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mineral processing handbook TELSMITH HANDBOOK A handy reference book for miners. This book contains the latest specifications and essential information on aggregate and minerals production and handling equipment. It should be noted that various factors, such as engineering advances, physical propert...

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MINERAL PROCESSING HANDBOOK

TELSMITH HANDBOOK A handy reference book for miners. This book contains the latest specifications and essential information on aggregate and minerals production and handling equipment. It should be noted that various factors, such as engineering advances, physical properties of raw materials, method of feeding and operating the equipment, moisture and physical conditions in material at the time of processing, altitude and other conditions will affect the equipment ratings as published and may yield results not exactly in accord with published data.

Thirteenth Edition First Printing by TELSMITH, INC. 10910 N. Industrial Dr. P.O. Box 539 Mequon, WI 53092-0539 Phone: (262) 242-6600 Fax: (262) 242-5812 For Repair Parts, Phone: 800-688-6601 Or contact us via our website: www.telsmith.com

Permission to reproduce portions of this handbook may be obtained from Telsmith, Inc., Mequon, WI 53092-0539

©2011 Telsmith, Inc. Mineral Processing Handbook 11/11 - 1st printing Printed in U.S.A

TABLE OF CONTENTS

SECTION I

PAGE 6–163

Feeders...................................................................6 Crushers ...............................................................22 Jaw Crushers ................................................26 Series “D” Crushers .....................................34 Series “H” Crushers .....................................42 SBS Series Crushers.....................................50 VFC Crushers ................................................58 Primary Impact Crushers ..............................66 HSI Impact Crushers.....................................70 Vertical Shaft Impactor (VSI) ..........................74 General Crusher Information ........................80 Screens .............................................................. 100 Washing Equipment .......................................... 128 Belt Conveyors................................................... 150 Stockpiling .......................................................... 161

TABLE OF CONTENTS (CONT)

SECTION II PAGE 164-183 Materials .............................................164 Aggregate Information ........................ 170 SECTION III PAGE 184-217 V-Belt Drives .......................................185 Electric Motor Drives ..........................190 General Information ............................198 Complete Index ..................................214

A PREFACE TO THE THIRTEENTH EDITION … The worldwide acceptance and popularity of the Telsmith Handbook since its inception in 1953 dictates that we must keep it accurate and up-to-date in its concept. This thirteenth edition has some information not contained in earlier editions along with some deletions and revisions to keep the handbook as accurate as possible. Whether your interest is in a single unit, or a completely integrated processing plant, Telsmith Engineering experience in producing aggregate and mining machinery of all types insures profitable production of high grade material. All along the processing line, Feeders, Grizzlies, Crushers, Scalpers, Classifiers, Washing Plants, Sizing Screens, Conveyors, Telsmith Equipment is processing material for all phases of industry. Feel free to consult Telsmith skilled engineering services whenever you have questions or comments. It is our sincere hope this handbook will help you in selecting, operating and maintaining our quality product line, thus assuring profits in your operation. TELSMITH, INC. Mequon, Wisconsin An Astec Company

4

HEAVY DUTY EQUIPMENT WITH HEAVY DUTY SUPPORT

5

TELSMITH FEEDERS Telsmith Feeders are used for holding and regulating surge loads and to promote a steady supply to maximize production in processing plants. These feeders are offered in four types to match material size, feed rate requirements, location and if fed from truck, shovel, loader, or mounted under a surge bin.

6

DATA REQUIRED FOR SELECTING A FEEDER

2. Weight per cubic foot (bulk density) of the material. 3. Distance material is to be conveyed. 4. Height material is to be raised. 5. Space limitations. 6. Method of loading feeder. 7. Characteristics of material. 8. Type of machine to be fed.

PROCEDURE FOR SELECTING A FEEDER STEP 1.

Select a type of feeder from the "Applications of Feeders Table - 2A".

STEP 2.

Select feeder width. The width may be dictated by the machine to be fed, i.e., a jaw crusher with a certain receiving opening, or by the size of the hopper opening to be used. Feeder width may also be determined by the maximum lump size in the feed, or by a desired depth of material and conveying speed.*†

STEP 3.

Check capacity of feeder selected against the data in the Feeders Tables 2A, B, C & D.

STEP 4.

Determine HP required from Tables in Section for Feeder selected in STEP 1.

* depth of 100 lbs./ ft.3 material may be found by:

D = depth in inches TPH = tons per hour FPM = feet per minute material is moved W = net width of feeder in inches † Do not use the above chart for Belt Feeder capacities.

7

FEEDERS

1. Tons per hour to be handled, including maximum and minimum.

APPLICATION OF FEEDERS TABLE – 2A DUTY

RECOMMENDED TYPE

Truck dumping or direct loading Super Heavy-Duty Apron by Dozer, Shovel or Dragline. Feeder with manganese Maximum lump size not to exceed flights. 75 percent of feeder width. Under hopper or bin, handling non- Super Heavy-Duty Apron abrasive material. Maximum lump Feeder with pressed steel size not to exceed 75 percent of flights. feeder width. Truck dumping or direct loading Heavy-Duty Apron Feeder by Dozer, Shovel or Dragline. Maximum lump size not to exceed 75 percent of feeder width. Under hopper or bin, handling Heavy-Duty Apron Feeder non-abrasive material. Maximum lump size not to exceed 30 percent of feeder width. Under Primary Crusher to protect belt conveyor.

Vibrating Feeder or Grizzly Feeder.

Under bins, hoppers or storage piles. Maximum lump size not to Belt Feeder exceed 30 percent of feeder width. Under Large Primary Crushers.

8

Heavy-Duty Apron Feeders

APRON FEEDER CAPACITIES — PER HOUR – TABLE 2B Standard and Heavy Duty Feeders Flight Speed FPM

30" Yds3

10

55

15

36" Tons

Yds3

74

80

83

112

20

110

148

24*

133

25

138

30

XHD (Extra Heavy Duty Feeders)

42" Tons

Yds3

108

109

120

162

160

180 186

165

223

35

193

40

220

48" Tons

Yds3

147

143

164

222

216

218

192

259

200

270

240

260 296

48" Tons

Yds3

192

143

214

289

294

284

262

354

273

369

324

327

280

378

320

432

60" Tons

Yds3

192

222

214

289

384

284

343

460

357

482

442

427

382

516

436

588

72" Tons

Yds3

Tons

300

320

432

333

450

480

648

384

444

600

640

864

343

460

533

720

768

1,037

357

482

555

750

800

1,080

577

427

577

666

900

960

1,296

500

673

500

673

777

1,050

1,120

1,512

572

768

572

768

888

1,200

1,280

1,728

50

711

961

1,110

1,500

1,600

2,160

60

854

1,154

1,332

1,800

1,920

2,592

* Standard speed that will be furnished unless otherwise specified. NOTE: Capacities based on continuous operation at flight speed shown with a bed depth of about 1/2 flight width and 100 lbs./ft3 material and .8 Feeding Factor to compensate for voids, resistance to flow, etc. Capacities will vary with material characteristics. For speeds above or below standard consult factory.

9

FEEDERS

VIBRATING FEEDERS AND GRIZZLY FEEDERS AT STANDARD MOUNTING ANGLES

WIDTH OF FEEDER

Delivery rates for Vibrating Feeders Table 2C NOTES: 1. Throw, Speed and Material Flowability combine to give estimated travel speeds of 40 FPM @ 0°; 65 FPM @ 5°; 120 FPM @ 10°. 2. 12" Bed Depth assumed at discharge of feeder or at beginning of Grizzly Bars, if used. 3. Material is 100 lb. per Ft3, Tons are 2000 lb. 4. Flowability, wt. per Ft3, bed depth are variables. 5. Use Factor of 0.8 for rip-rap or clean large stone. 6. Use Factor of 0.7—0.9 for Primary Crusher. 7. Variable Speed Drive may reduce capacity by 40% when feeder width is selected for largest stone or width of Primary Crusher.

10

CAPACITY OF BELT FEEDERS BASIS – 100 LBS. PER FT.3 MATERIAL

FEEDERS

Capacity – TPH Belt Speed – FPM

Belt Feeder

H (highest)

10

20

30

40

50

60

24" (W =18")

8

30

60

90

120

150

180 203

30" (W = 24")

36" (W = 30")

9

34

68

101

135

169

10

38

75

113

150

188

225

11

41

83

124

165

206

248

12

45

90

135

180

225

270

13

49

98

146

195

244

293

14

53

105

158

210

262

315

8

40

80

120

160

200

240

9

45

90

135

180

225

270

10

50

100

150

200

250

300

11

55

110

165

220

275

330

12

60

120

180

240

300

360

13

65

130

195

260

325

390

14

70

140

210

280

350

420 300

8

50

100

150

200

250

9

56

113

169

225

281

338

10

62

125

187

250

312

375

11

69

137

206

275

344

412

12

75

150

225

300

375

450

13

81

162

244

325

406

487

14

87

175

262

350

437

323

Table 2D 11

APRON FEEDERS Apron feeders are used where extremely rugged machines handling large feed are required, but where no fines removal is needed or where fines are removed by a separate Vibrating Grizzly. They are also used to handle muddy or sticky material. Normally located ahead of large, stationary primary crushers. They are sometimes used to collect material from the discharge of very large primary crushers where they absorb more impact than a rubber conveyor belt can economically withstand. These Apron Feeders can be equipped with standard (1/2" thick) fabricated pans (standard and heavy duty Feeders) or optional (11/4" thick) fabricated pans (XHD Feeders only). They are available in widths of 30" to 72" and lengths of 9' to 50'.

12

SPECIFICATIONS — CAPACITIES — APRON FEEDERS Feeder Size Length (Min. — Max. (Note 3)) Capacity — TPH at 24 FPM (Note 2)

30"

36"

42"

48"

60"

72"

9' — 21'

9' — 21'

9' — 21'

12' — 27'

15' — 30'

15' — 30'

180

259

354

460

720

1037

Horsepower Required for Standard Lengths (Note 1) 9'

5

5

71/2

—

—

—

12'

5

5

10

15

—

—

15'

71/2

71/2

10

15

25

30

18'

71/

2

10

15

20

25

40

21'

71/2

10

15

20

30

40

24'

—

—

—

20

30

40

27'

—

—

—

25

40

60

30'

—

—

—

—

50

60

NOTE 1. Horsepower ratings are based on normal operation with feeder mounted in horizontal position. For higher or lower speeds consult factory. NOTE 2. Capacities shown are for continuous operation at 24 feet per minute flight speed with a depth of material about 1/2 of flight width. NOTE 3. For longer lengths consult factory.

13

FEEDERS

HORSEPOWER OF APRON FEEDERS Total horsepower is calculated using the following formulas. L = C/L to C/L of sprockets W = Width in feet inside skirt boards H = Height in feet of material bed 1/ 2 2/ 3

Pan Width = Normal Pan Width = Maximum

s = 0.8 Slip Factor = Incline s = 0.9 Slip Factor = Horizontal M = Wt. per Ft.3 of Material S = Speed in FPM Total Load of Material = L × H × W × M

Width of Pan 30" 36" 42" 48" 60" 72" 84" 96"

Height = 1/2 Width Skirt Board Friction / Ft. 31# 55# 88# 113# 175# 252# 345# 450#

Hopper Shear 1000# 2133# 4000# 4600# 5800# 7200# 8850# 10500#

Total Force P = (1) + (2) + (3) (1) Wt. of Material Bed × Sin of Angle if Feeder is on an incline (2) Skirt Board Frictions and Hopper Shear (3) Friction Force on all bearings as given below Wt. of Material Bed + 1/2 Chain Weight = F. Lbs.

(3) = A + B HP Required P = Total force, above (1) + (2) + (3) S = Pan Speed in FPM

14

NOTES:

FEEDERS 15

VIBRATING FEEDERS AND VIBRATING GRIZZLY FEEDERS Vibrating Feeders are used where a compact feeder with variable speed control is required. Vibrating Grizzly Feeders have features similar to the Vibrating Feeder plus grizzly bars for separating fines from crusher feed. This feeder increases crushing plant production and reduces crusher liner wear because fines are bypassed around the primary crusher. Both feeders are available in widths from 36" through 72" and 12' through 30' long. Grizzly sections are straight or stepped. The stepped version tumbles stone to the lower section thus offering more efficient scalping.

16

SPECIFICATIONS – CAPACITIES – VIBRATING FEEDERS AND GRIZZLY FEEDERS 36" WIDE

STANDARD WIDTH STANDARD LENGTH

42" WIDE

48" WIDE

54" WIDE 18'

14'

16'

14'

16'

14'

16'

8,145

7,390

8,260

7,765

9,340

19,000 20,400 20,175 21,700 23,225 21,350 22,600 24,300 24,350 24,750 25,850

—

Vibrating Grizzly Feeder w/5' Grizzly Section–Total Wt.

7,005

8,310

7,625

8,550

8,015

9,625

19,350 20,750 20,575 21,900 23,475 21,800 23,050 24,750 24,550 25,750 26,300

—

Vibrating Grizzly Feeder w/8' Step Grizzly Sec.–Tot. Wt.

—

8,900

—

9,270

—

11,240

Vibrating Grizzly Feeder w/9' Step Grizzly Sec.–Tot. Wt.

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

23,775

—

—

25,300

—

7'6" 13'6"

7'6" 13'6"

8'0" 14'0"

8'0" 14'0"

8'6" 14'6"

8'6" 14'6"

8'6" 14'6"

8'6" 14'6"

9'0" 15'0"

9'0" 15'0"

9'0" 15'0"

9'6" 15'6"

9'6" 15'6"

9'6" 15'6"

10'5" 16'5"

—

—

—

24,545 26,900 29,575 27,475 30,125 33,125 36,325 40,675 44,750 38,875 43,525 47,875

—

20'

20,965

—

19,900 21,650 21,375 23,175

Loading Hopper W/O Ext.–Wt. 13,210 14,625 14,850 16,085 17,825 19,875 21,865 24,050 Loading Hopper With Ext.–Wt. 20,200 22,225 22,775 25,100 27,450 30,750 34,450 38,575

22'

18'

20'

—

23,200

—

—

22,850 24,700

22'

— —

18'

—

20'

H.D. 66" WIDE†

6,910

—

20'

72" WIDE

Vibrating Feeder – Tot. Weight

Vibrating Grizzly Feeder w/10' Step ...