The following example demonstrates a method of selecting the components of an aggregate plant. Good component efficiency and part performance pre-evaluation is essential to a solid design. The aggregate production requires the consideration of several crushers feeders and screens. This is not intended to be a typical situation though it does involve common crusher and screen units often used in aggregate plants.Get A Quote
The following example demonstrates a method of selecting the components of an aggregate plant. Good component efficiency and part performance pre-evaluation is essential to a solid design. The aggregate production requires the consideration of several crushers feeders and screens. This is not intended to be a typical situation though it does involve common crusher and screen units often used in aggregate plants.
Quarry rock of 12 in. maximum size is to be handled in a two-stage crusher plant at the rate of 70 tons per hour. The maximum size of output is to be 1 in. and separation of materials over 1 in. size and the minus 1 in. in the output is required. Select a jaw crusher like those included in this table.
The screens to be considered are a 1-in. screen with an estimated capacity of 2.7 tphsq ft and a 1-in. screen with a capacity of 2.1 tphsq ft. The solution will include the selection of adequate and economical crushers for the two stages and the sizes of screens between them and below the secondary stage.
For the primary crusher a jaw crusher will probably be most economical. A jaw crusher like 2036 in the Jaw Crusher Table here above would be able to take the maximum 12 in. size quarry stone but it would not have the required 70 tph capacity needed. To have the needed capacity a jaw crusher like the 2042 or 2436 sizeswill have to be selected overloading the secondary crusher.
A grid chart or curve for the selected crusher shows that for a 2-in. setting 54 of the material will pass a 1-in. screen or 46 will be retained this is like Jaw Crusher capacity table abovewhere 48 passes a 1 in. screen. The 46 of 70 tph gives the 32 tph fed to the secondary crusher shown in Figure below as a roll crusher.
A twin-roll crusher is selected like those given inthe Roll Crusher capacityTable above to serve as the reduction crusher. The smallest 24 x 16 roll crusher shown in theRoll Crusher capacity Table above has enough capacity with a setting of 1 in. but the maximum size feed will be too large that is the stage of reduction is not large enough. The maximum size of feed coming from the discharge of the primary crusher with a setting of 2 is about 3 in. as may be found in this Table.
Another possible solution to this problem would be to use a gyratory crusher for the primary crushing stage. A gyratory like Telsmith model1110 could be set at 1 in. in an open circuit with a capacity for 260 tph. The maximum size of stone in the output is estimated to be approximately 2 18 in. Then all the output from the primary crusher could be nipped by a 40 in. diameter twin-roll crusher with a 1-in. setting according to the Roll Crusher capacityTable above. The specifications and manufactured limitations rather than economy generally govern the selection of crushers.
To find the required areas of screen the rate of feed of material as well as gradation of the feed must be known. The 1-in. screen under the jaw crusher is the top deckno deck correction factor will be necessary. Therefore the 1-in. screen will need to be at least 702.7 29.9 sq ft in area. It must be at least 36 in. wide for an 18 x 36 jaw crusher. So a 4-ft by 8-ft screen would be acceptable. The 1-in. screen is a second deck for the 38 tph from the jaw crusher so the deck correction factor is 0.90 and that screen capacity is 2.1 x 0.9 1.89 tphsq ft.
The screen area needed under the jaw crusher is 381.89 20.1 sq ft. For the 1-in. screen below the roll crusher the capacity has no correction factor and the area needed is 322.1 15.2 sq ft. To handle the output from a 40 x 24 roll crusher the screen will have to be at least 24 in. wide. Perhaps it will be more effective to use one continuous screen of at least 20.1 15.2 35.3 sq ft. A 4-ft by 10-ft 1 in. screen should be satisfactory.
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