MP_PPT_BATCH_-1.pptx about mineral proceesing and crushing

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1. JNTUH UNIVERSITY COLLEGE OF ENGINEERING SCIENCE AND TECHNOLOGY HYDERABAD KUKATPALLY, HYDERABAD II.BTECH I SEMESTER [2023-2024] MINERAL PROCESSING

2. Presented By: Batch-1 Guguloth Pavan (19011A0616) Eshita Kundu (22011A0601) Rohith Polluru (22011A0602) Suddapalli Venkata Sathwik Sharma(22011A0603) Kedarajupalli Venugopi (22011A0604) Bommakanti Chandana (22011A0605) Yerramasetti TejaSree (22011A0606) Bhukya Eshwar (22011A0608)

3. Sampling

4. Table of content Introduction​ Definition of Sampling Objectives of Sampling Sample Division Methods ​Methods of Sampling Summary

5. Introduction Sampling is a fundamental process in mineral dressing, playing a crucial role in accurately characterizing ore bodies for efficient mineral processing. It forms the foundation for decision-making in the mining industry, impacting the design and optimization of mineral processing plants. Sampling 5

6. Definition of Sampling 6 Sampling is the systematic process of selecting and collecting representative samples from A bulk material, ensuring the obtained samples mirror the true nature of the entire ore body

7. Objectives of Sampling Representative Samples Obtain representative samples to reflect the true mineralogical and metallurgical characteristics of the ore body. Minimize Errors Minimize sampling errors through careful selection and execution of sampling techniques. Accurate Analysis Facilitate accurate mineralogical and metallurgical analysis by ensuring the samples are truly reflective of the ore Sampling 7

8. Types of sampling 8 Coning And Quartering : This is an old Cornish method which is often used in dividing samples of material. 2. The Jones Riffle : The Jones Riffle consists of a series of inclined chutes or channels that are arranged in a V-shape or zigzag pattern.

9. It consists of pouring the material into a conical heap and relying on its radial symmetry to give four identical samples when the heap is flattened and divided by a cross-shaped metal cutter. Two opposite corners are taken as the sample, the other two corners being discarded. The portion chosen as the sample may again be coned and quartered, and the process continued until a sample of the required size is produced. Although accuracy is increased by crushing the sample between each division, the method is very dependent on the skill of the operator and should not be used for accurate sampling. Sampling 9 CONING AND QUARTERING

10. Sampling 10

11. 11 THE JONES RIFFLE Sampling This splitter is an open V-shaped box in which a series of chutes is mounted at right angles to the long axis to give a series of rectangular slots of equal area alternatively feeding two trays placed on either side of the trough The laboratory sample is poured into the chute and split into equal portions by the slots, until after repeated cycles a sample of the desired size is obtained. A much more robust approach is to use a vibratory feeder to distribute the bulk sample into a number of wedge shaped containers as shown in Figure 3.5 This device is sometimes called a "spinning riffle" or "rotating sampler" and is the most accurate method of extracting representative samples from dry granular or powdered material.

12. 12 Sampling

13. Crushers Crushers 13

14. Table of Content Introduction Types of Crushers Primary Crushers Jaw Crusher Gyratory Crusher Secondary Crushers Cone Crusher Roll Crusher

15. Introduction Crushing is the first mechanical stage in the process of comminution in which a principal objective is the liberation of the valuable minerals from the gangue. Crushing is typically a dry operation that is performed in two- or three-stages

16. Crushing Jaw Crusher Gyratory Crusher Cone Crusher Roll Crusher PRIMARY CRUSHER SECONDARY CRUHSER The Feed Size Varies from 3” to 30” The Feed Size Varies from 1.5” to 6”

17. Primary Crusher 17 Jaw Crusher Gyratory crusher PRIMARY CRUSHING: Reduction of ore = as mined size 1m to 100mm size The objects of crushing are Size reduction Production of minimum amount of fines Primary crushing is done on dry material

18. JAW Crusher It has two crushing faces – JAWS. The jaws are made of cast steel. They are fitted with replaceable liners made of manganese steel or Ni-hard (a Ni-Cr alloyed cast iron). They are mounted on a rigid frame. One jaw is stationary, the other is movable. The feed ore is squeezed till it breaks. The fragments move down to a narrow part of the wedge. They get squeezed repeatedly. The final products escape through the narrow gap at the bottom. It moves towards and away from the stationary jaw by a small throw. 18 Crusher

19. Crushers TYPES OF JAW CRUSHERS 1.Blake Crusher 2.Dodge Crusher 3.Universal Crusher 19 Jaw crushers are classified based on: the point of minimum amplitude of motion on the moving face the way of transmitting the movement to the immovable face

20. 1.Blake jaw crusher(1858) – very large in size The Blake crusher of the jaw crushers used today was patented by E.W. Blake in 1858 and variations in detail on the basic form are found in most The patent states that the stone breaker “consists of a pair of jaws, one fixed and the other movable, between which the stones are to be broken.” The jaws are set at an acute angle with one jaw pivoting so as to swing relative to the other fixed jaw. Material fed into the jaws is repetitively nipped and released to fall further into the crushing chamber until the discharge aperture. The Blake crusher, the jaw is pivoted at the top and thus has a fixed receiving area and a variable discharge opening There are two forms of the Blake crusher: Single toggle Double toggle 20 Crusher

21. Single toggle jaw crusher In single-toggle jaw crushers the swing jaw is suspended on the eccentric shaft, which allows a lighter, more compact design than with the double-toggle machine. The motion of the swing jaw also differs from that of the double-toggle design. The swing jaw move toward the fixed jaw under the action of the toggle plate. This elliptical jaw motion assists in pushing rock through the crushing chamber The single-toggle machine therefore has a somewhat higher capacity than the double-toggle machine of the same gape The eccentric movement, increases the rate of wear on the jaw plates. Direct attachment of the swing jaw to the eccentric imposes a high degree of strain on the drive shaft, and as such maintenance costs tend to be higher than with the double-toggle machine. Crushers 21

22. Double Toggle Jaw crusher In a double-toggle Blake crushers, the oscillating movement of the swinging jaw is effected by vertical movement of the pitman, which moves up and down under the influence of the eccentric. The back toggle plate causes the pitman to move sideways as it is pushed upward. This motion is transferred to the front toggle plate, which in turn causes the swing jaw to close on the fixed jaw, this minimum separation distance being the closed set (or closed side setting). Downward movement of the pitman allows the swing jaw to open, defining the open set (or open side setting). Double-toggle machines are usually used on tough, hard and abrasive material. Crushers 22

23. Crushers 23 Double Toggle Jaw Crusher

24. 2.Dodge Crusher Here the jaw action is reverse to that of the Blake jaw crusher In the dodge crusher, the jaw is pivoted at the bottom, giving it a variable feed area but fixed delivery area Maximum crushing is given to the largest piece and minimum to the smallest. Only a small variation of set occurs on the advancing and receding actions of the movable jaw. It has constant discharge opening which we get more uniform product size The dodge crusher is restricted to laboratory use, where close sizing is required. Crushers 24

25. Dodge Crusher 25 Crushers

26. Gyratory Crusher Gyratory crushers are principally used in surface crushing plants. The gyratory crusher consists essentially of a long spindle, carrying a hard steel conical grinding element, the head, seated in an eccentric sleeve The spindle is suspended from a “spider” and, as it rotates, normally between 85 and 150 rpm, it sweeps out a conical path within the fixed crushing chamber, or shell, due to the gyratory action of the eccentric. The gyratory crusher is a good example of arrested crushing. The spindle is free to turn on its axis in the eccentric sleeve, so that during crushing the lumps are compressed between the rotating head and the top shell segments, and abrasive action in a horizontal direction is negligible 26 Crusher

27. The gyratory, unlike the jaw crusher, crit has a higher capacity than a jaw crusher of the same gape, roughly by a factor of 2.5 – 3 and , It is favored in plants handling large throughputs: in mines with crushing rates above 900 th ¯¹ , gyratory crushers are always selected. Gyratory crushers are identified by the size of the gape and the size of the mantle at the discharge They range in size up to ca. 1,600 mm x 2,900 mm (gape 3 mantle diameter) with power consumption as high as 1,200 kW and capable of crushing up to ca. 10,000 th ¯¹ at a discharge open side setting up to 240 mm 27 Crushers

28. Gyratory crusher 28 Crushers

29. Secondary Crusher 29 CONE Crusher RoLL crusher SECONDARY CRUSHING: Secondary crushers are lighter than the heavy-duty, rugged primary machines Secondary crushing is done to reduce the ore size suitable for (wet) grinding. The feed size will be less than 150 mm avg. Dia & product size - 12 mm av.Dia. Secondary crushers are arranged in series with the primary crushers. Crushers

30. The cone crusher is a modified gyratory crusher, and accordingly many of the same terms including gape, set, and throw, apply. The essential difference is that the shorter spindle of the cone crusher is not suspended, as in the gyratory, but is supported in a curved, universal bearing below the gyratory head or cone Product of cone crusher is the feed of grinding mill It is work in closed circuit with double deck screen Product is more uniform in size 30 CONE Crusher Crushers

31. Cone Crusher 31 Crushers

32. Roller crusher, also known as double roller crusher, when the material enters between two rollers, due to the effect of friction, the ore is carried into the crushing space between the two rollers, compressed and crushed . Roll crushers can be effective in handling friable, sticky, frozen, and less abrasive feeds, such as limestone, coal, chalk, gypsum, phosphate, and soft iron ores. Roll crusher operation is fairly straightforward: the standard spring rolls consist of two horizontal cylinders that revolve toward each other The gap (closest distance between the rolls) is determined by. Shims which cause the spring-loaded roll to be held back from the fixed roll. Reduction is progressive by repeated nipping action as the material passes down to the discharge, the crushing process in rolls is one of single pressure. 32 Roll Crusher Crushers

33. Angle of nip For a particular operation where the ore size is known, it is necessary to estimate the diameter of rolls required for a specific degree of size reduction. To estimate the roll diameter it is convenient to assume that the particle to be crushed is spherical and roll surfaces are smooth. The Figure shows a spherical particle about to enter the crushing zone of a roll crusher and is about to be nipped. For rolls that have equal radius and length, tangents drawn at the point of contact of the particle and the two rolls meet to form the nip angle (2 θ ). From simple geometry it can be seen that for a particle of size d, nipped between two rolls of radius R Crushers 33 Where R is the roll radius and L the distance between the rolls

34. Comparison between roll & cone crushers: Roll crusher production smaller of fines than cone crushers and smaller reduction ratio. Rolls, because of their inability to yield high reduction ratio, have not been installed in recent years Reduction ratio for rolls should not exceed similar to cone crushers Rolls remain to be the best device for intermediate crushing. Crushers 34

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