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New Trend in Crushing Plant Design and Layout Considerations

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New Trend in Crushing Plant Design and Layout Considerations

May 24, 2023 nflg 0 Comments

New Trend in crushing plant Design and Layout Considerations

In mining operations, the layout of crushing plant and ancillary equipment and structures is a crucial factor in meeting production requirements while keeping capital and operational costs to a minimum.

The fundamental goal for the design of a crushing plant is an installation that meets the required production requirements, operates at competitive cost, complies with today’s tough environmental regulations, and can be built at a reasonable price despite the rising costs of equipment, energy and construction labor. The following industry trends must be taken into account:

Equipment suppliers are offering ever-larger primary crushers , as well as secondary and tertiary machines of up to 3,000 mm (120 in).

Rising energy costs are causing owners to increase the integration of mine and mill design, so that they can identify ways of reducing overall electrical power consumption.

Electronic control of crusher discharge opening and feed rate. With adjustment of a crusher’s discharge opening, as the production continues through an on- line coarse size analysis of the crushed product (digital image analyses). Dance, A. 2001)

More attention is being paid to the impact on crushing circuit design caused by variations in ore characteristics, size distribution, moisture content, ore grade and climatic conditions.

Operators have always dreamed of reducing the need for crushing equipment; when SAG mills were first introduced, it was hoped that they would eliminate secondary and tertiary circuits. As it turned out, designers are now adding secondary or pebble crushers to SAG circuits, on both greenfield and retrofit projects, to increase feed rate to the SAG mill. In other words, crushing plants, from primary to quaternary circuits, are here to stay.

There are three main steps in designing a good crushing plant: process design, equipment selection, and layout. The first two are dictated by production requirements and design parameters, but the layout can reflect the input, preferences and operational experience of a number of parties.

These can include the owner’s engineering staff, safety personnel, operations and maintenance personnel, equipment manufacturers, and the engineering consultant. Ideally, the consultant combines his knowledge and experience with an understanding of all parties’ needs, to provide a balanced, workable, safe and economic plant design.

Crusher Plant Layout Mining Operation Process

In cement production process, the mining of limestone , clay, sandstone, gypsum, coal, mixing materials, and fuels, as well as clinker (sometimes with pieces of large clinker), need to be crushing, grinding, drying, transportation and storage.

As the production capacity of kilns, grinding supplier, such as single large combined mining technology development, crushing processes, and devices also have greater development. A crusher plant layout has many important features in mining process:

(1) Crushing enlarged equipment;
(2) Crushing flow sheets single segment;
(3) Crushing equipment of mobile;
(4) Crusher multifunctional.

According to the requirements yield, crushing ratio, material of physical properties and crusher character to choose the characteristics of crushing system section number and appropriate crusher.

System selection

1. The material properties

Material of hardness, water, shape and impurity content will directly influence the breakage of economic and technical index system, the selected system must be broken material with the physical properties of adaptation.

2. Material size

(1) Feed block; (2) Discharging size; (3)Crushing ratio

Crusher Plants Feed block

Maximum feed size of crushing system of mining the maximum block size. Crusher plant layout depends on the size of factories, mines blasting method, loading equipment, unloading equipment and the type and specification crushers.

Because the factories the size of the different requirements of different blasting methods, large scale with a massive blast. So maximum feed size is related factory scale.

Discharging granularity: Depending on the production process on crushing material particle size requirements. Best leaves the material granularity is the output of the crusher and mill are high and low power consumption results.

Determine the most suitable size of the basic principles: High hardness and Grindability of difference materials, discharge fine; granularity do not align, coarse material more material discharge fine; dry and open circuit grinding, material fine; different types of mill for limestone feed size requirements are different. Ball mills and pipe mill requires a fine: 15~25mm; single cartridge grinding more fine than two-cartridge and multy-cartridge; baseball ground can appropriate to relax size: 20~40mm; the wheel roll is coarse: 50~100mm; no media mill at 150~300mm.

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