EXPERIMENT #2

2.1. Objectives: The main objectives of this experiment are to study the various parts of
Laboratory Roll crusher with special emphasis on their functions, to perform a crushing test on a
given sample, to analyze the product by sieve analysis and to calculate its reduction ratio by feed
size and product size measurement

2.2. Summary: We need different sizes of particles for different purposes. But on earth crust
we may find majority of particles in bulk form. To make the particles of required size, we use
crushers. One of the best crushers used at industrial scale is Roll Crusher. This gives us 4:1
reduction ratio. Due to their fine reduction ratio, it is widely used in many mining industries as
well as in industries like cement, limestone etc. In this experiment, we gave a specific amount of
feed in roll crusher and after a while obtained the product. Its feed comes from the primary
crusher whose size is 10 cm - 25 cm. A roll crusher further reduces the size to 2 cm - 5 cm. Then
we analyzed the product through sieve analysis by passing it through different size screens. We
measured the respective amounts in sieve analysis and calculated the reduction ratio. Through
this experiment we came to know that how we can get particles of required sizes by using Jaw
Crusher. Furthermore we also made different graphs to ensure our calculations and concluded the
end results in the form discussion.

2.3 Theory:
2.3.1 Introduction
 Crushing:

“Crushing is the dry process to deform, pulverize and in which the large materials (e.g. ores,
minerals, rocks etc) are broken into small pieces by applying pressure through mechanical
operations.”

 Objectives of crushing:
 To increase the surface area.
 Better handling of material (easy transportation).
 Liberation of desired particles.
 To prepare the feed for desired purpose.
 Types of crushing:
 Primary crushing
 Secondary crushing
 Tertiary crushing

Primary crushing:
 In primary crushing, ore extracted from rock (100 cm) reduces into small particles with an
average diameter of 10-25 cm. The material reduces to such size that can be conveyed and
fed to the secondary crusher.

Primary crushers:

 Jaw crusher
 Gyratory crusher

Secondary crushing:

In secondary crushing, material from the primary crusher again reduces from 25cm to 2-5cm
in diameter.

Secondary crushers:

 Jaw
 Roll crusher
 Impact crusher or Hammer mill
o Fixed hammer mill
o Rotary hammer mill
 Cone crusher

Tertiary crushing:

In tertiary crushing, output material from primary crusher renters into it and again reduces
the size of particle from 10cm-0.5-2cm.

 Factors affecting the crushing process:

 Hardness of rocks
 Size distribution of feed
 Reduction ratio
 Speed and amplitude of strokes and movable jaw

2.3.2 Roll Crushers: Through the feed opening, the raw materials fall to between the two
rollers, after crushed, the final products drop naturally. When there are unbreakable materials or
the material is too hard, the roller will concede automatically under the effects of spring and
hydraulic pressure, which will widen the clearance between the rollers and make the hard or
unbreakable so as to avoid damaging the machine. The clearance between the two rollers can be
adjusted to change the sizes of final products.
2.3.3 Types of Roll Crusher:
a. Single roll type: In this type, there is one roll and fixed plate. Roll moves
towards the plate and nip the material due to friction.

Fig. 2.1

b. Double Roll Crusher: They are made up of two rolls that rotate towards each other.
Heavy-duty compression springs permit movement of the back roll to allow tramp metal and
other uncrushable materials to pass, avoiding overload and damage.

Fig.2.2

c. Triple Roll Crusher:

Triple Roll Crushers are ideal for producers who want to accomplish two stages of
reduction in one pass. They can be used in coal, salt, coke, glass and trona operations. Triple Roll
Crushers combine a Single Roll Crusher with a Double Roll Crusher to form a crusher that is
capable of achieving a 6:1 reduction ratio in the primary stage and a 4:1 reduction in the
secondary stage while producing a cubicle product at high capacity. An intermeshing tooth
design means that no timing gears are required. It can be best operator because it completes the
reduction in one stage rather than two stages.
 Fig.
2.3

d. Quad Roll Crusher:

Quad Roll Crushers are ideal for producers, including those with preparation plants, who
want to accomplish two stages of reduction in one pass. They can be used in coal, salt,
lime, pet coke and potash operations, among others. Quad Roll Crushers are capable of
achieving a 4:1 reduction ratio before dropping crushed material to the secondary stage
crusher for an additional 4:1 reduction to make the final product.

Fig. 2.4

2.3.4 Construction & Working :

A heavy and rigid cast iron frame supports the two roll assemblies, each of which comprises of a
shaft, a roll center and a shell of a wear-resisting metal (as the wear is high) such as high carbon
steel or manganese steel. Each roll is independently driven by V-belts from separate motors. One
of the two bearings is arranged to slide horizontally on the side frames. These movable bearings
are attached to heavy-duty compression springs with automatic reset which are used to dampen
crushing shock and to protect the crusher from oversize material.

The type of surface of the roll depends on the feed type. Smooth surfaces are used for fine
crushing for materials such as minerals and metal ores. Surfaces which are corrugated or have
intermeshing ‘teeth’ are used for coarse crushing for materials such as coal. These ‘teeth’ dig
into the rock and break it apart. This action involves both compression and ripping. The distance
between the rolls can be adjusted according to the size of feed and the required size of product

The two horizontal rolls revolve towards each other at equal speeds to create a nip into which
friable feed material is introduced. The feed must be spread uniformly over the whole width of
the rolls in order to give even wear and a simple method is to use a conveyor belt of the same
width as the rolls.

The particles are drawn into the gap between the rolls by their rotating motion. The two rolls
force the particle between their rotating surface into the ever smaller gap area, and it fractures
from the compressive forces presented by the rotating rolls. The pressure exerted on the feed
particles is in the range of 10-30 MPa.

There is no provision for swelling of crushed material and so choked crushing damages the
springs over long-term use. Therefore, roll crushers should be used in closed circuit with screens.

2.3.5 Design Parameters:

 Size of roll:
i. Increasing the size of rolls results in a larger reduction ratio.
ii. Increasing the size results in lower speed of rolls.
iii.
 Surface of roll:
Smooth surfaced rolls are used for fine crushing. They are used for minerals and metal
ores.
Rolls having corrugated surfaces or a series of intermeshing teeth protruding from the roll
surface are used for coarse crushing. These dig into the rock so that the action is a
combination of compression and ripping. They are used for friable limestone, coal etc.

 Nature of feed:
The coarser the feed, the larger is the angle of nip.
The coarser the feed, the slower is the speed of rolls.

2.3.6 Performance Indicators:

 Reduction Ratio:
Reduction ratio is defined as the ratio of the feed size to the product size. The theoretical
maximum reduction ratio for roll crushers is 4:1.

 Capacity:
Capacity is defined as the amount of material treated per unit time. It is usually expressed in tons
per hour. For roll crushers, the capacity is 10-110 ton/hour, depending on the size of the roll
crusher.

 Energy Consumption:
It is defined as the amount of energy used by a process per unit time. It is expressed in kWh of
energy used per unit mass of material. Roll crushers use 2.5-3.5 kWh/ton of energy on average.

2.3.7 Applications:
There is a gap between the economical product ranges of the gyratory crusher and the ball mill or
rod mill, which the roll crushers fill effectively. Similarly, a large number of roll crushers are
used in ore dressing mills throughout the world. Both single and double roll crushers have been
developed extensively for crushing coal, coke, shale and similar soft and friable materials.

2.3.8 Limitations or Drawbacks of Roll Crusher:

The main disadvantage of roll crusher is low processing capacity.

High wear, grinding teeth vulnerable to hard material and high

consumption of power.

2.4. Procedure:
The given sample of rocks is fed into the roll crusher, where it is crushed.
The product is collected in a steel tray and then put in a sieve shaker.
The sieve shaker is allowed to operate for 5-7 minutes which separates particles according to
their size.
Once the separation is done, the sieves are detached one by one.
The mass of product in each sieve is weighed in a bowl (whose mass has already been
measured).
The mesh number and aperture size are seen from the sieves.

2.5: Observations and Calculations:

Table 2.1:
SIZE (mm) INDIVIDUAL CUMMULATIVE
MASS MASSS %
passing retaining GM Measured %age passing Retaining
30 9.423 16.8 91 15.2 84.8 15.2
9.423 6.68 7.93 154 25.71 59.09 40.91
6.68 2.38 3.99 223 37.23 21.86 78.14
2.38 1 1.543 67 11.2 10.66 89.34
1 0.71 0.843 16 2.7 7.96 92.04
0.71 0.208 0.384 30 5 2.96 97.04
0.208 0.001 0.0144 18 3 0 100

Total= =100%
599

Table 2.2:
Log(G.M) Cumulative passing %age
1.22 84.8
0.89 59.09
0.60 21.86
0.18 10.66
-0.07 7.96
-0.42 2.96
-1.84 0

Table 2.3:
Log(G.M) Log(Cumulative passing %age)
1.22 1.93
0.89 1.77
0.60 1.34
0.18 1.03
-0.07 0.90
 -0.42 0.47
-1.84

Table 2.4:

Log(G.M) Log(log100/R)
1.22 -.88
0.89 -1.31
0.60 -1.60
0.18 -1.65
-0.07 -1.66
-0.42 -1.68
-1.84 -1.70

2.6 Graphs:
 Graph between G.M Vs Passing and G.M Vs Retaining
120
Cumulative passing and retaining %age

100

80

60
G.M Vs Passing%age

40 G.M Vs Retaining %age

20

0
0 2 4 6 8
G.M

(1)

Log(G.M) VS Cumulative passing %age

84.8
90
Log(Cumu;ative passing %age)

80
70 59.09
60
50
40 Log(G.M) VS Cumulative
30 21.86 passing %age
20
7.96 10.66
0 2.96 10
0
-2 -1.5 -1 -0.5 0 0.5 1 1.5
Log(G.M)

(2)
 Log(G.M) VS Log(Cumulative passing %age)
2.5
Log(Cumulative passing %age)

1.5 1.93
1.77
1 1.34
1.03
0.9
0.5
0.47
0
-0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1 1.2 1.4
Log(G.M)

Log(G.M) VS Log(Cumulative passing %age)

(3)

Log(G.M) VS Log(Log100/R)
0
-2 -1.5 -1 -0.5 0 0.5 1 1.5
-0.2
-0.4
-0.6
Log(Log100/R)

-0.8
-1 Log(G.M) VS Log(Log100/R)

-1.2
-1.4
-1.6
-1.8
Log(G.M)

(4)

2.7 Result: The reduction ratio of roll crusher was found to be 1.876
2.8 Comments: Roll is suitable for crushing when material is friable, sticky and less
abrasive.