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roller crushers for iron ore sydney

roll crusher with stable performance | fote machinery

roll crusher with stable performance | fote machinery

Applied materials: coal, pebble, limestone, dolomite, granite, construction waste, pebbles, glass, cement clinker, basalt, iron ore, quartz stone, coal gangue, etc. Its advantages: high capacity, ability to handle wet, sticky feeds.

Roll crusher, as one of the most economical and practical crushers, is designed to handle the first and second crushing of friable minerals and stones such as coal, clay, coal gangue, limestone, slag, cement clinkers, and shale, etc.

According to the number of rollers, the FTM roll crushers can be divided into three types: single roll crusher, double-roll crusher, and multi-roll crusher. And the most common one is double-roll crusher.

Roll crusher is applied more widely than other crushers because of its small volume and cheap price. With the adjustable discharging system, it can be used flexibly in coarse and fine crushing processes of the industries such as cement, chemical engineering, electricity, mining, metallurgy, building materials, and others.

Roll crushers can adjust the wedge device between rollers to control the feed and discharge size of the machine. Also, it is equipped with a spring device to protect the crushing machine and avoid shutdown caused by overload and iron passing.

When the adjustable bolt pulls the wedge upward, the wedge pushes the movable roller away from the fixed wheel, then the gap between the two rollers becomes larger, and the discharge port becomes larger, and vice versa.

The gasket device adjusts the size of the discharge by increasing or decreasing the thickness of the gasket. When the gasket is added, the gap between the two rollers becomes larger, and vice versa.

The unique structure of rollers makes selective crushing of the roll crushing equipment. Since minerals fed are crushed along its internal friable crack, the finished products are uniform with the cube shape.

The minerals are crushed under the force of rollers and machine body, and ores smaller than the gap between roller and machine frame (of single roll crusher) or roller (of multi-roll crusher) will pass directly without repeated crushing.

With the supporting CPU, operators can control roll crushing machines and monitor gaps between rollers, and clean up the crushing cavity through the central control room, which will help save energy of 30% to 50%.

The main working parts of the roller crusher is the cylindrical rollers. The rollers are supported by the fixed and movable bearings, and they are relatively rotating which are driven by the motor. The materials are crushed by the friction of the rotating rollers, and the finished products are discharged from the gap of the rollers.

The spring is used to balance the pressure generated between the rolls. If there are non-crushed materials falling between the two rollers, the compression spring of bearings can be pushed to make a large gap so that non-crushed materials can be discharged immediately.

The quality of the crushers has a great impact on its price. The high-quality equipment will cost more in terms of workmanship, technology, materials, etc. Meanwhile, it will have a long service life, low failure rate, and better performance, and bring more profit to investors.

In 2019, Fote has exported a total of 39 roll crushers to India, Indonesia, Zimbabwe, Vietnam, South Africa, the United States, Pakistan, the Philippines and other countries, mainly for coal, bentonite, rare earth ore, limestone, aluminum, manganese and others.

Exports of mining machinery have been booming in recent years and Fote has already opened markets in Africa, Southeast Asia, etc. Fote Heavy Machinery has supported foreign customers with low-price and high-quality roll crushing equipment, which has been popular among the majority of customers.

In recent years, the Indonesian government has taken actions to improve its infrastructure and promote economic development. As a result, Indonesia's demand for crushers has increased significantly.

The roll crusher produced by Fote has fine finished products and the best effect on sand making for river pebble. Due to its good finished product size, low powder content and low price, it is widely favored by Indonesian customers.

Firstly, Fote Heavy Machinery is a professional manufacturer of roller crushers. In order to improve the company's comprehensive strength, Fote has introduced international first-class production lines on the basis of original techniques.

Secondly, FTM produces various types of crushing equipment that is suitable for crushing, sand making and milling hundreds of minerals, and ensures excellent quality, good performance and low price.

Thirdly, Fote has provided patient and prudential after-sales service and all-round consideration for customers, and actively created high-tech crushing equipment to take the leading position in the international market.

As a leading mining machinery manufacturer and exporter in China, we are always here to provide you with high quality products and better services. Welcome to contact us through one of the following ways or visit our company and factories.

Based on the high quality and complete after-sales service, our products have been exported to more than 120 countries and regions. Fote Machinery has been the choice of more than 200,000 customers.

roller crushers in iron mining, how does the degradation of hadfield steel components occur? - sciencedirect

roller crushers in iron mining, how does the degradation of hadfield steel components occur? - sciencedirect

The performance of the crusher steel component is a function of abrasion-impact process.Two wear/damage scales: micro- and macro scales were observed.Dynamic recrystallization on the working surface of the Hadfield steel was detected.Mechanical twinning was the main deformation mechanism.Crack propagation was observed trough with carbides at the grain boundaries.Cracks propagated along the grain boundaries related to the (111) orientation.

This work shows, for the first time, a systematic wear and damage analysis on a novelty roller crusher component used in the iron ore mining industry. Crusher suffers from complex abrasive-impact load during the comminuting the mineral ore in processing plants, which induce severe damage and defects that can result in a decreased performance or in a crusher breakage. The wear mechanisms and the extent of deformation have been studied by microhardness measurements, optical microscopy (OM), scanning electron microscopy (SEM) including electron backscattering diffraction (EBSD) and transmission electron microscopy (TEM). It was found that the abrasive-impact contact causes a significant hardness increment of over 700HV, around three times than initial state of the base material, and the strain hardening extends up to a depth in the extremely deformed region above 18mm from the worn surface. SEM results of worn surfaces showed the impact and abrasion damages. Microstructure cross-section analyses exhibited the deformed microstructure is composed of bands and deformation twins. Also, it was observed the presence of crack propagated along with the large carbides at the grain boundaries. EBSD analysis of cracked and non-crack areas revealed that the high-distorted Taylor factor grains accompanied by grains oriented {111} parallel to the abrasive-impact dynamic load direction were susceptible to fatigue crack formation and propagation. Near to the cracks, a significant increase in dislocation density was found compared to other deformed regions, suggesting that these regions had a high level of stored energy resulting in an exhaust of the ability of plastic deformation. TEM results confirm the formation of nanoscale grains on the deformed surface layer.

iron ore processing,crushing,grinding plant machine desgin&for sale | prominer (shanghai) mining technology co.,ltd

iron ore processing,crushing,grinding plant machine desgin&for sale | prominer (shanghai) mining technology co.,ltd

After crushing, grinding, magnetic separation, flotation, and gravity separation, etc., iron is gradually selected from the natural iron ore. The beneficiation process should be as efficient and simple as possible, such as the development of energy-saving equipment, and the best possible results with the most suitable process. In the iron ore beneficiation factory, the equipment investment, production cost, power consumption and steel consumption of crushing and grinding operations often account for the largest proportion. Therefore, the calculation and selection of crushing and grinding equipment and the quality of operation management are to a large extent determine the economic benefits of the beneficiation factory.

There are many types of iron ore, but mainly magnetite (Fe3O4) and hematite (Fe2O3) are used for iron production because magnetite and hematite have higher content of iron and easy to be upgraded to high grade for steel factories.

Due to the deformation of the geological properties, there would be some changes of the characteristics of the raw ore and sometimes magnetite, hematite, limonite as well as other types iron ore and veins are in symbiosis form. So mineralogy study on the forms, characteristics as well as liberation size are necessary before getting into the study of beneficiation technology.

1. Magnetite ore stage grinding-magnetic separation process The stage grinding-magnetic separation process mainly utilizes the characteristics of magnetite that can be enriched under coarse grinding conditions, and at the same time, it can discharge the characteristics of single gangue, reducing the amount of grinding in the next stage. In the process of continuous development and improvement, the process adopts high-efficiency magnetic separation equipment to achieve energy saving and consumption reduction. At present, almost all magnetic separation plants in China use a large-diameter (medium 1 050 mm, medium 1 200 mm, medium 1 500 mm, etc.) permanent magnet magnetic separator to carry out the stage tailing removing process after one stage grinding. The characteristic of permanent magnet large-diameter magnetic separator is that it can effectively separate 3~0mm or 6~0mm, or even 10-0mm coarse-grained magnetite ore, and the yield of removed tails is generally 30.00%~50.00%. The grade is below 8.00%, which creates good conditions for the magnetic separation plant to save energy and increase production.

2.Magnetic separation-fine screen process Gangue conjoined bodies such as magnetite and quartz can be enriched when the particle size and magnetic properties reach a certain range. However, it is easy to form a coarse concatenated mixture in the iron concentrate, which reduces the grade of the iron concentrate. This kind of concentrate is sieved by a fine sieve with corresponding sieve holes, and high-quality iron concentrate can be obtained under the sieve.

There are two methods for gravity separation of hematite. One is coarse-grained gravity separation. The geological grade of the ore deposit is relatively high (about 50%), but the ore body is thinner or has more interlayers. The waste rock is mixed in during mining to dilute the ore. For this kind of ore, only crushing and no-grinding can be used so coarse-grained tailings are discarded through re-election to recover the geological grade.

The other one is fine-grain gravity separation, which mostly deals with the hematite with finer grain size and high magnetic content. After crushing, the ore is ground to separate the mineral monomers, and the fine-grained high-grade concentrate is obtained by gravity separation. However, since most of the weak magnetic iron ore concentrates with strong magnetic separation are not high in grade, and the unit processing capacity of the gravity separation process is relatively low, the combined process of strong magnetic separation and gravity separation is often used, that is, the strong magnetic separation process is used to discard a large amount of unqualified tailings, and then use the gravity separation process to further process the strong magnetic concentrate to improve the concentrate grade.

Due to the complexity, large-scale mixed iron ore and hematite ore adopt stage grinding or continuous grinding, coarse subdivision separation, gravity separation-weak magnetic separation-high gradient magnetic separation-anion reverse flotation process. The characteristics of such process are as follows:

(1) Coarse subdivision separation: For the coarse part, use gravity separation to take out most of the coarse-grained iron concentrate after a stage of grinding. The SLon type high gradient medium magnetic machine removes part of the tailings; the fine part uses the SLon type high gradient strong magnetic separator to further remove the tailings and mud to create good operating conditions for reverse flotation. Due to the superior performance of the SLon-type high-gradient magnetic separator, a higher recovery rate in the whole process is ensured, and the reverse flotation guarantees a higher fine-grained concentrate grade.

(2) A reasonable process for narrow-level selection is realized. In the process of mineral separation, the degree of separation of minerals is not only related to the characteristics of the mineral itself, but also to the specific surface area of the mineral particles. This effect is more prominent in the flotation process. Because in the flotation process, the minimum value of the force between the flotation agent and the mineral and the agent and the bubble is related to the specific surface area of the mineral, and the ratio of the agent to the mineral action area. This makes the factors double affecting the floatability of minerals easily causing minerals with a large specific surface area and relatively difficult to float and minerals with a small specific surface area and relatively easy to float have relatively consistent floatability, and sometimes the former has even better floatability. The realization of the narrow-level beneficiation process can prevent the occurrence of the above-mentioned phenomenon that easily leads to the chaos of the flotation process to a large extent, and improve the beneficiation efficiency.

(3) The combined application of high-gradient strong magnetic separation and anion reverse flotation process achieves the best combination of processes. At present, the weak magnetic iron ore beneficiation plants in China all adopt high-gradient strong magnetic separation-anion reverse flotation process in their technological process. This combination is particularly effective in the beneficiation of weak magnetic iron ore. For high-gradient strong magnetic separation, the effect of improving the grade of concentrate is not obvious. However, it is very effective to rely on high-gradient and strong magnetic separation to provide ideal raw materials for reverse flotation. At the same time, anion reverse flotation is affected by its own process characteristics and is particularly effective for the separation of fine-grained and relatively high-grade materials. The advantages of high-gradient strong magnetic separation and anion reverse flotation technology complement each other, and realize the delicate combination of the beneficiation process.

The key technology innovation of the integrated dry grinding and magnetic separation system is to "replace ball mill grinding with HPGR grinding", and the target is to reduce the cost of ball mill grinding and wet magnetic separation.

HPGRs orhigh-pressure grinding rollshave made broad advances into mining industries. The technology is now widely viewed as a primary milling alternative, and there are several large installations commissioned in recent years. After these developments, anHPGRsbased circuit configuration would often be the base case for certain ore types, such as very hard, abrasive ores.

The wear on a rolls surface is a function of the ores abrasivity. Increasing roll speed or pressure increases wear with a given material. Studs allowing the formation of an autogenous wear layer, edge blocks, and cheek plates. Development in these areas continues, with examples including profiling of stud hardness to minimize the bathtub effect (wear of the center of the rolls more rapidly than the outer areas), low-profile edge blocks for installation on worn tires, and improvements in both design and wear materials for cheek plates.

With Strip Surface, HPGRs improve observed downstream comminution efficiency. This is attributable to both increased fines generation, but also due to what appears to be weakening of the ore which many researchers attribute to micro-cracking.

As we tested , the average yield of 3mm-0 and 0.15mm-0 size fraction with Strip Surface was 78.3% and 46.2%, comparatively, the average yield of 3mm-0 and 0.3mm-0 with studs surface was 58.36% and 21.7%.

These intelligently engineered units are ideal for classifying coarser cuts ranging from 50 to 200 mesh. The feed material is dropped into the top of the classifier. It falls into a continuous feed curtain in front of the vanes, passing through low velocity air entering the side of the unit. The air flow direction is changed by the vanes from horizontal to angularly upward, resulting in separation and classification of the particulate. Coarse particles dropps directly to the product and fine particles are efficiently discharged through a valve beneath the unit. The micro fines are conveyed by air to a fabric filter for final recovery.

Air Magnetic Separation Cluster is a special equipment developed for dry magnetic separation of fine size (-3mm) and micro fine size(-0.1mm) magnetite. The air magnetic separation system can be combined according to the characteristic of magnetic minerals to achieve effective recovery of magnetite.

After rough grinding, adopt appropriate separation method, discard part of tailings and sort out part of qualified concentrate, and re-grind and re-separate the middling, is called stage grinding and stage separation process.

According to the characteristics of the raw ore, the use of stage grinding and stage separation technology is an effective measure for energy conservation in iron ore concentrators. At the coarser one-stage grinding fineness, high-efficiency beneficiation equipment is used to advance the tailings, which greatly reduces the processing volume of the second-stage grinding.

If the crystal grain size is relatively coarse, the stage grinding, stage magnetic separation-fine sieve self-circulation process is adopted. Generally, the product on the fine sieve is given to the second stage grinding and re-grinding. The process flow is relatively simple.

If the crystal grain size is too fine, the process of stage grinding, stage magnetic separation and fine sieve regrind is adopted. This process is the third stage of grinding and fine grinding after the products on the first and second stages of fine sieve are concentrated and magnetically separated. Then it is processed by magnetic separation and fine sieve, the process is relatively complicated.

At present, the operation of magnetic separation (including weak magnetic separation and strong magnetic separation) is one of the effective means of throwing tails in advance; anion reverse flotation and cation reverse flotation are one of the effective means to improve the grade of iron ore.

In particular, in the process of beneficiation, both of them basically take the selected feed minerals containing less gangue minerals as the sorting object, and both use the biggest difference in mineral selectivity, which makes the two in the whole process both play a good role in the process.

Based on the iron ore processing experience and necessary processing tests, Prominer can supply complete processing plant combined with various processing technologies, such as gravity separation, magnetic separation, flotation, etc., to improve the grade of TFe of the concentrate and get the best yield. Magnetic separation is commonly used for magnetite. Gravity separation is commonly used for hematite. Flotation is mainly used to process limonite and other kinds of iron ores

Through detailed mineralogy study and lab processing test, a most suitable processing plant parameters will be acquired. Based on those parameters Prominer can design a processing plant for mine owners and supply EPC services till the plant operating.

Prominer has been devoted to mineral processing industry for decades and specializes in mineral upgrading and deep processing. With expertise in the fields of mineral project development, mining, test study, engineering, technological processing.

predicting the operational efficiency of high-pressure roller crushers | springerlink

predicting the operational efficiency of high-pressure roller crushers | springerlink

Models based on regression analysis for predicting the operational efficiency of high-pressure roller crushers are considered. A systematized and structured production database is created and statistically analyzed. The consistency of the data is verified. The parameters with the greatest influence on the productivity are identified. The basic structure of the mathematical models is determined, and the limits on their applicability are assessed. Predictive mathematical models are developed. Their adequacy is verified, and their precision is established in assessing the productivity of mills at an enrichment plant where the mineral composition of the incoming ore varies.

Strategiya razvitiya mineralno-syrevoi bazy Rossiiskoi Federatsii do 2035 goda (utverzhdennaya Rasporyazheniem Pravitelstva RF ot 22 dekabrya 2018 goda no.2914-r (The Strategy of Development of Mineral Resources of Russian Federation until 2035 Aproved by the Resolution of RF Government No. 2914-r of December 22, 2014), Moscow, 2014.

Morkun, V.S. and Lutsevich, I.A., Adaptivnye sistemy optimalnogo upravleniya tekhnologicheskimi protsessami gorno-obogatitelnykh kombinatov (Adaptive Systems for Optimal Control of Technological Processes of Mining and Processing Plants), Moscow: Mineral, 2009.

Kozin, V.Z., Trop, A.E., and Komarov, A.Ya., Avtomatizatsiya proizvodstvennykh protsessov na obogatitelnykh fabrikakh; Uchebnoe posobie dlya vuzov (Automated Industrial Processes at Processing Plants: Manual for Higher Education Institutions), Moscow: Nedra, 1980.

Protsuto, V.S., Avtomatizirovannye sistemy upravleniya tekhnologicheskimi protsessami obogatitelnykh kombinatov (Automated Control Systems of Technological Processes at the Processing Plants), Moscow: Nedra, 1987.

Zaitseva, T.V., Vasina, N.V., Pusnaya, O.P., et al., Computer-based solution tree software for implementation of the problems of classification and forecasting, Nauchn. Ved. Belgorod. Gos. Univ., Ser.: Ekon., Inf., 2013, vol. 7 (150), no. 26-1, pp. 121127.

Ivashchuk, O.A., Ivashchuk, O.D., Fedorov, V.I. et al. Predicting the Operational Efficiency of High-Pressure Roller Crushers. Russ. Engin. Res. 40, 970972 (2020). https://doi.org/10.3103/S1068798X2011009X

roller crusher, double toothed roll crusher, smooth roll crusher, teeth roll crusher - ftm crusher company

roller crusher, double toothed roll crusher, smooth roll crusher, teeth roll crusher - ftm crusher company

The crushing capacity of roller crusher machine mainly depends on a pair of cylindrical rollers, which are installed horizontally on frame. Materials are crushed under the active force of rotational rollers. Therefore, we call it roller crusher.

1. Users can take the roller crusher to crush mineral ores with medium harness. Since the shape, size and array of teeth on roller surface can be changed with the property of raw material, either the secondary or tertiary crushing is easy to realize.

3. If the compressive strength of raw material is less than 160MPa, clients can take use of the smooth roll crusher. Double roll crusher has advantages like small discharging size, cheap price, strong wearable parts and reliable operation, etc.

1. If some non-crushing material enter into the space between rollers like drill bit, severe consequence will occur. Therefore, before crushing the material, smooth roller crusher should equip an device for absorbing iron and other matters.

2. If the double roll crusher works for a much longer period of time, the discharging size of finished products will be overly fine. At this time, users should adjust the discharging mouth or overhaul the whole machine.

The so-called double toothed roller crusher has discharger on its roller, which can clean tooth ace and roller surface. The applied material for teeth roller crusher are diverse. Double toothed roller crusher can crush limestone and rocks with compressive strength more than 200MPa. However, the most suitable materials for teeth roll crusher are clammy ones with water content between 25%-30% or hard material with mud inside. Since the teeth roll crusher has advantages like little dust, low noise and small floor space, etc, more and more people would like to throw olive branch to it.

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