Mechanical Maintenance department

Additive and corrective crushers

Prepared by
Eng. Feras Sulaiman Alhamdi
Additive and corrective Supervisor
CRUSHING PRINCIPLES
Size reduction of rock can be obtained in three different ways, which all relate to
differ-
ent crusher types:

1- crushing by means of compression

2- crushing by means of impact
3- crushing by means of attrition
Factors for choice crusher type
1- feed size
2- feed material type
3- capacity
4- cost

Operating principle
The chamber of crusher consists of rotor, the first impact plate, the second impact
crusher, grinding plate and lining plates. The reasonable chamber can improve
crushing efficiency and ensure regular product size. The main motor drives the
rotor with big inertia by V-belt. The material are fed trough the inlet opening by a
feeder and fall down to the rotating rotor with high speed. The comminution
occurs when the blow bars of rotor hit the material at a high peripheral speed. The
thrown material is further reduced in size in the crusher chamber by colliding with
each other
Tertiary crushers (Line 5)

Impact crusher
Impact crusher serves to crush similar brittle material, such as limestone,
siltstone, shale, gypsum, coal etc. by impact principle. Comparing with
extrusion crusher such as jaw crusher, gyratory crusher, taper crusher, roller
crusher etc., the impact crusher can reduce the materials from the run-of-
quarry to product of minus 75mm by only one stage. Thus the capital cost can
be cut down and the crusher system become simple
he impact crusher, as a general rule, can work well only when the materials are
fed over entire width of the rotor. The materials are crushed in the crusher by
the blow bars at a high peripheral speed, thus the feeding of different size will
result in different energy consumption. To keep the balance between required
energy and the imposed energy, the speed of the feeder MUST be adjustable
according to the load of the rotor motor.
 Technical characteristics
NPF1618 Crusher type
rpm 365 Rotational speed of the
rotor
t/h 400~350 Capacity

1RR5504-6JA90-Z Motor Type

500KW Rating power

r/min 1194 Rotational speed

about 52.7 t Total weight (excluding the

motors)
passing 80 mm Product size

t 18.5 Weight of rotor

Structure
he crusher is mainly composed of rotor, casing, first impact plate, second impact
plate, grinding plate, and drive unit. The outline of the crusher is shown in Fig. 1.
Rotor
he rotor is the key assembly of the crusher (Fig. 2). It is composed of
rotor body, blow bars, main shaft, bearings and large belt wheel etc.
The rotor body is rigid cylindrical structure, mainly composed of roller
bush, disc plates
The blow bars are inlayed in the four slots which are distributed evenly
on the cylindrical surface of the rotor body. These bars are made of
special hard alloy steel which is high-quality abrasion-resistant

241BC2
 Casing
The casing is welded by high-quality steel plates with reasonable welding process. All
flanges are safely connected by bolts. All the parts of the casing that may be touched
by stone are protected by abrasion-resistant liner plates. Liner plates have high
interchangeablity, fixed by
bolts. Both sides of the most liner plates can be used. The inspection door and the
maintenance door are set upon the casing. The anti-rotating pin holes are set beside
both sides of the casing, and the position-limit curved rod is set into the pin hole when
the maintenance is hold on to protect the worker and the crusher.
First impact plate
The first impact plate bears strong crush of the ore. The plate body is totally
forged by abrasion-resistant alloy steel. The up side of the plate body is hinged
with the crusher casing, the down side of the plate body is hinged with the spring
mechanism which is specially designed to absorb shock and vibration of the crush.
The gap between the plate and the working circle of the rotor is adjustable by the
spring mechanism, and the reference value of the gap is 150mm. The actual value
is set according to the size of the feeding and the product of the stone.
Second impact plate
Similar to the first impact plate, the second impact plate also has the spring
buffer and adjustment structure. The gap between the plate and the working
circle of the rotor is 75mm, it can be adjusted according to the working
condition to make the crushed stone distributed reasonably between the work
area of the second impact plate and the grinding plate. The gap will affect the
particle size coming to the next crushing stage. The liner plates on the impact
plate are totally interchangeable. When the liner plate in the lowest part is
worn obviously, it can be changed with the plate on the upper part which wear
less. The structure is shown in Fig.
 Grinding plate
The grinding plate is set in the bottom cavity of the casing, and composed of
toothed plate, support frame and a set of spring adjustment mechanism which is
designed specially. The contour of the plate and the working circle of the rotor
form the wedge cavity, the gap in the lowest part is less than the product size. The
reference value of the gap is 35mm, it can be adjusted according to the actual
working condition. In this work area, the material which is oversize will be crushed
further
Drive Unit
The drive unit is the power source of the crusher, and it is composed of belt wheel,
flywheel, shaft, bearings, couplings, motor, base frame and slide rail etc. The small
belt wheel is driven by motor through couplings, and the large belt wheel of the
rotor is dragged by the small belt wheel through the high-quality V-belt. And then
make the rotor rotate correctly. With the help of the adjustment bolts on the base
frame, the enough tensity of V-belts can be achieved. The structure is shown in Fig
Maintenance
General requirements:
♦ When the operation is to stop, the rotor motor should not be switched off
until the materials in the crusher chamber have been completely discharged.
♦ Never permit to feed extra-large lumps into the crusher.
♦ Care must be always taken to monitor the running of the crusher. If any
unusual sound be heard, the crusher must be stopped and checked with order.
♦ All bearings should be lubricated regularly with lithium soap grease.
♦ The bearing blocks are equipped with electric thermo-couples (WZPM-
201BA2) which have temperature measuring scope of –100℃~+100℃.The
warning device, cooperating with the temperature transmitter, will alarm when
the temperature surpass the warning temperature. If the temperature goes up
to the top of safe temperature, the motor will be switched off automatically.
The alarm and switch off temperatures can be reset on the warning device.
The bearings can suffer a temperature of 100℃ without damage.
♦ The rotation parts, such as belt wheels, belts and so on, should be guarded
by protective cover.
Maintenance Schedule
Breakdown and handling
Hammer crusher ( single stage )
single stage hammer crusher serve to crush medium-hard rock and similar
brittle material, such as limestone, marlstone, argillaceous siltstone, shale,
gypsum, coal and the mixture of limestone and clay. Comparing with the
traditional multi-stage crushing process, it can reduce the materials from the
run-of-quarry to product of minus 25mm for feeding of the ball mill by only one
stage
Technical characteristics

PCF2018 Crusher type

rpm 310 Rotational speed of the

rotor
500t/h~450 Capacity

1RR5566-6JA80-Z Motor Type

710KW Rating power

1RR5566-6JA80-Z Total weight (excluding

the motors)
passing 25 mm 90% Product size

t 31 Weight of rotor
 main assemblies
 The crusher consists mainly of rotor, crushing plate, outlet grate, casing,
emergency gate and drive unit
Rotor
The rotor is the core assembly of the crusher, which is composed of middle discs,
side discs, hammers, hammer axles, main shaft, flywheel, bearings, and bearing
housings and so on. The middle discs and side discs are fixed on the shaft
Breaking Wall
The breaker wall is fitted in the front of the rotor above the horizontal central line.
The top end of breaker wall is jointed on the upper casing and can swivel by
screwing the adjusting bolt on the bottom end, to gain a variation of gap between
the breaker wall and the working circle of rotor. The gap will affect the particle
size coming to the discharge zone and normally is to keep 20 mm.
 Outlet Grate
 The outlet grate mounted beneath the rotor has an 130º enclosure angle. The gap
between the tooth-tip of the grate plate and the working circle of the rotor is
adjustable. With the help of jacks and adjusting bolts, the gap a, b and c (illustrated
in Fig.4) can reach the demanding value of about 25 mm. The oversize of the gap
will lead to the pileup of the materials at the grate area, and the crushing efficiency
will descend obviously
Emergency gate( fens)
 The emergency gate next to the outlet grate is hinged on the lower casing. It
can be adjusted, by turning the axle holders upside down, according to the
position of the outlet grate. The gap between the toothed surface of the arc
gate and the working circle of the roto should be about 25 mm. The
emergency gate will be opened by centrifugal force of foreign inclusions and
evacuate them immediately and then close automatically by means of
counter weight to protect the uncrushed grain from spilling.
 Casing
The casing composed of upper casings, lower casings, door frames and lining plates, is of
solid welded design . The interior surfaces of casing which may contact with material are
protected with lining plates from wearing.
 Drive Unit
The rotor is driven through V-belts by the drive unit. The drive unit is composed of
motor, couplings, base frame, slide rail and adjustment bolts. The motor is mounted
on the base frame. With the help of the adjustment bolts, the correct tensity of V-
belts can be achieved.
Maintenance Schedule
Maintenance Schedule
Breakdown and handling
Breakdown and handling
L5 Flow sheet
Clay crusher ( double stage crushing )
Twin shaft sizer (Technical characteristics)
MMD 625 series (twin shaft sizer) Type

Max 450t/h Crushing rate

1*250kw Motor

1500mm Feed size

150mm Product size

Roll crusher (Technical characteristics)
WB2S-3-80/250M.H (Roll crusher) Type

Max 450t/h Crushing rate

2*160kw Motor

150mm Feed size

25mm Product size

Operating principle
Operating principle
Sizer Assembly
Sizer Assembly
Sizer Assembly
Sizer Assembly
Sizer Assembly
Sizer Assembly
Sizer Assembly
Sizer Assembly
Breaker shaft Assembly
Breaker shaft Assembly
Bearing Assembly
Tertiary Crs L4 ( Double stage crushing )

PEG160/210 (Impact crusher) Type

400t/h Crushing rate

1600mm Rotor diameter

2100mm Rotor width

1500mm Feed size

0-250mm Product size

Technical characteristics
Technical characteristics
Technical characteristics
Operating principle
design
Design
Design
Design
Breakdown and handling
Breakdown and handling
Check list
Check list
Check list
Mec.Crushers department organization

Eng. Ehab Medht

Mechanical Manger

Eng.
Abdelmottaleb
Boussaada
Crushers
Superintendent

Eng. Feras Alhamdi Eng. Amjad

Additive and Almattrafi
corrective supervisor Limestone Supervisor
Mechanical Engineer responsibilities
 Managing maintenance activities in additive &corrective crushers
 Maintain records on equipment histories and costs, coordinates with
 Analyse, record, troubleshoots equipment problems, and proffer
 procedure
 Diagnose root cause and specify method of repair for plant equipment.
 Provide guidance to the technicians in the execution of maintenance
 Works
 Plan and excite minor & Major Maintenance (Kiln shut-down) for
crushers area .
 Responsible for prepare yearly spare parts budget
Example for KSD plan
Thank you