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FEEDER

Surge feeding tends to overload a crusher, and then the


surge is followed by an insufficient supply of stone. Using
a feeder ahead of a crusher eliminates most surge
feeding problems that reduce crusher capacity.
Types of feeder

Apron, Vibrating, Plate dan Belt

Apron Feeder
A feeder constructed of overlapping pans that form a
continuous belt

Vibrating Feeder
A vibrating grizzly feeder eliminates fines from the
material entering the crusher

Plate
A plate can be made to move back and forth on a
horizontal plane and can be used to uniformly feed
material to a crusher

Belt Feeder
The belt feeder is used for smaller sizes of material,
usually sand or small-diameter aggregates.

SURGE PILES
The stone is temporary storage ahead of a crusher is
referred to as a surge pile

Advantages and Disadvantages of


Surge Piles
Advantages

Enhancing uniform feed and ensuring high crusher efficiency

Should the primary crusher break down, the rest of the plant
can continue to operate

Repairs can be made to either the primary or secondary


sections of the plant without complete stoppage of
production

Disadvantages

Taking up additional storage area

Requiring the construction of storage bins or reclaiming


tunnels

Increasing the amount of stone handling

CRUSHING EQUIPMENT SELECTION


Things to consider

The kind of stone to be crushed


The required capacity of the plant needed output
production
The size ranges or the maximum size of the feed stones
The method of feeding the crushers
The specified size ranges of the product

Plant Layout
Things to consider :
An appropriate equipment configuration within the
plant.
A productive, logical flow of material from the point
where the trucks leave the plant with the crushed
aggregate product
The physical environmental requirements of each piece
of equipment (foundation, water requirements, and
power requirements)
Drainage
Access for maintenance personnel

SEPARATION INTO PARTICLE SIZE


RANGES
SCALPING CRUSHED STONE
Referring to a screening operation
Removing, from the main mass of stone to be processed, that
stone that is too large for the crusher opening or is small
enough to be used without further crushing.
Can be performed ahead of a primary crusher
SCREENING AGGREGATE
Revolving Screens
Vibrating Screens

Revolving Screens
Advantages : the operating action is slow and simple,
and the maintenance and repair costs are low.
They are usually used to wash and screen sand and
gravel
If the aggregate to be washed contains silt and clay, a
scrubber can be installed near the entrance of a screen
to agitate the material in water.

Vibrating Screens

Efficiency Factors
Permissible
Screen
Efficiency (%)

Efficiency Factor

95

1.00

90

1.25

85

1.50

80

1.75

75

2.00

The efficiency of a screen can be


defined as the ratio of the amount
of material passing through a
screen divided by the total amount
that is small enough to pass
through.

Deck Factors
For Deck
Number

Deck Factor

1.00

0.90

0.75

0.60

Aggregate-Size Factors
Percent of Aggregate
Less than 0.5 the Size
of Screen Opening

Aggregate Size Factor

10

0.55

20

0.70

30

0.80

40

1.00

50

1.20

60

1.40

70

1.80

80

2.20

90

3.00

If the material to be screened contains a surplus of small sizes, the


capacity of the screen will be increased.
If the material contains a surplus of large sizes, the capacity of the
screen will be reduced.

Determining the Screen Area


Required
The minimum area of a screen to provide a given
capacity is determined from the equation

Q
A
CEDG

Q = capacity of screen, (tons/hour)


A = area of screen, (sqft)
C = theoretical capacity of screen,
(ton/jam/sqft)
E = efficiency factor
D = Deck Factor
G = aggregate-size factor

Example
Determine the minimum-size single deck screen, having 1 in-sq.
openings, for screening 120 tph of dry crushed stone, weighing 100 lb/cf
when crushed. The screen box is 4 ft wide. A screening efficiency of 90%
is satisfactory. An analysis of the aggregate indicates that approximately
30% of it will be less than in. in size. The values of the factors to be
used in equations are :
Q = 120 tph
C = 3.32 tph/sf
E = 1.25
D = 1.0
G = 0.8

Q
A
CEDG
A

120
36.4sf
3.3x1.25x1.0x0.8

In view of the possibility of variations in the factors used, and to


provide a margin of safety, it is recommended to select a screen
whose total calculated capacity is 10 to 25% greater than the
required capacity.

A 36.4x1.1 40.0sqf 3.7m

Sand Preparation and Classification


Machines

LOG WASHERS
Removing the deleterious material before using the
aggregate

SEGREGATION
It is necessary to handle the crushed and screened
stone carefully in order to maintain the graduation
requirements.
If aggregate is permitted to flow freely off the end of a
belt conveyor, especially at some height above the
storage pile, the material will segregate by size.
The end of the belt conveyor should be kept as low as
possible to prevent segregation.

SAFETY
Safety devices is totally necessary, but even with them, basic
safety practices should be followed at all times :
Do not remove guards, covers, or shields when the equipment is
running
Replace all guards, covers or shields after maintenance
Never lubricate the equipment when it is in motion
Always establish a positive lockout of the involved power source
before performing maintenance
Block parts as necessary to prevent unexpected motion while
performing maintenance or repair
Do not attempt to remove jammed product or other blockage
when the equipment is running

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