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fine countershaft crusher

cone crusher parts

cone crusher parts

The cast steel spider cap has been designed to serve as a feed distribution plate for coarse materials. It is recessed on the 22, 30, 36 and 48-in. crushers. For fine materials, the wobble plate feeder a more effective means of distributing the feed is recommended.

The annealed cast steel top shell and spider are made in one piece. The spider is of the three arm type, equipped with a self-aligning, Scor-Proof plastic ball and socket bearing in crusher sizes 22 to 48-in., and with an hourglass type bearing in sizes above 48-in. The lubricant is sealed in with a garter type oil seal. Bearings can be lubricated from outside the topshell on the 51, 60 and 84-in. crushers through oil holes in spider caps of the four smaller sizes.

The mainshaft is of high grade forged steel, annealed for stress relief. It is tapered to gauge for head center fit. The bottom of the shaft is fitted with a polished bronze step bearing. The journal for the spider bearing is formed by a sleeve shrunk on the shaft on the 51, 60 and 84-in. crushers. Short, heavy mainshaft design results in long life.

The step bearing consists of a bronze mainshaft step, a bronze piston wearing plate, and an alloy steel washer between the two. The washer is drilled for oil cooling and lubrication. Both the mainshaft step and the piston wearing plate are made of high lead bronze, selected to give the best bearing surface. The washer and plate are pinned in place, and the bearing surfaces are grooved to permit distribution of the lubricating oil.

The Mantalloy head mantle of this cone crusher is a replaceable wearing surface. It is made of alloyed manganese steel, and is held in place with a self-tightening head nut. On the 51-in. Hydrocone crushers and larger, the bottom portion of the mantle is ground to gauge to fit the head center, and the top portion is zinced. For crushers smaller than 51-in., the entire inner surface of the mantle is ground to gauge and no zincing is required.

The Mantalloy concave ring, or the stationary crushing surface, is available in three standard types, coarse, intermediate and fine. Helices, cast into the bottom of the concave ring, engage similar helices on the top of a cast steel concave support ring. The support ring is held by a key to the top shell to facilitate assembly, after which it is supported on the bottom shell. The helical surfaces make the concave ring self-tightening; no zincing is required.

The dust seal is a plastic ring suspended in a housing from the head center and encircling the dust collar. It is designed to accommodate the vertical adjustment and the gyrating and rotating motion of the head. All wearing parts are replaceable. The crusher is fitted with a connection for introducing low pressure air inside the seal for additional dust protection.

The eccentric is made of high carbon cast steel and fitted with a bronze inner wearing sleeve. The eccentric turns in a bronze bottom shell bushing. Both sleeve and bushing are replaceable. The eccentric throw can be changed in the field by installing a different sleeve.

The alloy steel pinion is mounted on a turned shaft. The cast steel pinionshaft housing is bolted to the machined opening in the bottom shell. It is equipped with anti-friction bearings sealed inside and out, and has separate pool lubrication in all sizes except the 36 and 48-inch machines. The 36 and 48-inch Hydrocone crushers have sleeve type counter-shaft bearings which are lubricated by the external oiling system.

The annealed cast steel bottom shell is of the three arm, open discharge type, bored to gauge for the top shell and eccentric bushing. It is bored and faced for the bottom plate, pinionshaft bearing and dust collar.

The external oil conditioning system furnished with Hydrocone crushers consists of a large oil storage tank on which are mounted a condenser type cooler, pressure type filter, motor, and a pump which pumps the lubricant to the crusher automatically. These units both cool and filter the oil. The accumulator and tank for the Automatic Reset are mounted separately from the oil storage tank.

All oil conditioning systems are equipped with oil flow and temperature safety switches which are adjusted to open the motor circuit and stop the crusher if the temperature becomes too high or if there is not a sufficient flow of oil. Flexible hose connects the lubricating unit to the crushers, greatly reducing the number of pipe fittings required and simplifying the installation.

Oil for the tank is pumped through the filter and cooler to the step bearing and up the inner eccentric bearing. It flows down the outer eccentric bearing, lubricates the gear and pinion, then returns to the tank. Tank capacities vary from 30 gallons for the 22-in. Hydrocone crusher to 240 gallons for the 84-in. machine.

23. Feed Plate 24. Screw 25. Torch Ring 26. Locking Bolt 27. Dust Shell 28. Clamp Ring 29. Adjustment Ring 30. Mainshaft Pin 31. Pin 32. Socket Liner 33. Socket 34. Eccentric 35. Eccentric Bushing 36. Counterweight 37. Counterweight Guard 38. Gear 39. Thrust Bearing 40. Countershaft Box 41. Countershaft Box Guard 42. Oil Finger Cover 43. Oil Finger 44. Countershaft Bushing 45. Countershaft 46. Pinion

CRUSHING CHAMBER may be any one of three standard types (Fine, Intermediate and Coarse) designed to assure a cubical, well-graded product. Shape of mantle and concave ring, and the range of adjustment available, results in maximum life and minimum scrap when replacing parts. Special crushing chambers also available.

BEVEL PINION AND GEAR are of the spiral design in the larger sizes provide greater tooth contact and smooth, trouble-free operation under most severe conditions. Bevel spur and pinion gears are used on smaller size Hydrocone crushers.

INNER CRUSHING CONE or mantle is one-piece Mantalloy casting held in place by a self-locking head nut. Complete contact of the ground inner surface with steel head center eliminates need for zincing in all but the larger sizes.

OUTER CRUSHING RING or concave ring is one-piece Mantalloy casting. Necessity of zincing or clamping concave ring in place is eliminated by ground-to-fit finish on outer surface and the use of an effective self-locking device.

3-PIECE STEP BEARING accommodates gyrating motion of main shaft and transmits crushing pressure to hydraulic piston. Designed to withstand bearing pressures much greater than those encountered in actual service.

While it is one of the major parts in the machine, there are few essential differences between the adjustment ring in the 10 ft. crusher and in the smaller machines, except as to size. Material of the ring which weighs 70,000 pounds is cast steel. Rigidity of the adjustment ring cross-section is essential. In this case, increased section thickness, with ordinary carbon steels, results in a reduction in deflection.

This part, which is screwed into the adjustment ring, is the means of setting of the machine. Adjustment is performed by rotating the bowl relative to the adjustment ring. In the 10 ft. machine provision has been made to adjust the setting during crushing. This increases the availability of the crusher substantially. Past practice had been to stop feed to the crusher during adjustment.

During crushing the position of the bowl and adjustment ring is maintained on the slant flank of the threads by means of the crushing force. The slant flank helps in centering the two elements. The clamp ring acts somewhat like a locking device to take up clearances. Ideally, the clamping cylinders do not have to have any greater capacity than is necessary to overcome the weight of the bowl. Practically, the clamp ring capacity is many times higher to withstand tramp passage.

To adjust the setting of the machine, hydraulic rams are used to rotate or counter-rotate the bowl in the adjustment ring. The seal between the adjustment cap and hopper is a simple, continuous, tightly fitting flap which allows free, relative rotation but prevents intrusion of dust into the thread area. The lower end of the thread connection between bowl and adjustment ring is also sealed. The hopper assembly, which is actually a part of the bowl assembly, including the hopper, hopper liner and cap closure, comprises the section in which the feed is introduced. It includes a dead bed, reducing wear and shock from the fall of the feed from the feeder above.

The adjustment rams are pressurized hydraulically and provide a setting adjustment. For normal adjustment of setting due to wear, installation and removal of the bowl is made through a swivel sheave and a cable turn applied around the adjustment cap. The bowl is then rotated by use of the maintenance crane.

The crushing head, similar in section to that of the 7 ft. machine, had three-dimensional photoelastic studies made using the technique of freezing stresses into a loaded plastic model, sectioning the model and examining the slices under polarized light. As a result of these techniques, stresses have been reduced. The core of the head consists of six massive ribs to support the crushing forces on the surface of the head. The head is cast steel.

The main shaft is of turbine rotor steel of high quality and refinement, the chemistry of which is low carbon to reduce the possibility of heat checking. It includes chrome nickel additions for deep hardening, notch toughness and resistance to fatigue. The shaft extension is provided to reduce the relative strain between the head and shaft and thereby reduce fretting in the fit, which has a heavy press. The shaft diameter is 50 percent greater than the 7 ft. crusher shaft. As a result, the shaft operates at lower values of bending stress and deflection. Reduced deflection produces distinct benefits in bearing behavior because of uniformity of oil film under load. Reduced stresses assure longer life and resistance to overloads.

The head-shaft assembly is supported by the socket and socket liner which is, in essence, a spherical thrust bearing. The function is to carry the vertical component of the crushing force while allowing the head to oscillate around the theoretical center of rotation.

The socket of carbon steel is of dowelled design. The forces between the head and the socket are normal to the spherical surface of the head and pass through the theoretical center. The line of action of these forces is such that practically pure compression is applied to the socket and liner, reducing deflection and stress to a minimum and promoting good bearing performance.

The force distribution throughout the crusher is based on a vector diagram of the cavity forces during crushing and the reactions at various associated loading points in the crusher. The vector diagram establishes their relative magnitude, direction and points of application. The actual magnitude of these forces is established by the crushing force necessary to lift the adjustment ring off the frame seat. This condition represents the maximum allowable force for normal crushing.

A baffle ring attached to the head is sub-merged around its entire periphery in a water trough resting on the socket. Dust tends to settle into the trough and must be continuously removed to prevent caking. For this reason, water is continuously fed through specially designed nozzles which scour the trough. Overflow water is carried off by internal piping and passages. The seal chamber is vented to atmosphere to prevent siphoning which may cause oil contamination of the water or vice versa.

The gears are straight tooth bevel gears and are designed to AGMA standards using a computerized program which, upon input of the basic information, such as DP, diameters, gear ratio, material properties, tooth type, provides a complete printout of the rated power on the basis of tooth strength and surface durability of the gear. The factor of safety on the gear is in excess of three on the strength basis and in excess of two on the durability basis.

cone crushers for sale

cone crushers for sale

The cone crusherwas designed primarily with a view to achieving top performance in the field of fine-reduction crushing. It has also been adapted to what is designated simply as fine crushing, which extends into a range below that ordinarily defined by the term fine-reduction. Although the eccentric speeds of the various sizes of this type are not quite so high as the speeds used for the Newhouse crusher, the Hydro-cone crusher definitely rates as a high-speed machine, its product comparing quite closely to that of the former type, for equal close-side settings.Probably the outstanding feature of the. Hydrocone crusher is the hydraulic support, from which its name is derived and which is clearly shown in the sectional view. This device makes it possible to adjust the crusher to any desired setting within its range in a matter of seconds;adjustments may be made while the crusher is running, although the feed must be shut off before operating the adjusting pump. An accumulator in the hydraulic system provides protection against tramp iron or packing.

Cone crushers are used in AG and SAG grinding circuits to increase tonnage by effectively dealing with any pebble (critical size) build-up problem. Normally, heavy-duty short-head crushers are employed to crush pebbles. Power and crusher cavity level are the key variables for monitoring and controlling the crusher operation. Crusher product size is adjusted by changing the closed side setting.

On the left is a diagram of the Hydro-cone crushing chamber. A comparison of this chamber with those previously discussed is interesting. It will be noted that the choke-point has been raised far above the discharge level, in fact, to a point not far below the nip-point for the recommended maximum one-way feed dimension. By virtue of the decided flare of the head, and the corresponding flare of the top shell bore, the line-of-mean-diameters slopes sharply away from the crusher centerline. For some, distance above the discharge point the angle between head and concave is very acute; in fact, at the open-side position of the head, this zone is almost parallel. For recommended operating conditions, i.e., for safe combinations of throw and setting, and with screened feed, this type of crushing chamber does not approach anything like a choke or near-choke condition. For the combination shown in the diagram the ratio of volume reduction is almost 1:1 from zone 0-1 to zone 2-3 at the choke-point; consequently, if the crusher is given a screened feed (as all fine-reduction crushers should be) the reduction in voids by the time the choke-point is reached cannot very well reach serious proportions. The diagram shows the standard chamber. With screened feed, these crushers will operate at closed-side discharge settings equal to the throw of the head at the discharge point (usually spoken of as eccentric-throw.)

The level in the crusher feed pocket is an important variable since it can indicate whether the feed is building up. A build-up could lead to a plugin the feed chute, a spill through the skirting on the crusher feed, or a crusher plug. None of these are desirable.

In a normal feed situation, the level in the crusher cavity is kept fairly low, just enough to ensure that there is sufficient feed to keep the crusher working, but if the feed has to be suspended suddenly because of impending plugging, the crush-out wont take too long (10 seconds or less). Normal feed is usually used in standard crushers where the feed particle size is quite large, say greater than 65 mm.

Choke feed is when the crusher cavity is kept full, without spilling out through the skirting. Choke feeding is usually used in short-head crushers where the feed particle is smaller than that for a standard crusher.

This crusher is a modification of the standard machine, developed for fine-crushing duty. Mechanically, the machine is the same in every respect as the standard crusher of the same type, but for each developed size of machine a special top shell and the concave ring has been designed, with reduced receiving opening, reduced angularity between head and concave, and, consequently, superior characteristics at the finer settings. Medium crushing chambers may be operated at close-side settings of one-half the eccentric-throw, on screened feed; hence capacities at the finer settings are better than those of the standard type. Fine crushing chambers operate at one-fourth the eccentric throw. Inasmuch as the maximum feed size is smaller in the case of the fine chamber, the ratios of reduction are approximately the same for both machines.

There are two main types of cone crushers: standard and shorthead. They differ by the shape of the cavity. The standard crusher cavity is wider to accommodate larger feed-size material. The short head crusher is designed to crush finer material and to produce a finer product.

The closest approach between the mantle and the bowl liner is called the closed side setting. This is usually specified by the metallurgist to give the desired crusher product discharge size. It can be checked by running the crusher empty, hanging a lead plug into the crusher bowl, and then removing it to measure the gap. The gap is adjusted by rotating the bowl. Some crushers are equipped with a hydraulic jack mechanism on the crushing head assembly instead of having a bowl adjustment ring. The head can be raised or lowered to meet the operators needs. It can be very helpful in operation and process control.

The Symons Cone Crusher has come into almost universal use during the last few years for the final stage of crushing. It is a development of the secondary gyratory crusher, which is merely a small gyratory crusher designed to break the product of the primary machine down to about 1-in. size; but the main shaft of a cone crusher instead of being suspended from a spider is supported on a large socket bearing situated immediately under the crushing head and protected from grit and dust by a sealing assembly, this bearing taking the whole of the crushing load.

Fig. 8 gives a sectional view of the machine. The main shaft is carried in a long gear-driven eccentric, the rotation of which causes the gyration of the head in the usual way, but the center of gyration is at the apex of the crushing head instead of in the spider. At the top of the bowl, therefore, the lumps of ore entering the crushing zone are cracked by short powerful strokes; but at the bottom the head has a much longer but less powerful stroke, enabling the ore in the finishing stages to be rapidly crushed and quickly discharged without any tendency to choke, a condition which reduces over crushing to a minimum. This, together with the curved shape of the bowl, accounts for the large reduction ratio possible with this type of machine and makes it superior to other secondary crushers and coarse rolls.

It will be seen that the head and the bowl are parallel at the lower part of the crushing zone. The parallel space is deep enough, in conjunction with the speed of gyration, to ensure that no piece of ore can pass through it without being struck two or three times by the head before it falls clear. It follows that, unlike the jaw and gyratory crushers, the size of the product is determined by the distance apart of the bottom edges of the head and bowl in the position when they are closest together.

Coarse buttress threads on the outer circumference of the bowl fit into corresponding threads on the inner side of the adjusting ring, which is held down to the mainframe by a circle of long heavy springs, flexible enough to allow the whole assembly to rise should tramp iron or other uncrushable material enters the crushing zone. By means of a windlass and chain, the bowl can be rotated in the threads that support it in the adjusting ring while the machine is running, thus enabling the bowl liner to be adjusted for wear or the size of the product to be changed without stopping. The cone crusher is usually set to give a 3/8-in. or -in. product when discharging to ball mills.

Table 9 gives particulars of the different sizes of crushers. The capacity figures are based on material weighing 100 lb. per cubic foot and must be increased in direct proportions for heavier ores. It will be noted that each size of machine has two ranges of capacity; this is due to the fact that it can be fitted with a coarse or a fine crushing bowl according to the duty that is required of it. With either one, the range of reduction is greater than is economically possible with any other type of dry crushing machine.

A possible disadvantage of the cone crusher is that as a rule it cannot be choke-fed, but must be given an even feed of ore if it is to do efficient work. Should circumstances call for the installation of a machine that can be run if necessary with the ore piled up over the top of the head, a secondary gyratory crusher of the suspended shaft type will be required. The Traylor Reduction Crusher Type TZ, which is constructed on the principles of an ordinary gyratory crusher, but is fitted with a curved bowl liner similar to that of the Symons Cone Crusher, is designed to meet the case. Although the suspension of the shaft restricts the movement of the head to a smaller circle of gyration than that of the cone crusher, the ratio of reduction is still large enough to enable it to crush the product of the primary breaker to -in. size (-in. for the large machines), and it fulfills the condition that it can be choke-fed. Owing to the smaller movement of the head, however, the capacity for a given range is much less than that of the equivalent size of cone crusher, and the latter is therefore preferred when choke-feeding can be avoided.

The Symons Shorthead Cone Crusher, which is constructed on the same general principles as the larger machine, is designed to follow the latter, taking its product at 1-in. and reducing it to about -in. size. The strains imposed on the crushing members, however, would be very heavy if the machine were run with the discharge opening set to -in. or less. It is usual, therefore, to crush in closed circuit with a screen, the discharge opening of the bowl being set to 5/8 or in. Thus a circulating load is built up and a certain amount of choke-crushing takes place, but the method actually gives greater efficiency with a finer product than can be obtained in an open circuit, whatever the discharge setting of the bowl in the latter case.

In ordinary crushing practice, the grinding section is supplied with -in. or 3/8-in. material direct from Symons Cone Crushers. But the demand is for a finer feed and it seems likely that the Shorthead Cone Crusher will satisfy this demand to the exclusion of fine crushing rolls.

Symons Cone Crushers have been used extensively for secondary crushing in metallic, non-metallic, rock products, and industrial operations. The Symons Cone was developed to give large capacity, fine crushing. The combination of high speed and wide travel of the cone results in a series of rapid, hammer-like blows on the material as it passes through the crushing cavity and permits the free flow of material through the cavity.

Reduction in size of any particle, with each impact of the head, is regulated by the opening between the head and bowl at that point. A threaded arrangement of the bowl affords a quick and easy method for changing the size of the product or to compensate for wear. This adjustment can be made while the crusher is operating. A parallel zone between the lower portion of the crushing members assures uniform sizing.

Frame, adjustment ring, and cone are made of cast steel; gears are made of specially treated steel and have cut teeth; all bearings are bronze; mantle and bowl liners are manganese steel. The head and shaft can be removed as a unit, and other parts such as the eccentric and thrust bearings can easily be lifted out after the head is removed. The countershaft assembly can also be removed as a complete unit.

The circle of heavy coil springs, which holds the bowl and adjustment ring down firmly onto the frame, provides automatic protection against damage due to tramp iron. These springs compress, allowing the bowl to rise the full movement of the head until non-crushable material passes through. The springs then automatically return to their normal position.

Symons Cone Crushers are made in Standard and Short Head types. They are of the same general construction but differ in the shape of the crushing cavity. The Standard cone is used for intermediate crushing. The Short Head cone is used for finer crushing. It has a steeper angle of the head, a shorter crushing cavity, and greater movement of the head at the top of the crushing cavity.

If you observe the illustrations you will notice that the center line of the main shaft is at an angle to the center line of the crusher. The center of the main shaft bisects the center line of the crusher at the opening of the crushing chamber. As the MANTLE revolves that point is the pivot point of the mantle. This means that both the top and the bottom of the crusher mantle have a circular gyrating motion.

Tramp iron had long been a source of worry to those engaged in fine crushing.Here is what one operator had to say.Shutdowns were frequent, costs were uncertain because of enforced delays due to excessive breakage. Plugged machines had to be freed continually with a torch tocut out frozen and wedged-in tramp iron.The cone crusher overcame these troubles,helped reduce and stabilize costs. The bestevidence of this statement is the universalacceptance of the cone as the outstandingcrusher in its field.

While tramp iron is not recommended as a regular diet for a Cone Crusher, its construction is such that damage will not result should any ordinary noncrushable material get into the crushing cavity. The band of heavy coil springs encircling the frame allows the bowl to lift from its seat with each movement of the head until Such non-crushable object passes off into the discharge. The tramp iron shown in the accompanying illustration passed the protective devices installed for its removal and would have resulted in expensive repairs and long shutdown periods for any crusher except the Symons Cone.

Cone crushers can have two types of heads, standard and short head types. The principle difference between the two is in the shape (size and volume) of the crushing cavities and feed plate arrangements. Standard head cone crushers have cavities that are designed to take a primary crushed feed ranging up to 300mm generating product sizes around 20mm to 40mm. For finer products, short head cone crushers are normally used. They have a steeper angle of the head and a more parallel crushing cavity than the standard machines. Due to the more compact chamber volume and shorter working crushing length, the much needed higher crushing forces/power can be imparted to the smaller-sized material being fed to the crusher. Cavities for the short head machine are designed to produce a crushed product ranging from 5mm to 20mm in a closed circuit.

At the discharge end of the cone crusher is a parallel crushing section, where all material passing through must receive at least one impact. This ensures that all particles, which pass through the cone crusher, will have a maximum size, in at least one dimension, no larger than the set of the crusher. For this reason, the set of a cone crusher can be specified as the minimum discharge opening, being commonly known as the closed side setting (CSS).

Here are facts about the conecrusher known as Hydrocone. This line of hydraulically adjusted gyratory crushers was developed in smaller sizes some fifteen years ago by Allis-Chalmers to meet a demand for improved secondary or tertiary crushing units. The line is now expanded to include sizes up to 84-in. diameter cones.

This modern crusher is the result of many years of experience in building all types of crushing equipment, when the first gyratory or cone crusher, the Gates, was put into operation. Overall these years AC has followed a continuing policy of improvement in crusher engineering, changes in design being based on operating experience of crushers in actual operation.

The Hydrocone cone crusher is the logical outgrowth, a crusher having a means of rapidly changing product size or compensating for wear on the crushing surfaces a crusher which produces a better, more cubical product than any comparable crusher and a crusher so designed that it can be operated and maintained with a minimum of expense.

The most important fact about the Hydrocone crusher is its hydraulic principle of operation. Hydraulic control makes possible quick, accurate product size adjustments fast unloading of the crushing chamber in case of power failure or other emergency protection against tramp iron or other uncrushable materials in the crushing chamber. Another important fact about this crusher is its simplicity of design and operation. The accompanying sketch shows the simplicity of the Hydrocone crushers principle of operation. The main shaft assembly, including the crushing cone, is supported on a hydraulic jack. When oil is pumped into or out of the jack the mainshaft assembly is raised or lowered, changing the crusher setting.

Since the crushing cone is supported on a hydraulic jack, its position with respect to the concave ring, and therefore the crusher setting, can be controlled by the amount of oil in the hydraulic jack.

Speed-Set control raises or lowers the crushing shaft assembly hydraulically, and permits quick adjustment to produce precise product specifications without stopping the crusher. Speed-Set control also provides a convenient way to compensate for wear on crushing surfaces.

On Hydrocone crushers in sizes up to 48-in., the Speed-Set device is a hand-driven gear pump; on the larger sizes a motor-driven gear pump operated by push-button. On all sizes the setting can be changed in a matter of minutes by one man without additional equipment, reducing downtime materially.

Protection against tramp iron or other uncrushable materials is afforded by an accumulator in the hydraulic system. This consists of a neoprene rubber oil-resistant bladder inside a steel shell. This bladder is inflated with nitrogen to a predetermined pressure higher than the average pressures encountered during normal crushing.

Ordinarily, the Automatic Reset remains inoperative, but if steel or some other foreign material should enter the crushing chamber, the oil pressure in the hydraulic jack will exceed the gas pressure in the accumulator. The bladder will then compress, allowing the oil to enter the steel shell. This permits the crushing cone to lower and discharge the uncrushable material without damage to the crusher.

After the crushing chamber is freed of the foreign material, the gas pressure in the accumulator will again exceed the oil pressure in the hydraulic system. Oil is then expelled from the accumulator shell and the crushing cone is returned to its original operating setting automatically.

A Hydrocone crusher will produce a cubical product with excellent size distribution and a minimum of flats and slivers. This is especially important in the crushed stone industry where a cubical stone is required to meet rigid product specifications. It is also of considerable significance in the mining industry where the elimination of large amounts of tramp oversize reduces circulating loads or makes open circuit crushing possible.

The reason why the Hydrocone crusher will produce such a uniform, cubical product is that it has a small eccentric throw with respect to the crusher setting. This means a smaller effective ratio of reduction during each crushing stroke, and therefore, the production of fewer fines and slivers. Likewise, a small eccentric throw means a small open side setting, which results in a smaller top size of the product. A large percentage of the product from a Hydrocone crusher will be of a size equal to or finer than the close side setting.

For fine crushing, or in installations where the feed to the crusher is irregular, the use of a wobble plate feeder is recommended. This feeder is installed in place of the spider cap and affords a means of controlling the feed to the crusher, as well as a means of distributing the feed evenly around the crushing chamber.

Essentially, the feeder consists of a plate that is oscillated by a shaft extending down into the crushers main shaft. The motion of the main shaft oscillates or wobbles the feeder plate. The plate is supported on a rubber mounting which permits its motion and, at the same time, positively seals the top of the spider bearing against the entry of dust. Maintenance is reduced by the use of self-lubricating bushings between the feeder plate shaft and the crusher main shaft.

Hydrocone crushers are mounted on rubber machinery mountings in order to reduce installation costs and make it possible to locate these machines on the upper floors of crushing plants. These mountings operate without maintenance, absorb the gyrating motion of the crusher, thereby eliminating the need for massive foundations. Rubber mountings also prolong the life of the eccentric bearing, since this bearing is not subjected to the severe pounding encountered when rigid mountings are used.

The exclusion of dust and dirt from the internal mechanism of the crusher is of extreme importance from a maintenance standpoint. To accomplish this, Hydrocone crushers are equipped with one of the most effective dust seals yet devised.

This seal consists of a self-lubricating, graphite impregnated plastic ring which is supported from the head center in such a way that it is free to rotate, or gyrate, independently of the head center.

The plastic ring surrounds the dust collar with only a very slight clearance between the two parts. With the plastic ring being free to move as it is, it accommodates the rotation, gyration, and vertical movement of the main shaft assembly, maintaining the seal around the dust collar at all times. Because of its lightweight and self-lubricating characteristics, wear on the plastic ring is negligible.

The ease with which any wearing part can be replaced is of the utmost importance to any crusher operator. With this in mind, the Hydrocone crusher has been designed so that any part can be replaced by disturbing only a minimum number of other parts.

For example, the Mantalloy crushing surfaces are exposed by simply removing the top shell from the crusher. This can be done easily by removing the nuts from the studs at the top and bottom shell joint. The eccentric and hydraulic support mechanisms are serviced from underneath the crusher without disturbing any of the feeding arrangements, or the upper part of the crusher.

Efficient lubrication of all wearing parts is one of the reasons why crushing costs are low with the Hydrocone crusher. On most sizes, lubrication is divided into three distinct systems, each functioning independently.

This bearing, whether of the ball and socket type as on the smaller sizes, or of the hourglass design (as shown) found on the larger Hydrocone crushers, is pool lubricated. On the 51, 60 and 84-inch sizes, provision is made for introducing the lubricant from outside the top shell through the spider arm. On the smaller crushers, oil is introduced through an oil inlet in the spider cap. On all sizes, oil is retained in the bearing by a garter-type oil seal located in the base of the spider bearing.

All Hydrocone crushers are provided with a compact external lubrication system consisting of an oil storage tank, an independently motor-driven oil pump, a pressure-type oil filter, and a condenser-type cooler.

Cool, clean oil is pumped into the crusher from the conditioning tank, lubricating first the three-piece step bearing assembly. The oil then travels up the inner surface of the eccentric, lubricating the eccentric bearing and main shaft.

At the top of the eccentric, the oil is split into two paths. Part of the oil flow passes through ports in the eccentric and down its outer surface, lubricating the bronze bottom shell bushing, driving gears and wearing ring. On the 48-in. and smaller crushers, the balance of the oil overflows the eccentric and returns over the gears to the bottom of the crusher where it flows by gravity back into the conditioning tank. On the 51-in. and larger Hydrocone crushers, any oil which overflows the top of the eccentric is returned directly to the conditioning system without coming into contact with the gears.

On all but the 36 and 48-in. Hydrocone crushers, the countershaft bearings are of the anti-friction type with separate pool lubrication. Both ends of the countershaft bearing housing are sealed by garter spring-type oil seals to prevent dirt or other contaminants from entering the system.

Rather than use one eccentric throw under all operating conditions, Hydrocone crushers are designed to operate most efficiently with a predetermined ratio of eccentric throw to the crusher setting. By operating with an eccentric throw specifically selected for a given application, the most desirable crushing conditions are attained the most economical use of Mantalloy crushing surfaces reduced crusher maintenance a more cubical product.

The eccentric throw is controlled by a replaceable bronze sleeve in the cast steel eccentric. This sleeve, being a wearing part, can be renewed readily in the field. Also, should operating conditions change, the throw or motion of the crushing head can be changed accordingly.

Because of the large choice of eccentric throws available and the variety of crushing chambers that may be obtained a Hydrocone crusher may be selected that will fulfill the requirements of almost any secondary or tertiary crushing operation.

They may be used in the crushed stone industries to produce a premium cubical product in the mining industries to produce a grinding mill feed having a minimum of oversize, thereby reducing circulating loads and making open circuit crushing possible. The Hydrocone crusher is used in the cement industry to reduce cement clinker prior to finish grinding.

One of three general types of crushing chambers can be furnished for any size Hydrocone crusher to suit your specific needs. The selection of the proper chamber for a given application is dependent upon the feed size, the tonnage to be handled and the product desired. A crusher already in use can be readily converted to meet changing requirements, making this machine highly flexible in operation.

The Coarse crushing chamber affords the maximum feed opening for a given size crusher. Crushers fitted with a Coarse chamber can be choke fed, provided that product size material in the feed is removed.

The Coarse chamber has a relatively short parallel zone and is designed to be operated at a close side setting equal to or greater than the eccentric throw. For example, a crusher with a 3/8-in. the eccentric throw should be operated at a 3/8-in. (or more) close side setting, and therefore a -in. open side setting. Optimum capacity and product will result when operated under these conditions, as well as most economical wear on the mantalloy crushing surfaces.

One way dimension (slot size) of the feed to a crusher fitted with a Coarse chamber should not exceed two-thirds to 70 percent of the feed opening. The maximum feed size to an 848 Hydrocone crusher would therefore be about 5-in. one way dimension.

The use of a wobble plate feeder, furnished as optional equipment, is recommended if the feed size is relatively large, if the crusher is to be operated in closed circuit, or if the feed to the crusher is irregular.

If the Hydrocone crusher is operated with a Coarse crushing chamber, the product will average about 60% passing a square mesh testing sieve equal to the close side setting of the crusher. On certain materials which break very slabby, this percentage will be somewhat lower, and on cubically breaking material the percentage will be somewhat higher. As an average, approximately 90% of the product will pass a square mesh testing sieve corresponding to the open side setting, although this percentage frequently runs higher.

The Intermediate crushing chamber has a feed opening somewhat less than a coarse crushing chamber, but because of its longer parallel zone, is designed to be operated at a close side setting equal to or greater than half the eccentric throw. For example, with a -in. eccentric throw, the minimum close side setting would be 3/8-in.

Crushers fitted with this type of chamber can be choke fed, provided that product size material in the feed be removed ahead of the crusher. The one-way dimension or slot size of the feed to a crusher should not exceed approximately half the receiving opening. A 436 Hydrocone crusher with a 5/8-in. the eccentric throw could be operated at 5/16-in. close side setting and feed size should not exceed 2-in. one-way dimension.

The wobble plate feeder, although not required under most circumstances, is recommended if the feed is irregular, or if the crusher is operated as a re-crusher, at a relatively close setting, or in a closed circuit.

Because of the longer parallel zone in this crushing chamber, a somewhat greater percentage of the product will pass a square mesh testing sieve equal to the close side setting. This will usually average about 65 to 70%, with this percentage varying, depending on the material being crushed. Very frequently, 100% of the product will pass a square mesh testing sieve equal to the open side setting of the crusher.

The Fine crushing chamber has the longest parallel zone and therefore the smallest feed opening for any given size crusher. It can be operated at ratios of eccentric throw to close side setting of up to 4 to 1. With a -in. throw, for example, a 236 Hydro-cone crusher could be operated at 3/16-in. on the close side.

Because of their design, crushers with Fine crushing chambers cannot be choke fed but must be equipped with the wobble plate feeder. The maximum one-way dimension of the feed approaches the crusher feed opening. A 348 Hydrocone crusher can be fed with material up to 3-in. one-way dimension.

The Fine crushing chamber will give the highest percentage passing the close side setting of any of the chambers discussed here. The product will average approximately 75% passing a square mesh testing sieve equal to the close side setting. Because of the long parallel zone, the top size of the product will be only slightly larger than the close side setting of the crusher.

In addition to the three general types of crushing chambers described here, special chambers can be designed to meet varying operating requirements, giving the crusher even greater flexibility than can be obtained with these three main types.

For example, a special concave ring can be used in a 636 Hydro-cone crusher which will reduce the feed opening to 5 inches and permits a two to one ratio of eccentric throw to close side setting. Thus, the crusher can be furnished to fit the exact requirements of any application.

The following capacity table gives a complete range of all Hydrocone cone crusher capacities with varying crushing chambers and eccentric throws. This table shows the minimum recommended setting for any given eccentric throw, the recommended maximum one-way (slot size) dimension of the feed, and the maximum recommended horsepower for any eccentric throw.

Capacities given are based on crushing dry feed from which the product size material has been removed. The material must readily enter the feed opening and be evenly distributed around the crushing chamber. The table is based on material weighing 100 lb per cubic foot crushed. Any variation from this must be accounted for.

The curves on the following page can be used to approximate the screen analysis of the product from any given Hydrocone crusher. These curves are only approximations since the actual screen analysis of the product of a Hydrocone crusher will depend upon the nature of the material being crushed, the feed size and a number of other considerations which could not be taken into account in these curves. Within these limits, the curves should give fairly accurate estimates.

Note that the Coarse crushing chamber is represented as giving a product of which 60 percent will pass the close side setting, the Intermediate chamber 67 percent and the Fine chamber 75 percent passing the close side setting. These percentages are the averages of a large number of tests and some variations from these must be expected. If material breaks slabby the percentage with a coarse crushing chamber may be as low as 50 percent; if it breaks very cubically it might be as high as 70 percent, or even higher.

These curves have been prepared so that they can be used for any crushing chamber. To estimate the product of any Hydrocone crusher, it is necessary to know the type of crushing chamber used (Coarse, Intermediate or Fine), the close side setting and the eccentric throw.

If the crusher is a 636 Hydrocone crusher with a 3/8-in. throw and a 3/8-in. close side setting, the approximate screen analysis would be the curve that would pass through the 3/8-in. horizontal line and the vertical line representing the close side setting for the Coarse crushing chamber, which is the 60 percent passing line. If no curve passes through the precise point of intersection between the horizontal and vertical lines, an approximate curve can be sketched in which parallels the other curves. The same procedure can be used for approximating the products from any other crushing chamber.

Barite..170 Basalt.100 Cement Clinker.95 Coal..40-60 Coke.23-32 Glass..95 Granite100 Gravel.100 Gypsum..85 Iron Ore.125-150 Limestone..95-100 Magnesite.100 Perlite..95 Porphyry.100 Quartz..95 Sandstone..85 Slag..80 Taconite125 Talc..95 Trap Rock100

We canprovide testing to solve the most difficult crushing problems. Laboratory equipment makes it possible to measure the crushing strengths and characteristics of rock or ore samples accurately, and this data is used in the selection of a crusher of proper size and type.

Impact and batch tests are frequently sufficient to indicate the type and size crusher that will be the most economical for a particular application. However, batch testing is often followed by pilot plant tests to provide additional information about large-scale operations, or to observe rock or ore reduction under actual plant operating conditions.

Pilot plant tests duplicate a continuous crushing operation provide a practical demonstration of the commercial potential of the process on a pilot scale. Such tests are useful because they may disclose factors that affect the full-scale operation, favorably or otherwise, but which remain hidden in tests on limited samples.

All Laboratory tests are guided by modern scientific knowledge of crushing fundamentals and by ourinvaluable backlog of experience in engineering and building all types of crushing equipment for any crushing application.

In addition to the facilities for crushing tests, the Laboratory maintains complete batch and pilot mill facilities for use in investigating an entire process. Tests in grinding, sizing, concentrating, thickening, filtering, drying, and pyro- processing can be made.

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