.37 75.63
3 13.33 9.423 11.21 134 4.93 19.44 80.56
4 9.423 6.68 7.93 141 5.18 14.26 85.74
5 6.68 4 5.17 125 4.60 9.66 90.34
6 4 0.01 0.2 263 9.67 0 100
∑2720g

Calculations
Maximum feed size= 0.93*0.7=0.651mm

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 Maximum product volume= 132.2686mm

Reduction ratio =Maximum feed volume/Maximum product volume

= 0.0651/132.2686
=4.92*10^-4

1.7) Graphs

a) Size Of Aperture Vs Cumulative Mass

size of aperture vs cumulative mass

120

100 100
cumulative mass

80
retaining cumulative mass
60 %
passing cumulative mass %
40

20

0 0
0 5 10 15 20 25 30 35
size of aperture

d10= 17.5197

d25= 47.4252

d50= 55.53957

d75= 147.1102

b) LOG NORMAL PLOT

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 log normal plot
70
60
cumulative mass %

50
40
log normal plot
30
20
10
0 0
0.1 1 10 100
size aperture

Standard deviation= d84-d50

= 165.0535- 55.53957
=109.51

c) Gaudin-Schuhmann distribution
100
cumulative mass passing %

10 Gaudin–Schuhmann Dis-
tribution
Linear ( Gaudin–
Schuhmann Distribu-
tion)

1
0.1 1 10 100
size of aperture

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This is the equation of a straight line if x and y are plotted on a log–log scale. The slope of the
straight line will be the distribution parameter, a, and the intercept of the straight line, when y =
100%, will be the size parameter, k
a/Slope= 1.993701

k/Y-intercept= -2.41731

d) Rosin-Rammler distribution
100
cumulative mass retain %

10
Rosin–Rammler
Linear ( Rosin–Rammler )

1
0.1 1 10 100
apreture size

1.8) Conclusion
The reduction ration calculated from the experiment was 4.92*10^-4 . Low reduction ratio
concludes of high capacity and more energy consumption of machine plus product size was
large. Hence giving coarse particle as product

1.9) Applications of Jaw Crusher:

Jaw Crusher is used in following in following areas:
 Mining and coal industry
 Chemical industry
 Concrete recycling
 In Quarry
 Construction industry and in mobile crushing plants
 Smelting

1.10) Limitations of Jaw Crusher:

Following are limitations of Jaw Crusher:

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 Lower productivity
 High vibrations
 Small crushing ratio
 Not suitable for sticky materials
 180-degree machine

1.11) References

 McCabe, L. W., Smith, J.C. and Harriott, P., “Unit Operations of Chemical
Engineering”, 7 th (5 th) Ed., McGraw-Hill Book Co. New York, 2005 (1993).
 Ashok Gupta, Denis S. Yan - Mineral Processing Design and Operations. An
Introduction-Elsevier (2016)
 Finch, James A._ Wills, Barry Alan - Wills' Mineral Processing Technology,
Eighth Edition_ An Introduction to the Practical Aspects of Ore Treatment and
Mineral Recovery-Butterworth-Heinemann
 Particle Technology Lab Manual (By M. Shahzad) - Short (Without Related
Theory)

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