Nordberg 7 FT symons cone crusher【china HYMAK】
Gyradisc crusher is specially used for fine product crushing.
Gyradisc crusher is different from cone crusher. General cone crushers and other kinds of crushers all directly squeeze the materials by crushing parts, which is called “single-liner crushing”. However, the Gyradisc crusher can turn the action between crushing parts and the mass into combination of impact and attrition of a multilayered mass of particles, which is called “interpartical comminution”, that is how the crusher works.
Thanks to the unique design, the Gyradisc crusher can accomplish interpartical comminution:
First, a motorized rotating feed distributor will guarantee the homogenous mix of coarse and fine particles is not only constantly fed to the cavity but also spread radially outward to the perimeter of the cavity. Thus, it can avoid packing and keep a constant maintenance of material in the surge chamber.
Second, the angle of the lower liner is less than the angle of repose of the material undergoing reduction. When the material get through the cavity, it will be deposited and crushed by interpartical comminution.
Third, the reasonable velocity of stroke and gyration can accurately control the timing of the stroke and the speed of the fed. When the head recedes and return to hit, the material will be reoriented while falling down, so as to change the alignment of particles. This change is helpful to produce a cubical shaped product with high degree of uniformity in both size and shape.
Those features above all of the Gyradisc crusher will benefit the clients in:
- Low operating cost—the operating cost of product per ton with high quality is very low. Usually, is used for the third or fourth (extreme fines) crushing.
- The product is uniform—the product will always be uniformly cubical shaped.
- Little wear of the liners—the material is crushed in the multilayered mass, so the wear of the liners in unit is low.
Manufactured sand—a rapidly expanding market
With the reducing of the natural sand deposits, the market demand more and more manufactured sand. Manufactured sand is a construction material produced by crushing or grinding, screening, and classifying rock or gravel. Most material which is used for constructive aggregate can be produced into manufactured sand.
For the macadam courts that have constructive aggregate, they can improve the potential marketing capacity by adding the equipments of crushing, screening and classifying. Almost all the macadam courts that produce constructive aggregate can use the Gyradisc crusher to produce fine aggregate which also meets specification. In most cases, manufactured sand producing can be a sole part of the macadam courts. The manufactured sand device can be either connected with other equipments, or independent from the others.
The comparison between manufactured sand and natural sand
The manufactured sand produced by the Gyradisc crusher is cubical shaped. Cubical shaped sand, in batch mixes, makes a superior concrete or asphalt. Compared to the natural sand, the cubical shaped sand has more market.
Further savings are made because less cement is required. Tests have proved that the more cubical the aggregate and the less the flaky and elongated particles, the better constructive aggregate will be. Natural sands have a tendency to have rounded corners and consequently produce a concrete which is not quite as strong as concrete using manufactured sand.
More stable the asphalt will be. Because of the interlocking of angular aggregate particles, while the surface of the cubical crushed particle provides greater area for the volume occupied than the round particle, the particles cement together with asphalt and the possibility of displacement is reduced. Therefore, Gyradisc manufactured sand produces a stronger and more stable mixture for asphalt.
The comparison between Gyradisc crusher and other kinds of crusher
Prior to the development of the Gyradisc crusher, manufactured sand was produced by rod mills, impact crushers, and roll crushers. Compared to Gyradisc crusher, the disadvantages of all these methods of sand production are:
Rod mill—although the rod mill is capable of producing fines, the power consumption and metal cost make contributions to the relatively high final cost of rod mill sand. At the same time, the rod mill produces an excess of extreme fines resulting in low quality of the manufactured sand.
Impact crushers—on one hand, the impact crusher develops high wear rates to the impacting plates and other elements when crushing abrasive materials. The efficiency is low, while the cost is high. On the other hand, the impact crusher normally creates an excess of extreme fines. The specifications for most construction and road permit only 2 to 10 percent passing a No.100 sieve, any excess produced in this range must be removed.
Roll crushers—it is difficult for roll crushers to produce fines in the 30, 50 and 100sieve sizes, because:
- Low yield.
- Difficult to control the products’ size owning to the wear of the roll shell.
- High circulating loads.
The manufactured sand produced by Gyradisc crusher is better with less cost
Gyradisc crusher operating-at-cost-per-ton of manufactured sand includes liners, maintenance and power draw:
The liner cost is related to the abrasive characteristics of the material being crushed and the surface moisture. Average liner costs are between 0.3~0.6yuan per ton of sand.
Proper maintenance, excluding liners, will result in cost not exceeding 0.1yuan per ton.
Power consumption will be in the area of 3 kwh per ton of sand.
Typical sand circuit of Gyradisc crusher
“The typical manufactured sand circuit” is a successful sand producing circuit. The functions of the equipments are:
Prescreening—in order to remove the extreme fines smaller than 5mm and abundant free water, the new feed is prescreened on a No.4 opening screen before it enters the Gyridisc crusher surge bin. If the proportion of the extreme fines which smaller than 5mm is more than 10 percent, the extreme fines will occupy the void of the particles, which is harmful to interpartical comminution of the multilayered particles.
Surge bin—the prepared feed enters a surge bin of sufficient capacity to sustain continuous full load operation. The size of the surge bin has great impacts on the efficiency or continuity of the new feed rate entering the sand circuit. Generally speaking, the bin size should be at least 20 ton live storage for the Gd75 and Gd155, while 40 ton for the Gd240 and Gd340. Only under the condition of full load, can the Gyridisc crusher accomplish the most efficient interpartical comminution.
Feeder—a vibrating feeder or variable speed conveyor belt takes new feed from the surge bin and delivers it to the crusher, that’s how the feed is controlled.
Gyridisc crusher—the feed is crushed into cubical shaped particles. In order to minimize the reaction time between the control point (feeder) and the Gyridisc crusher, it is recommended that the crusher be located as close to the bin and feeder as practical. This circuit arrangement is well suited for automation or efficient manual control.
Screening—the crusherd product should be screened on a double deck dry screen. The exact sizes of screen openings will vary and are dependent on the crushing characteristics of the materials and the final specification. Usually, a cloth having a No.4 opening is used on the top deck and No.8, 10 or 14is used on the bottom deck.
Flop Gate—the flop gate regulates the amount of between deck material that is returned to the Gyridisc crusher. The correct percentage of material passing the top or bottom deck screen can be controlled by adjusting the flop gate to increase or decrease the recirculating load. To eliminate size segregation in the bin and increase the effective surge capacity, the circulating load between the surge bin and the feeder should return to the crusher.
Classifier—Excess fines (passing No.100) are removed thorough the use of the spiral classifier.
Separator—an air separator can be employed when the disposal of tailing is difficult, when water is unavailable, or where a market exists for excess fines in the form of mineral filler.
Gyradisc crusher is specially used for fine product crushing.
Gyradisc crusher is different from cone crusher. General cone crushers and other kinds of crushers all directly squeeze the materials by crushing parts, which is called “single-liner crushing”. However, the Gyradisc crusher can turn the action between crushing parts and the mass into combination of impact and attrition of a multilayered mass of particles, which is called “interpartical comminution”, that is how the crusher works.
Thanks to the unique design, the Gyradisc crusher can accomplish interpartical comminution:
First, a motorized rotating feed distributor will guarantee the homogenous mix of coarse and fine particles is not only constantly fed to the cavity but also spread radially outward to the perimeter of the cavity. Thus, it can avoid packing and keep a constant maintenance of material in the surge chamber.
Second, the angle of the lower liner is less than the angle of repose of the material undergoing reduction. When the material get through the cavity, it will be deposited and crushed by interpartical comminution.
Third, the reasonable velocity of stroke and gyration can accurately control the timing of the stroke and the speed of the fed. When the head recedes and return to hit, the material will be reoriented while falling down, so as to change the alignment of particles. This change is helpful to produce a cubical shaped product with high degree of uniformity in both size and shape.
Those features above all of the Gyradisc crusher will benefit the clients in:
- Low operating cost—the operating cost of product per ton with high quality is very low. Usually, is used for the third or fourth (extreme fines) crushing.
- The product is uniform—the product will always be uniformly cubical shaped.
- Little wear of the liners—the material is crushed in the multilayered mass, so the wear of the liners in unit is low.
Manufactured sand—a rapidly expanding market
With the reducing of the natural sand deposits, the market demand more and more manufactured sand. Manufactured sand is a construction material produced by crushing or grinding, screening, and classifying rock or gravel. Most material which is used for constructive aggregate can be produced into manufactured sand.
For the macadam courts that have constructive aggregate, they can improve the potential marketing capacity by adding the equipments of crushing, screening and classifying. Almost all the macadam courts that produce constructive aggregate can use the Gyradisc crusher to produce fine aggregate which also meets specification. In most cases, manufactured sand producing can be a sole part of the macadam courts. The manufactured sand device can be either connected with other equipments, or independent from the others.
The comparison between manufactured sand and natural sand
The manufactured sand produced by the Gyradisc crusher is cubical shaped. Cubical shaped sand, in batch mixes, makes a superior concrete or asphalt. Compared to the natural sand, the cubical shaped sand has more market.
Further savings are made because less cement is required. Tests have proved that the more cubical the aggregate and the less the flaky and elongated particles, the better constructive aggregate will be. Natural sands have a tendency to have rounded corners and consequently produce a concrete which is not quite as strong as concrete using manufactured sand.
More stable the asphalt will be. Because of the interlocking of angular aggregate particles, while the surface of the cubical crushed particle provides greater area for the volume occupied than the round particle, the particles cement together with asphalt and the possibility of displacement is reduced. Therefore, Gyradisc manufactured sand produces a stronger and more stable mixture for asphalt.
The comparison between Gyradisc crusher and other kinds of crusher
Prior to the development of the Gyradisc crusher, manufactured sand was produced by rod mills, impact crushers, and roll crushers. Compared to Gyradisc crusher, the disadvantages of all these methods of sand production are:
Rod mill—although the rod mill is capable of producing fines, the power consumption and metal cost make contributions to the relatively high final cost of rod mill sand. At the same time, the rod mill produces an excess of extreme fines resulting in low quality of the manufactured sand.
Impact crushers—on one hand, the impact crusher develops high wear rates to the impacting plates and other elements when crushing abrasive materials. The efficiency is low, while the cost is high. On the other hand, the impact crusher normally creates an excess of extreme fines. The specifications for most construction and road permit only 2 to 10 percent passing a No.100 sieve, any excess produced in this range must be removed.
Roll crushers—it is difficult for roll crushers to produce fines in the 30, 50 and 100sieve sizes, because:
- Low yield.
- Difficult to control the products’ size owning to the wear of the roll shell.
- High circulating loads.
The manufactured sand produced by Gyradisc crusher is better with less cost
Gyradisc crusher operating-at-cost-per-ton of manufactured sand includes liners, maintenance and power draw:
The liner cost is related to the abrasive characteristics of the material being crushed and the surface moisture. Average liner costs are between 0.3~0.6yuan per ton of sand.
Proper maintenance, excluding liners, will result in cost not exceeding 0.1yuan per ton.
Power consumption will be in the area of 3 kwh per ton of sand.
Typical sand circuit of Gyradisc crusher
“The typical manufactured sand circuit” is a successful sand producing circuit. The functions of the equipments are:
Prescreening—in order to remove the extreme fines smaller than 5mm and abundant free water, the new feed is prescreened on a No.4 opening screen before it enters the Gyridisc crusher surge bin. If the proportion of the extreme fines which smaller than 5mm is more than 10 percent, the extreme fines will occupy the void of the particles, which is harmful to interpartical comminution of the multilayered particles.
Surge bin—the prepared feed enters a surge bin of sufficient capacity to sustain continuous full load operation. The size of the surge bin has great impacts on the efficiency or continuity of the new feed rate entering the sand circuit. Generally speaking, the bin size should be at least 20 ton live storage for the Gd75 and Gd155, while 40 ton for the Gd240 and Gd340. Only under the condition of full load, can the Gyridisc crusher accomplish the most efficient interpartical comminution.
Feeder—a vibrating feeder or variable speed conveyor belt takes new feed from the surge bin and delivers it to the crusher, that’s how the feed is controlled.
Gyridisc crusher—the feed is crushed into cubical shaped particles. In order to minimize the reaction time between the control point (feeder) and the Gyridisc crusher, it is recommended that the crusher be located as close to the bin and feeder as practical. This circuit arrangement is well suited for automation or efficient manual control.
Screening—the crusherd product should be screened on a double deck dry screen. The exact sizes of screen openings will vary and are dependent on the crushing characteristics of the materials and the final specification. Usually, a cloth having a No.4 opening is used on the top deck and No.8, 10 or 14is used on the bottom deck.
Flop Gate—the flop gate regulates the amount of between deck material that is returned to the Gyridisc crusher. The correct percentage of material passing the top or bottom deck screen can be controlled by adjusting the flop gate to increase or decrease the recirculating load. To eliminate size segregation in the bin and increase the effective surge capacity, the circulating load between the surge bin and the feeder should return to the crusher.
Classifier—Excess fines (passing No.100) are removed thorough the use of the spiral classifier.
Separator—an air separator can be employed when the disposal of tailing is difficult, when water is unavailable, or where a market exists for excess fines in the form of mineral filler.
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Specification
|
Closed side discharge setting (mm) and corresponding capacity
|
|
5
|
6.3
|
10
|
12.5
|
16
|
19
|
25
|
32
|
38
|
50
|
64
|
|
S75B
|
|
|
45
|
59
|
72
|
91
|
118
|
136
|
163
|
|
|
|
S75D
|
41
|
54
|
68
|
90
|
100
|
127
|
|
|
|
|
|
|
S155B
|
|
|
|
109
|
132
|
159
|
200
|
230
|
260
|
350
|
|
|
S155D
|
59
|
82
|
104
|
136
|
163
|
200
|
230
|
|
|
|
|
|
S240B
|
|
|
|
|
181
|
204
|
260
|
340
|
380
|
420
|
--
|
|
S240D
|
90
|
136
|
163
|
210
|
255
|
290
|
335
|
|
|
|
|
|
S400B
|
|
|
|
|
|
544
|
712
|
880
|
1034
|
1425
|
1815
|
|
S400D
|
218
|
308
|
372
|
410
|
465
|
580
|
680
|
|
|
|
|
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