ROCK PROCESSING
1. PROCESSING
Processing is needed for crushing and classification of raw material
for the building and metallurgical industry, and for the recycling
industry.
The processing technology is the science of the systematic
changing of raw materials.
These raw materials are goods for :
- concrete additives
- asphalt additives
- road construction materials
- building construction raw materials ( mortar and plaster )
- industrial minerals and fuels ( ore, coal, …)
- recycling of asphalt, concrete,…..
That processing – proceedings influences following quality-criterions
of a feed materials :
- screen curve
- shape ( cubicity )
- content of filler
- grain strength
In the following sheets we will discuss about the machines which
we are using for
producing that kind of raw materials.
2. MASS CONSUMPTION
In the enclosed drawings we can see average consumptions of raw
materials in different kind of buildings.
Page 1
HOUSE: 150 to
HOSPITAL: 4800 to FLAT: 80 – 100 to
MOTORWAY: 18.000 to/km SCHOOL: 2600 to
CONSUMPTION / PERSON
ROAD: 12.000 to / km
Algier: 3 to / Person MAINTENACE: 1.500 to / km
France: 7 to / Person
Austria: 10 to / Person
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2. 1. PROCESSING
The target each processing is the production of definite relations of
grain-surfaces in raw materials.
Examples:
- Cement : more fines higher compactness (stability)
- Grading material : more fines higher bonding
- asphalt gravel : more fines higher wear resistance
2. 2. BASIC KNOWLEDGE ABOUT PROCESSING
- Screen curves
The produced surface is not described with the grain-surface each
weight-unit.
It is described with screen curves.
- Relation between screen curve and surface
There is not a exact mathematical relation between grain surface
and grain diameter, there is just a statistic one.
The grain partition in the processing technology is named with the K
– 80 value.
The K – 80 value is that kind of screen size, on which 80 % of the
screened samples are falling through and 20 % oversized grain
remains on the screen.
Examples : A) Surface of 1 cube with 100
2
=6m
B) Surface of 1000 cubes with each 100 mm edge length
= 60 m2
C) Surface of 1 000 000 cubes with each 10 mm edge
length = 600 m2
A
A(s) = 6 x (1x1) x (1cube) = 6 m2
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B
B(s) = 6 x (0.1 x 0.1) x (1000cubes) = 60
2
m
C
C(s) = 6 x ( 0.01 x 0.01) x (1 000 000
2
cubes ) = 600 m
Page 4
Diagram : Surface in relation to the grain-size
Page 5
- Power demand for grain-surface production
The power demand for the grain-surface production can be
calculated with
the “ BONDS – EQUATION “.
E(s) = w(i) x [ ( 10/K80product ) - ( 10/K80feed ) ] x Q
w(i) = work index (material index)
K80 value = add in micrometer
Examples
- Reduction from 1000 mm to 100 mm ; w(i) = 10 kWh/to ; Q = 100
to/h
E,s) = w(i) x [ ( 10 / 100 000 ) – ( 10 / 1 000 000 ) ] x 100 to/h =
21,6 kW
RESULTS:
The “Bonds-equation” shows, that the production of grain-surfaces
(screen curves) is always in a relation to the power demand.
The power demand of one reduction is at first addicted from the
material (work index), and from the produced surface.
Secondly the power demand is addicted from the type of crushing
machine and its efficiency.
The used crushing machine has to be equipped with that kind of
motor power to make that grain reduction.
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3. PROCESSING MACHINES
3.1. CRUSHERS
1. Primary crushers
Are used for pre-crushing the material. This material is not a ready
made product. It will be used for further processing.
Stone size reduction rate : 1: 5
Feed size : 500 – 2000 mm
Capacity : up to 2000 to/h
Machines: - Single toggle crusher
- Double toggle crusher
- Gyratory crusher ( Jaw/Cone crusher )
- Impact crusher
2. Secondary crushers
Are mainly used for railway material and gravel production.
Stone size reduction rate: 1: 6 to 1:10
Feed size: 100 – 400 mm
Capacity: up to 1000 to/h
Machines: - Cone crushers
- Impact crushers
- Hammer mill
- Grinding mill
3. Tertiary crushers (“shaping machines”)
Are used for fine production with good cubical (shape).
Production of high-class gravel
Stone size reduction rate: 1: 6 to 1:10
Grain quality: over 80 % cubical (good shape)
Filer content: depends on type of machine (higher or
lower)
Machines: - Cone crusher
- Impact crusher
- Vertical shaft impact crusher
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- Hammer mill
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3. 2. CLASSIFY MACHINES
There are 2 important parameters which we are always using :
- Oversize material
- Undersize material ( which goes through the screen )
Screen capacity : depends on the screen surface ( m2) and the mesh
size
How to calculate the screen capacity (roughly):
SCREEN CAPACITY ( m3/h ) = SCREEN SURFACE ( m2 ) x MESH SIZE
( mm )
3.2.1. Grids and screens
For separation of about 200 to 2 mm
Fixed grids
Vibrating grids
Circular motion screens
Linear motion screens
Elliptic motion screens
Drum screens
Sizer
3.2.2 Fine screens
For seperation under 2 mm ( dry or even wet screening )
Dry screening
high frequency screeners and seizers up to 3000 rpm
Drum screens
Cyclons
Wind separator
Wet screening
Hydrocyclones
Bucket wheels
Worm classifier ( screws )
Chain classifier
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