“In Tune” with a VSI Crusher

Transcription

Tuning and Functions
www.conexpoconagg.com
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Who am I?
• Neil R. Hise
• Lived Road
construction since
1947
• Crushing and
Mining Equipment
since 1962
• Manufacturing VSI
crushers since 1967
My purpose today is
to present to you
factual Information
gleaned from years
of working with VSI
crushers
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Who is CEMCO?
• Manufacturer of VSI crushers since 1967
• Experienced in proper applications of VSI
crushers
• Modern Facility
–
–
–
–
CNC Machining
Manual and Robotic Welding
Engineering
Testing
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Types of Crushing:
• Compression
• Impact
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To reduce size by pressure
• Roll
• Cone
• Jaw
• Gyratory
Grinding may be considered pressure crushing
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A clash or collision imparting
force that results in breakage
• Vertical Shaft Impact
• Horizontal Shaft Impact
• Hammer mill
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The History of Crushing
Crushing as we know today is relatively new. Mining and quarrying
operations relied on hand labor for thousands of years. In the late 18th
century there was an industrial revolution that created a greater demand for
materials, which spawned mechanical means of ore reduction.
The first patent for a rock crushing device in the United States was
issued in 1830. The crusher operated on the drop hammer principle, and
was most likely the predecessor of the stamp mill used as a finishing crusher
in mines during that time period.
The Blake Jaw was created by Eli
Whitney Blake. This double-toggle jaw
crusher was patented in 1858 and is still
in use today. It can generate
tremendous compressive forces suitable
for crushing very hard materials. A small
discharge area and slow reciprocating
action limited the capacity of the crusher.
Blake Jaw Crusher
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The History of Crushing
The Gates Gyratory. During the 1860’s and 1870’s several gyratory
designs were patented. The Gates crusher included the basic features found in
today’s primary gyratory crushers. Gates was found to be more productive than
a Blake jaw crusher in a 1883 production contest by crushing 9 cu. yd. of stone
in 20.5 minutes. Gyratory crushers of that day had a 48 inch maximum feed
openings, and reigned supreme until about 1908.
No. 21 Allis-Chalmers "Gates" Gyratory Crusher
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Roll Crushers
An older technology finishing crusher suitable for soft to
medium hard rocks, including damp and sticky material. Roll
crushers can achieve moderate product sizing with a limited
throughput capacity.
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Cone Crushers
Secondary or tertiary crusher that is designed for
standard, fine and very fine production. They have
good production capacity and can candle hard,
tough and abrasive materials. Clays and sticky
materials should not be fed to cone crushers.
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Jaw Crusher
Primary crusher suitable for breaking large, hard, tough,
abrasives rocks. The jaw crusher generates great
compressive forces and is good for coarse blocky material.
This crusher is not good for wet, sticky or slabby material.
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Gyratory Crushers
A primary (sometimes
secondary)
compression crusher
that is tall, high in
capacity, efficient and
effective against
slabby materials.
Clays and other sticky
materials will reduce
throughput or even
plug the crusher
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ROLLER MILL
The Raymond®
Roller Mill is an
airswept vertical
ring-roll mill with an
integral
classification
system that
simultaneously
dries, pulverizes
and classifies clays,
minerals and
manufactured
materials that are 5
or less on the Mohs
scale
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The Hammermill
Can be classified
as a primary or
finishing crusher
depending
whether or not it
has grates. As a
finishing crusher it
uses initial
impacting then a
shearing until it is
small enough to fit
through holes in
the grates.
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Horizontal Shaft Impact Crusher
Primary and
Secondary if the
material is friable
and non-abrasive.
Impeller bars strike
the feed material
and drive it against
impact bars or
plates. The
product is
generally wellgraded and cubical.
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WHY?
• Why would you want a Vertical Shaft Impact
crusher?
– Secondary Crushing
– Tertiary Crushing
– Quaternary Crushing
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Materials Processed by VSI’s
• Aplite
• Basalt
• Bauxite
• Brick Products
• Cement Clinker
• Coal
• Coke
• Copper Slag
• Garnet
• Glass
• Gold Ore
• Granite
• Gravel
• Limestone
• Perlite
• Plastic
• Quartz
• River Rock
• Rod Mill Feed
• Sand-1/4” Gravel
• Sandstone
• Shale
• Silica
• Zeolite
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Mohs Scale of Hardness
Mohs’ scale of hardness was developed by Friedrich Mohs and measures the
hardness of rock on a scale of 1-10 using a scratch test. The Moh scale is not
technically a scale, merely a table of reference. Below is a list of minerals and
their Moh hardness.
Mohs’ Scale of Hardness
Moh Mineral
Brinell
Scratchability
10
9
8
7
6
5
4
3
2
1
Diamond
Corundum
Topaz
Quartz
Feldspar
Apatite
Fluorspar
Calcite
Gypsum
Talc
667
304
178
147
137
64
53
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3
Moh Hardness
• Fingernail:
• Penny:
• Knife Blade:
2.5
3
5.5
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The L.A. Abrasion Test measures the degradation of a
coarse aggregate sample that is placed in a rotating drum with
steel spheres. The lower L.A. abrasion loss values indicate
aggregate that is tougher and more resistant to abrasion.
Table 2: Typical L.A. Abrasion Loss Values
L.A. Abrasion Loss (by percent
weight)
Rock Type
General Values
Hard, igneous rocks
10
Soft limestones and
sandstones
60
Ranges for specific rocks
Basalt
10 - 17
Dolomite
18 - 30
Gneiss
33 - 57
Granite
27 - 49
Limestone
19 - 30
Quartzite
20 - 35
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VSI Applications
• Reduce “slabby” or slivered material in
product.
• Meet constantly changing state DOT
specifications.
• Produce product in a tight gradation range.
• Produce intermediates and fines.
• Balance plant production capabilities.
• Plant Expansion
• Complement or replace existing equipment.
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PROPERLY SIZED VSI’s CAN
REPLACE CONE CRUSHERS
Secondary
Crushing
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Chips & Sand Source
Tertiary Crushing
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High Quality Fine Sand Production
Quaternary Crushing
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VSI Crusher
Principles of Operation
Feed material drops through the feed tube onto
the impeller table or enclosed rotor which, through
centrifugal force, throws the material against
chrome white iron stationary anvils. When the rock
impacts the anvils at a 90º angle, it shatters along
natural grain structures, creating a uniform, cubical
product. This method of crushing is simple and
economical to operate.
The SuperChipper™ rotor is suitable for highly
abrasive materials including, basalt, cement clinker,
glass, abrasive quarry rock, granite, quartzite, river
gravel, slags and silica sand. Impeller tables are
used for larger material that is low to moderately
abrasive, such as limestone.
Product output is easily controlled by varying the
rotor speed or by reconfiguring the crusher.
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VSI Crusher Components
Hopper:
Feeds Material into
Crusher
Rotor:
SuperChipper™
or Shoe Table
Vibration Sensor :
Mechanical/Analog
/ PLC Ready
Pedestal System:
Filtered Oil Lubrication
Impact Surface:
Anvil Ring or
Rock Shelf
Motor :
Electric
or
Diesel
Drive :
Belts and Sheaves
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10 COMMANDMENTS OF
VERTICAL SHAFT IMPACT CRUSHING
• THOU SHALT
MEASURE AND
MEASURE MORE
• THOU SHALT KNOW
THY FEED & HAVE NO
METAL IN THY FEED
• THOU SHALT KNOW
THY LA ABRASION
NUMBER
• THOU SHALT PROVIDE
TRAINED OPERATORS
• THOU SHALT INSPECT
THY CRUSHER TIMELY
• THOU SHALT KNOW THY
POWER NEED
• THOU SHALT KNOW THY
ROTOR SPEED
• THOU SHALT
UNDERSTAND BALANCE
AND VIBRATION
• THOU SHALT PROVIDE
PROPER LUBRICATION
THOU SHALT TRY TO UNDERSTAND MOTHER NATURE!
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Proper Use of Your
Plant Design
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Plant Design Pointers
1. It is cheaper to screen than it is to
crush, excessive fines cause:
•
•
•
•
Reduced crusher capacity
Create high power draw
Can cause packing and choking
Increase liner wear
2. Excessive reduction ratios are selfdefeating.
•
•
Lower crusher reduction ratios yield higher
production, require less power, and give longer
wear part life.
Crushers constantly running at design limits are
highly stressed and struggling. Liner wear is
increased, and likelihood of crusher failure is
increased.
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Good Screening Effect
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Poor Screening
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VSI Crushing!
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Measure, Measure, Measure
• Don’t presume your plant is doing what it is
designed to do.
• Measure the production of each piece of
equipment
• Check gradations at feed and output of each
crusher
• Check gradations at each screen deck
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Belt Cuts
How to Calculate TPH
(37 lbs / 2ft) = (18.5lbs / 1 ft)
(300ft / min) x (18.5 lbs / 1 ft) =
(5550 lbs / min)
(5550 lbs / min) x (1ton / 2000
lbs) =
(2.775 tons / min)
(2.775 tons / min) x (60 mins / 1
hr) =
(166.5 tons / hr)
166.5 TPH
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Belt Scales
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CEMCO INC.
DATE
CUSTOMER
10/ 5/ 2000
CEMCO
INQUIRY
RESEARCH &
DEVELOPMENT
MATERIAL
GRANITE
CONGLOMERATE
TURBO
CONFIGURATION
175
# ANVILS 5 6
TABLE SIZE 4 8 "-3 SHOE
MECHANICAL ANALYSIS
Reduction
Ratio
Calculation
952
FEED SIZE
4 8 " 3 SHOE TABLE
2 3 ANVIL 9 0 0 RPM
SIEVE SIZE
% PASSING
% PASSING
12
10
8
5
3 1/ 2
3
2 1/ 2
2
1 1/ 2
1
3/ 4
5/ 8
1/ 2
1 0 0 .0
8 2 .0
4 2 .0
1 3 .0
7 .0
0 .0
% PASSING
3 2 .8
1/ 4
2 4 .6
4
1 9 .9
8
16
30
50
1 2 .8
7 .8
4 .9
2 .1
% PASSING
% PASSING
Reduction Ratio is calculated by dividing
80% of the feed gradiation by 80% of
the product gradaton
1 0 0 .0
9 5 .3
9 3 .8
9 2 .3
8 6 .1
7 3 .8
6 2 .0
5 2 .3
4 6 .8
3 9 .6
3/ 8
% PASSING
Reduct ion Rat io
6 .7
4 8 " 3 SHOE 2 3 ANVIL 9 0 0 RPM
1 0 0 .0
8 0 .0
6 0 .0
4 0 .0
FEED
2 0 .0
0 .0
12
10
8
5
3
1/ 2
3
2
1/ 2
2
1
1/ 2
1
3/ 4 5/ 8 1/ 2 3/ 8 1/ 4
4
8
16
30
50
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HP Requirements
• Material absorbs HP during crushing
• Large material is often easier to crush than
small material.
• Rotor RPM creates velocity needed to
achieve for crushing in a VSI
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HP Requirements
• Why does small material need more HP to
crush?
• Small material takes more energy (Velocity)
to break than large material therefore more
RPM is needed to impart that velocity.
• This RPM created velocity needs large HP
input to achieve
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Material
X
Velocity
=
Energy
The more
Energy
the more
breakage
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MxV=E
(Large Material) X (Velocity)
= Energy
(Smaller Material) X (Same
Velocity) = Less Energy
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Large Energy will cause the bigger rock to
break more easily than small rock.
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Higher velocity is needed to obtain the additional
crushing of the smaller rock
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Rules of Thumb
• Feed size affects Ton/Hour Feed Rate in a VSI.
• Feed rate/size affects product obtained from
material.
• Increasing the rotor diameter increases the speed
at which material exits the port.
• Increased speed results in greater impact energy
and more fracture.
• An optimum throw distance that maximizes
fracture can be determined under balanced plant
conditions.
• There is an optimum throughput that maximizes
fracture.
• In certain materials, adding water may reduce
packing and degrade crushing.
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Small Table
Rs = 17.8125”
n = 1,000 RPM
m = 10.0 LBS.
V1= 2*π* 1000*Rs
60
V1 = 105 * Rs
V1 = 1,870 in/sec
EK1 = ½ m * V1²
EK1 = 5,116 [Ĵ]
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Large Table
Rb= 23.875”
n=1,000 RPM
m= 10.0 LBS.
V2= 2*π* 1000*Rb
60
V2 = 105 * Rb
V2 = 2,507 in/sec
EK2 = ½ m * V2²
EK2 = 9,195 [Ĵ]
25% larger radius will provide
a 44% greater energy and impact force
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Throw Distance
Changing an anvil ring with more or fewer anvils alters the
throw distance and final product.
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Relationship of Velocity & Distance
to Obtain Optimal Crushing
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Feed Size / Rotor Speed Relationship
Larger Sizes
Increases in Rotor Speed
will cause increase in
"Fines" production.
PRODUCT
OUTPUT
Optimal RPM
Smaller Sizes
Low RPM
High Rpm
ROTOR R.P.M.
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4 Possible Combinations
SuperChipper™/ Anvil Ring
Shoe Table/ Anvil Ring
SuperChipper™/ Rock Shelf
Shoe Table/ Rock Shelf
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Two Types of Rotors
CLOSED OR AUTOGENOUS
OPEN SHOE TYPE
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Shoe Table Components
*Open Shoe
Table
Rotors are
selected for
non -abrasive
materials and
larger feed
sizes.
Edge Liner
Shoe/ Impeller
Feed disc
Lower Table Liner
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Shoe Table Assembly
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OPEN SHOE TABLE / ANVIL RING
WEAR PATTERN
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Do the Tables actually Crush?
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Hard Abrasive
material causes
Table damage in a
short time
Quite often some
parts do not justify
their use due to
cost.
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48” – 4 Shoe
Table
Straight
Curved
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Closed Rotor
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SuperChipper™ Rotor Components*
SuperChipper™
Rotors are selected
for abrasive
materials.
Note that the
Rotor is fully
covered
with liners.
* View shows top
removed for
clarity.
Outer Tungsten Carbide Pin
Material Pack
Inner
Tungsten Carbide
Pin
Deflector Plate
Edge Liner
Lower Ramp Liner
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Material Pack in SuperChipper™
Material Pack
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CLOSED ROTOR / ANVIL RING
WEAR PATTERN
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Impact Surface
• Anvils - Most Efficient
– Uses less energy
– Cleaner output
– More breakage
• Rockshelf – Perhaps works
– Energy Hungry
– Dirty material
– Shaping not crushing
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Stationary Crusher Component
Anvil Ring
Rock Shelf
Anvil
Rock
material pack
Material impacts the
28 chrome white iron
anvils where the crushing
takes place.
Material packs the rock
shelf, and shaping takes
place when feed impacts
with the packed material.
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Anvils - Most Efficient
Uses less energy
Cleaner output
More breakage
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2” Granite Feed to C-33 Sand
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This is about as good as it gets
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Material feed off-center is not distributed evenly to
anvil rings, resulting in uneven wear.
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Off-Center Feed
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HORSEPOWER CONSUMPTION
• ANVIL RING USES
1.5 HP PER TON
• ROCKSHELF USES
3.0 HP PER TON
• $$$$$$$
• THE COST OF
USING A ROCK
SHELF IS PAYED IN
THE MONTHLY
POWER BILL
IE. A TRUE CRUSH
COST OF 150 HP
WITH ANVILS IS
$9.56 PER HR
BUT WITH
ROCKSELF THE
HP WOULD NEED TO
BE 300 AT A COST
OF $19.12
PER HOUR
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Rockshelf – Perhaps works
Energy Hungry
Dirty material
Shaping not crushing
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Autogenous Crushing
Rotor Feed
Particle Cloud
Rock Shelf
Crushing Chamber
Shaped Product?
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Bypass feed type
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Rock Shelf
Material Pack
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Rock Shelf Material Pack
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Least Efficient
•
•
•
•
Rock bypassing Rotor or Table
Energy Wasted
Little crushing takes place
Some shaping is apparent
Feed
Product
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Anvil Ring vs. Rock Shelf Gradation
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Effects of Moisture in Feed Material
• Zero moisture in the material is ideal but rarely the case.
• Some moisture, usually less than 1%-4% has little effect on
crushing.
• Materials containing clay may pack inside the crusher. Severe
packing may wear the rotor and obstruct throughput.
WHAT TO DO:
1. Add water to the feed.
2. Flow water at strategic locations inside the crusher
during crushing.
3. Clear the crusher at regular intervals.
4. Install a mechanical solution to reduce packing.
5. Add large feed occasionally
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Not Enough Water or too
much Clay in feed material
can cause problems.
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Wash Kits
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Dry
Material
Dust generation
is inherent to
VSI crushers ...
..But it CAN be
controlled.
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CHANGING AIRFLOW WITH HOPPER AIR-SHIMS
3” of Air
3” of Air
8” ID
Feed Diameter only 7”
13” ID
Reducing Air
Intake
13” ID
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Hopper Air Shims
89
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CHANGING AIRFLOW WITH HOPPER AIR-SHIMS
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90
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SELF CLEANING
DUSTCOLLECTION
SYSTEM
This portable system eliminates
dust problems when working in
environments where dust could
create problems.
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TRAMP STEEL
Unforgiving
Forgiving
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TRAMP METAL PROTECTION
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MAGNET
METAL DETECTOR
95
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96
96
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The “P-Factor”
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Electrical Tips
• Speed = Horsepower = Kilo watt usage.
• Kilo watt usage = $$$
• Motor efficiency is optimum at FLA (Full Load Amps)
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VFD and Soft Starts
• VFD (variable
frequency drive)
• Ease of speed
change
• Application variances
• Kw savings
• V-twin applications –
shares the loads on
the motors
• Soft starts
• Reduces amp draw
on start-up
• Easier on equipment
• Sizing of generator
• Cost value
• Genset Failures
100
10
0
What is a VFD?
A variable-frequency drive (VFD) is a system for controlling the rotational speed of an
alternating current (AC) electric motor by controlling the frequency of the electrical
power supplied to the motor. A variable frequency drive is a specific type of adjustablespeed drive. Variable-frequency drives are also known as adjustable-frequency drives
(AFD), variable-speed drives (VSD), AC drives, microdrives or inverter drives. Since the
voltage is varied along with frequency, these are sometimes also called VVVF (variable
voltage variable frequency) drives.
Variable frequency drives operate under the principle that the synchronous speed of an AC motor
is determined by the frequency of the AC supply and the number of poles in the stator winding,
according to the relation:
Where
RPM = Revolutions per minute
f = AC power frequency (hertz)
p = Number of poles (an even number)
Synchronous motors operate at the synchronous speed determined by the above equation. The
speed of an induction motor is slightly less than the synchronous speed.
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1
Motor and Drive Maintenance
•
•
•
•
Greasing of Motor
Attention to belt tensioning
Periodic inspection of voltage/power source
Periodic inspection of starts/motor connections
and cables.
• Check Temperature with
Infrared Thermograph
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2
Maintenance
• Tub & Crusher Frame
• Lid & Hopper
• Drivetrain
• Pedestal & Oil system
• Rotor Maintenance
BE SURE OF THE CORRECT ROTATION!
•Balancing
103
10
3
Check Rotation after ANY electrical work!
104
10
4
Safety!!!
• ALWAYS LOCK OUT TAG OUT
ELECTRICAL MOTORS
• ALWAYS LOCK OUT TAG OUT FEED
CONVEYOR
• ALWAYS LOCK OUT TAG OUT
DISCHARGE CONVEYOR
• KEEP THE DAMN KEY IN YOUR POCKET!!
105
10
5
SAFETY HAZARD! NO GUARDS!
106
10
6
Prevent Added strain!
107
10
7
Leave room to work!
108
10
8
Rotor Maintenance &
Balancing
109
10
9
Use Proper tools for inspection!
110
11
0
Unbalanced Wear Parts
111
11
1
Occasionally oversize feed may
cause excessive vibration
112
11
2
Looking from the inside!
113
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3
We know how you measure, this is
customer 2”
114
11
4
When replacing castings, keep weights equal on opposite
sides of the rotor. Replace worn out castings in pairs or
sets.
Replace pairs that are on
opposite sides of each casting.
11.65 lbs
11.65 lbs
115
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5
Disorganized Casting Storage, Resulting in Badly
Weighted Sets, and SuperChipper Imbalance
116
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6
Store your castings in organized sets.
You will find your sets more easily, and
increase the life of your SuperChipper.
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7
Vibration Sensors
Mechanical Style
PC Control Style
118
11
8
Well balanced, the crusher should not vibrate at all.
This nickel was placed on a crusher running at
1600rpm..
119
11
9
Yes…This Crusher is Running.
120
12
0
GENERAL CRUSHER
MAINTENANCE
•Lubrication
–Use recommended lubrication
–Avoid dirt
–Change at recommended intervals
•Belt tension
–Avoid over tightened belts
–Replace worn sheaves
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12
1
Dirt kills Bearings
122
12
2
Oil And
Grease
Flows
123
12
3
V-Twin Motors
Vs
In-Line Motors
124
12
4
CYCLIC VIBRATION:
IN-LINE vs. V-TWIN
1800
RPM
1500
RPM
1500
RPM
1800
RPM
1800
RPM
1800
RPM
125
12
5
Force
Force
Belts/Motor
126
12
6
Huge Differences in MFG’s
127
12
7
128
12
8
129
12
9
More bearings
are not always
better!
130
13
0
Totally Worn-out Sheave
131
13
1
Use Correct Number and Size Drive Belts
132
13
2
EXCESSIVE SPEED CAN DESTROY CRUSHERS!
133
13
3
BE POSITIVE OF THE CORRECT SIZE
DRIVEN SHEAVE!
134
13
4
Economic Benefits of Proper
Maintenance
• Maximize availability
• Minimize cost per ton
• Planned maintenance routine
• Use costing replacement logs
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13
5
Controlling VSI Costs
Aggressively monitor and record casting wear life. Use the
information to predict when castings must be changed. In time, a sharp
operator will maximize wear parts life and minimize downtime for
casting changes.
• Change castings between shifts or during off shift hours.
• Spare rotors, shoe tables, and anvil rings on site can minimize
downtime for casting changes in some instances.
• Have a scale on site for weighing casting and matching odd casting
into pair sets.
• Optimize the crusher throughput. Too much feed and not
enough feed increases wear cost per ton.
• Screen out the fines. Fines cause much of the wear in VSI’s.
Maximizing screen efficiency prolongs wear parts life. In reality, it is
the screens that produce paying product.
136
13
6
Water adds cost to crushing, but may
be necessary for other reasons
137
13
7
With increased wear, more changing
of parts on time becomes important
138
13
8
Poor Maintenance usually
results in serious & costly damage
139
13
9
INSPECTION
KNOWLEDGE VS COSTS
COST/TON
TOO SHORT
WASTE OF LINER
TOO LONG
DAMAGE TO ROTOR
40
30
20
10
MAX TONS
THROUGH
O
GOOD PRACTICE
110%
% WEAR LIFE
140
14
0
Narrow wear pattern- approx. 55% throw away on anvil.
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14
1
Ceramics and Castings
142
14
2
Automation Software
• Monitors VSI Crusher’s Operating Speeds
• Monitors Vibration, Temperatures, Oil Flow, Oil
Levels, Moisture in Oil.
• Monitors the Crusher’s Hours Running to Help
with Routine Maintenance
• Easily integrates into Automated Plants or
Upgrade Existing Crushers
143
14
3
Summary
• This is a very brief touch of VSI operation
• Crushers are like women, treat them with
respect and they might work with you.
• Remember the 10 Commandments
144
14
4

“In Tune” with a VSI Crusher

Transcription

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