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Jaw and gyratory crushers are used for initial size reduction to convert big rocks into small stones. This is generally followed by a cone crusher. A combination of rod mill and ball mills are then used if the ore must be ground below 325 mesh (45 μm). Instead of grinding the ore dry, slurry is used as feed for rod or ball mills, to avoid dusting.

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Jaw crushers are an excellent primary crusher when used to prepare rock for subsequent processing stages. Cone and gyratory crusher. These are also compression-type machines that crush material between a moving and a stationary piece of steel. The setting between the two pieces controls the output.

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Charge calculations, fuel calculations and estimation of the product yield are primary ... • Intermediate crushing –Jaw, cone or roll crushers break ores from 10 cm to 1-2 cm • Fine crushing –Short head cone, roll crushers, hammer mills break ores from 1-2 cm to 0.5 cm Grinding (2 stages)

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The chief difference between cone and gyratory or jaw crushers is the nearly parallel arrangement of the mantle and the cone at the discharge end in the cone crusher. This is illustrated in Figure 5.2. Reduction ratios in the following ranges are common for cone crushers: 6:1 - 8:1 for secondaries 4:1 - 6:1 for tertiary and quaternary crushing.

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For a set of crusher sizes and set openings, the calculations obtained from the work of Rose and English and others can be compared with data from equipment manufacturers. Figure 4.10 shows a plot of the results. Assuming a value of S C of 1.0, the calculations show an overestimation of the capacity recommended by the manufacturers.

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Cone Crushers. Originally designed and developed by (1920). Similar to gyratory except the spindle is supported at the bottom of the gyrating cone instead of being suspended. The head to depth ratio is larger than gyratory crushers. Cone angle are flatter and the slope of the mantle and concaves are parallel.

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Considering a 30-in. diameter roll crusher the maximum size particle that can be nipped with the roll crusher set at 1 in. according to this Equation is F = 0.085 (15) + 1.0 = 2.28 in. <3½ in. feed. It will take larger than a 40-in. diameter roll crusher.

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