Hard rock Crushing Plant (PDF)

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Hard rock Crushing Plant
Descriptions are given of plant process flowsheets, hard rock crushing plant to
produce roadstone from a gritstone.

hard rock crushers, roadstone crusher, rock crushing plant, stone
crushing plant, stone crusher

The following figure depicts the flowsheet for a plant producing various
forms of dry (uncoated) roadstone including high PSV (+60) surface
chippings. The production of surface chippings would probably require
that a gritstone was being quarried. Many igneous rocks, such as
granites and basalts, exhibit moderate values of PSV and are suitable for
all other types of roadstone and reference is made to their production.
Limestones have a very low PSV but are used extensively in road

construction below the wearing course. The operation of a quarry solely
for the production of high PSV surface chippings cannot justified so it is
likely that any gritstone will also be sold as dry stone, macadams and
even concrete aggregate. Since any quarry is likely to contain beds of
lower quality and weathered rocks it will also produce fill materials.

The quarried stone is dumped onto a grizzly feeder which removes
scalpings and feeds the oversize to the primary double-toggle jaw
crusher for breakage. The scalpings are re-screened at a finer size to
increase the yield of clean stone.

Where a soft limestone (containing little silica as flint or chert) is being
processed the primary crusher may also be a jaw crusher, usually of the
single-toggle type, although fixed blow-bar impactors are common.

Elsewhere in the flowsheet impactors will be used in place of cone
crushers. Where the throughput of the plant exceeds 2200tph,
especially for igneous rocks, the jaw crusher is replaced by a primary
gyratory crusher. In this case, the dump trucks usually discharge directly
into the crusher and scalping is carried out upon the primary crusher
The crushed rock is fed onto a stock-pile ahead of the main process plant
from which it is reclaimed by a tunnel conveyor. This arrangement
permits the plant to operate outside the hours of the quarry and during
interruptions to quarry operations. A market may also exist for this
'crusher-run' material. Reclaimed stone is further crushed by a
secondary cone crusher but a secondary gyratory might also be used. In
order to increase plant capacity a primary screen can be installed ahead
of the secondary crusher to remove material finer than the setting of the
crusher which by-passes this stage of comminution. The material is now
screened with oversize being recycled to the secondary crusher.

Commonly, the crusher product is divided into coarse and fine fractions
prior to sizing as finished products. At this stage it is probable that this
simple screening will generate saleable materials having relatively wide
size distributions. Type 1 dry stone aggregate for road construction is a
good example which may constitute a substantial proportion of the

quarry output. Provision is made for recovery and stocking of this

Screening of the crushed aggregate into narrow size ranges employs
multiple deck vibrating screens often mounted directly above the
respective storage/outloading bins. However, screening of the
secondary crusher product is unlikely to yield sized stone in the
proportions demanded by the markets which are usually greater for the
finer aggregates. Provision is made for recrushing the coarser fractions
through a tertiary cone crusher. Indeed, the bin system can be designed
so that once the bins containing coarser sizes are full they overflow
automatically to feed the recrushing circuit. Fine aggregates may also be
recrushed and recirculated to the fine screens. Machines suitable for this
purpose, which may be encountered in various combinations, include
fine cone crushers, vertical shaft impactors (illustrated) for the
manufacture of sand. The impactor or cone crusher, operating with a
low reduction ratio, may also be used at this stage to impart a cubical
shape to the product intended for surface chippings.

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