MP_PPT_BATCH_-1.pptx about mineral proceesing and crushing

JNTUH UNIVERSITY COLLEGE OF ENGINEERING SCIENCE
AND TECHNOLOGY HYDERABAD
KUKATPALLY, HYDERABAD
II.BTECH I SEMESTER [2023-2024]
MINERAL
PROCESSING

PRESENTED BY: BATCH-1
Guguloth Pavan (19011A0616)
Eshita Kundu (22011A0601)
Rohith Polluru (22011A0602)
Suddapalli Venkata Sathwik Sharma(22011A0603)
Kedarajupalli Venugopi (22011A0604)
Bommakanti Chandana (22011A0605)
Yerramasetti TejaSree (22011A0606)
Bhukya Eshwar (22011A0608)

TABLE OF CONTENT
Introduction
Definition of Sampling
Objectives of Sampling
Sample Division Methods
Methods of Sampling
Summary

INTRODUCTION
• Sampling is a fundamental process in mineral
dressing, playing a crucial role in accurately
characterizing ore bodies for efficient mineral
processing.
• It forms the foundation for decision-making in the
mining industry, impacting the design and
optimization of mineral processing plants.
Sampling 5

DEFINITION OF SAMPLING
6
1. Sampling is the systematic process of selecting and
collecting representative samples from A bulk
material, ensuring the obtained samples mirror the
true nature of the entire ore body

OBJECTIVES OF SAMPLING
•Representative Samples
• Obtain representative samples to reflect the true
mineralogical and metallurgical characteristics of the
ore body.
•Minimize Errors
• Minimize sampling errors through careful selection
and execution of sampling techniques.
•Accurate Analysis
• Facilitate accurate mineralogical and metallurgical
analysis by ensuring the samples are truly reflective of
the ore
Sampling 7

TYPES OF SAMPLING
8
1.Coning And Quartering :
• This is an old Cornish method which is often used
in dividing samples of material.
2. The Jones Riffle :
• The Jones Riffle consists of a series of inclined
chutes or channels that are arranged in a V-shape
or zigzag pattern.

• It consists of pouring the material into a conical heap and
relying on its radial symmetry to give four identical samples
when the heap is flattened and divided by a cross-shaped
metal cutter.
• Two opposite corners are taken as the sample, the other two
corners being discarded.
• The portion chosen as the sample may again be coned and
quartered, and the process continued until a sample of the
required size is produced.
• Although accuracy is increased by crushing the sample
between each division, the method is very dependent on the
skill of the operator and should not be used for
accurate sampling.
Sampling
9
CONING AND QUARTERING

11
THE JONES RIFFLE
Sampling
• This splitter is an open V-shaped box in which a series of
chutes is mounted at right angles to the long axis to give a
series of rectangular slots of equal area alternatively feeding
two trays placed on either side of the trough
• The laboratory sample is poured into the chute and split into
equal portions by the slots, until after repeated cycles a
sample of the desired size is obtained.
• A much more robust approach is to use a vibratory feeder to
distribute the bulk sample into a number of wedge shaped
containers as shown in Figure 3.5
• This device is sometimes called a "spinning riffle" or "rotating
sampler" and is the most accurate method of extracting
representative samples from dry granular or powdered
material.

TABLE OF CONTENT
Introduction
Types of Crushers
• Primary Crushers
• Jaw Crusher
• Gyratory Crusher
• Secondary Crushers
• Cone Crusher
• Roll Crusher

INTRODUCTION
• 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.
• Crushing is typically a dry operation that is performed
in two- or three-stages

CRUSHING
Jaw Crusher Gyratory Crusher Cone Crusher Roll Crusher
PRIMARY
CRUSHER
SECONDARY
CRUHSER
The Feed Size Varies from 3” to 30” The Feed Size Varies from 1.5” to 6”

PRIMARY CRUSHER
17
JAW CRUSHER GYRATORY CRUSHER
PRIMARY CRUSHING:
• Reduction of ore = as mined size 1m to 100mm size
• The objects of crushing are
1. Size reduction
2. Production of minimum amount of fines
• Primary crushing is done on dry material

JAW CRUSHER
 It has two crushing faces – JAWS.
 The jaws are made of cast steel.
 They are fitted with replaceable liners made of manganese steel or Ni-hard (a
Ni-Cr alloyed cast iron).
 They are mounted on a rigid frame.
 One jaw is stationary, the other is movable.
 The feed ore is squeezed till it breaks.
 The fragments move down to a narrow part of the wedge.
 They get squeezed repeatedly.
 The final products escape through the narrow gap at the bottom.
 It moves towards and away from the stationary jaw by a small throw.
18
Crusher

Crushers
TYPES OF JAW CRUSHERS
1.Blake Crusher 2.Dodge Crusher 3.Universal Crusher
19
Jaw crushers are classified based on:
1. the point of minimum amplitude of motion on the moving face
2. the way of transmitting the movement to the immovable face

1.BLAKE JAW CRUSHER(1858) – VERY LARGE IN SIZE
• The Blake crusher of the jaw crushers used today was patented by E.W. Blake
in 1858 and variations in detail on the basic form are found in most
• The patent states that the stone breaker “consists of a pair of jaws, one fixed
and the other movable, between which the stones are to be broken.”
• The jaws are set at an acute angle with one jaw pivoting so as to swing relative
to the other fixed jaw.
• Material fed into the jaws is repetitively nipped and released to fall further into
the crushing chamber until the discharge aperture.
• The Blake crusher, the jaw is pivoted at the top and thus has a fixed receiving
area and a variable discharge opening
There are two forms of the Blake crusher:
1. Single toggle
2. Double toggle
20
Crusher

SINGLE TOGGLE JAW CRUSHER
• 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.
• The swing jaw move toward the fixed jaw under the action of the
toggle plate.
• This elliptical jaw motion assists in pushing rock through the
crushing chamber
• The single-toggle machine therefore has a somewhat higher
capacity than the double-toggle machine of the same gape
• The eccentric movement, 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 the drive shaft, and as such maintenance costs
Crushers 21

DOUBLE TOGGLE JAW CRUSHER
• In a 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).
• Downward movement of the pitman allows the swing jaw to
open, defining the open set (or open side setting).
• Double-toggle machines are usually used on tough, hard
and abrasive material.
Crushers 22

Crushers 23
Double Toggle Jaw Crusher

2.DODGE CRUSHER
• Here the jaw action is reverse to that of the Blake jaw crusher
• In the dodge crusher, the jaw is pivoted at the bottom, giving it a variable feed
area but fixed delivery area
• Maximum crushing is given to the largest piece and minimum to the smallest.
• Only a small variation of set occurs on the advancing and receding actions of
the movable jaw.
• It has constant discharge opening which we get more uniform product size
• The dodge crusher is restricted to laboratory use, where close sizing is
required.
Crushers 24

GYRATORY CRUSHER
 Gyratory crushers are principally used in surface crushing plants.
 The gyratory crusher consists essentially of a long spindle, carrying a hard steel
conical grinding element, the head, seated in an eccentric sleeve
 The spindle is suspended from a “spider” and, as it rotates, normally between
85 and 150 rpm, it sweeps out a conical path within the fixed crushing chamber,
or shell, due to the gyratory action of the eccentric.
 The gyratory crusher is a good example of arrested crushing.
 The spindle is free to turn on its axis in the eccentric sleeve, so that during
crushing the lumps are compressed between the rotating head and the top shell
segments, and abrasive action in a horizontal direction is negligible
26
Crusher

 The gyratory, unlike the jaw crusher, crit has a higher
capacity than a jaw crusher of the same gape, roughly by
a factor of
2.5 – 3 and ,
 It is favored in plants handling large throughputs: in mines
with crushing rates above 900 th¯¹, gyratory crushers are
always selected.
 Gyratory crushers are identified by the size of the gape
and the size of the mantle at the discharge
 They range in size up to ca. 1,600 mm x 2,900 mm (gape
3 mantle diameter) with power consumption as high as
1,200 kW and capable of crushing up to ca. 10,000 th ¯¹ at
27
Crushers

SECONDARY CRUSHER
29
CONE CRUSHER ROLL CRUSHER
SECONDARY CRUSHING:
• Secondary crushers are lighter than the heavy-duty, rugged primary
machines
• Secondary crushing is done to reduce the ore size suitable for (wet)
grinding. The feed size will be less than 150 mm avg. Dia & product
size - 12 mm av.Dia.
• Secondary crushers are arranged in series with the primary crushers.
Crushers

 The cone crusher is a modified gyratory crusher, and
accordingly many of the same terms including gape,
set, and throw, apply.
 The essential difference is that the shorter spindle of
the cone crusher is not suspended, as in the gyratory,
but is supported in a curved, universal bearing below
the gyratory head or cone
 Product of cone crusher is the feed of grinding mill
 It is work in closed circuit with double deck screen
 Product is more uniform in size
30
CONE CRUSHER
Crushers

 Roller crusher, also known as double roller crusher, when
the material enters between two rollers, due to the effect of
friction, the ore is carried into the crushing space between
the two rollers, compressed and crushed.
 Roll crushers can be effective in handling friable, sticky,
frozen, and less abrasive feeds, such as limestone, coal,
chalk, gypsum, phosphate, and soft iron ores.
 Roll crusher operation is fairly straightforward: the
standard spring rolls consist of two horizontal cylinders
that revolve toward each other
 The gap (closest distance between the rolls) is determined
by. Shims which cause the spring-loaded roll to be held
back from the fixed roll.
 Reduction is progressive by repeated nipping action as the
material passes down to the discharge, the crushing
process in rolls is one of single pressure.
32
ROLL CRUSHER
Crushers

ANGLE OF NIP
• For a particular operation where the ore size is known, it is necessary to estimate the
diameter of rolls required for a specific degree of size reduction. To estimate the roll
diameter it is convenient to assume that the particle to be crushed is spherical and
roll surfaces are smooth. The Figure shows a spherical particle about to enter the
crushing zone of a roll crusher and is about to be nipped. For rolls that have equal
radius and length, tangents drawn at the point of contact of the particle and the two
rolls meet to form the nip angle (2θ). From simple geometry it can be seen that for a
particle of size d, nipped between two rolls of radius R
Crushers 33
Where R is the roll radius and L the distance between the rolls

COMPARISON BETWEEN ROLL & CONE CRUSHERS:
• Roll crusher production smaller of fines than cone crushers and smaller
reduction ratio.
• Rolls, because of their inability to yield high reduction ratio, have not been
installed in recent years
• Reduction ratio for rolls should not exceed similar to cone crushers
• Rolls remain to be the best device for intermediate crushing.
Crushers 34

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