Gyratory Mill

A gyratory mill is similar in basic concept to a jaw mill, consisting of a concave surface and a conical head; both surfaces are typically lined with manganese steel surfaces. The inner cone has a slight circular movement, but does not rotate; the movement is generated by an eccentric arrangement. As with the jaw mill, material travels downward between the two surfaces being progressively crushed until it is small enough to fall out through the gap between the two surfaces. A gyratory mill is one of the main types of primary mills in a mine or ore processing plant. Gyratory mills are designated in size either by the gape and mantle diameter or by the size of the receiving opening. Gyratory mills can be used for primary or secondary crushing. The crushing action is caused by the closing of the gap between the mantle line (movable) mounted on the central vertical spindle and the concave liners (fixed) mounted on the main frame of the mill. The gap is opened and closed by an eccentric on the bottom of the spindle that causes the central vertical spindle to gyrate. The vertical spindle is free to rotate around its own axis. The mill illustrated is a short-shaft suspended spindle type, meaning that the main shaft is suspended at the top and that the eccentric is mounted above the gear. The short-shaft design has superseded the long-shaft design in which the eccentric is mounted below the gear

Jaw Mill

A jaw or toggle mill consists of a set of vertical jaws, one jaw being fixed and the other being moved back and forth relative to it by a cam or pitman mechanism. The jaws are farther apart at the top than at the bottom, forming a tapered chute so that the material is crushed progressively smaller and smaller as it travels downward until it is small enough to escape from the bottom opening. The movement of the jaw can be quite small, since complete crushing is not performed in one stroke. The inertia required to crush the material is provided by a weighted flywheel that moves a shaft creating an eccentric motion that causes the closing of the gap. Single and double toggle jaw mills are constructed of heavy duty fabricated plate frames with reinforcing ribs throughout. The mills components are of high strength design to accept high power draw. Manganese steel is used for both fixed and movable jaw faces. Heavy flywheels allow crushing peaks on tough materials. Double Toggle jaw mills may feature hydraulic toggle adjusting mechanisms.

Hammer Mill

1. Device outline Hammer mill is one of the most excellent pulverizer for easily crushable materials such as limestone, coal, chemical fertilizer and so on. Fibrous materials such as synthetic resin and bark are also able to be crushed with appropriate types of hammer. Hammer mill has excellent performance in the wide field of aggregate, chemical, iron & steel and recycling resources. 2. Characteristics (1) Material which enters through an opening at the top side of casing is crushed by striking with swinging hammers and discharged from grates at the mill bottom. (2) The construction is strong and simple as designed to ensure easy maintenance. (3) The installation area is small and the machine weight is light as compared with the crushing capacity. (4) The crushing ratio is large and the efficiency is high. (5) Control of the product size is easily achieved by adjustment of the opening of the grate and or the hammer speed. (6) Swinging hammers keep smooth operation.

Impactor
The bottom of the PCC Reversible Impactor is open, allowing sized materials to pass through almost instantaneously. Liberal clearance between hammers and the breaker blocks eliminates attrition. Crushing is by impact only.

In crushing, impact is the sharp, instantaneous impingement of one moving object against another. Both objects may be moving (a bat connecting with a ball), or one object may be motionless (a golf ball hit off a tee). Two Variations of Impact Gravity impact: An example of gravity impact is coal being dropped onto a hard surface such as a steel plate. This method is most often used to separate two materials which have different friability. The more friable material is broken, while the less friable material remains unbroken. Separation is then done by screening. The PCC Bradford Breaker is an example of a mill which uses gravity impact only. Dynamic impact: Material dropping in front of a moving hammer (both objects in motion) illustrates dynamic impact. When crushed by gravity impact, free-falling material is momentarily stopped by the stationary object. But when crushed by dynamic impact, the material is unsupported and the force of impact accelerates movement of the reduced particles toward breaker blocks and/or other hammers. Dynamic impact is the crushing method used by PCC Impactors. Dynamic impact has definite advantages for the reduction of many materials and is specified under the following conditions: When a cubical particle is needed. When finished product must be well graded, and meet intermediate sizing as well as top and bottom specifications. When ores must be broken along natural cleavage lines in order to free and separate undesirable inclusions (such as mica in feldspars). When materials are too hard and abrasive for hammermills, but where jaw mills cannot be used because of particle shape requirements, high moisture content or capacity.

Attrition Mill

Figure : Schematic Layout of a High-Speed Attrition Mill General Description: The function of the attrition mills is to dry the coal, to reduce the coal from stockpile size to fuel size, typically 70% passing 75 micrometres (200 mesh), and to transport the fuel (PF) to the boiler. Coal is continuously fed to the pulverisers from the power station bunkers. Hot air enters the pulverisers and continuously conveys the PF to the boilers. This transport air is generally known as "primary air". Figure 12 shows a general schematic of a mill. Hot primary air is blown through the mill by the primary air fan while coal is fed in at the required rate by a feeder. The temperature of the air/coal mixture exiting the mill is normally controlled (typical temperature 70 C) by adjusting the temperature of the inlet air. This is done by balancing the mix of air from the air-heater and ambient air. The wetter the coal fed to the mill, the higher must be the inlet temperature.

Tumbling Mill

Figure : Schematic Layout of tumbling Mill

A cone mill is similar in operation to a gyratory mill, with less steepness in the crushing chamber and more of a parallel zone between crushing zones. A cone mill breaks rock by squeezing the rock between an eccentrically gyrating spindle, which is covered by a wear resistant mantle, and the enclosing concave hopper, covered by a manganese concave or a bowl liner. As rock enters the top of the cone mill, it becomes wedged and squeezed between the mantle and the bowl liner or concave. Large pieces of ore are broken once, and then fall to a lower position (because they are now smaller) where they are broken again. This process continues until the pieces are small enough to fall through the narrow opening at the bottom of the mill. A cone mill is suitable for crushing a variety of mid-hard and above mid-hard ores and rocks. It has the advantage of reliable construction, high productivity, easy adjustment and lower operational costs. The spring release system of a cone mill acts an overload protection that allows tramp to pass through the crushing chamber without damage to the mill.

Fluid Energy Mill

Figure : Schematic Layout of a fluid energy Mill

Itis a jet mill (fluid energy mill) employing compressed air or gas to produce particles less than one micron. Inside the Micronizer, precisely aligned jets create a vortex. Material is fed into this vortex along an engineered tangent circle and accelerates. High-speed rotation subjects the material to particle-on-particle impact, creating increasingly smaller fines. While centrifugal force drives large particles toward the perimeter, fine particles move toward the center where they exit through the vortex finder.

Ball Mill

Figure : Schematic Layout of a Ball Mill

Ball mill is an efficient tool for grinding materials like ores, chemicals, ceramic raw materials , paints etc. in to fine powder or fine paste by grinding in a wet way. The Ball Mill operates by rotating a cylinder with grinding balls like steel, CI, ceramic and pebble balls as grinding media. Material fed through the mill is crushed by impact and grounded by attrition between the balls and also the internal cascading effect reduce the material in to a fine powder. Ball Mills usually have liners inside which are replaceable when they wear. Liners will be of wave shape which key the ball charge in to the shell and prevent the slippage. The rotation of the powder mixer is usually between 4 to 20 revolutions per minute, depending upon the diameter of the mill. The larger the diameter is, the slower the rotation will be. Ball Mills are generally used to grind material " and finer, down to the particle size of 20 - 75 microns. To achieve reasonable efficiency, the ball mills are to be operated in a closed system, with oversize particles continuously being re-circulated back to the mill and to be reduced

Roll Crusher

Figure : Schematic Layout of Roll crusher

Roll crusher Application: The roll crusher is of simple structure, reliable operation and low cost. It is widely used in middle and small sized mines for intermediate and fine crashing of the brittle and soft ores of intermediate hardness like coal and coke. Roll crusher Applicable material: 1) Clay 2) Shale clay 3) Coal gangue 4) River silt Roll crusher Working principle: The particles are drawn into the gap between the rolls by their rotating motion and a friction angle formed between the rolls and the particle, called the nip angle. The two rolls force the particle between their rotating surface into the ever smaller gap area, and it fractures from the compressive forces presented by the rotating rolls. Some major advantages of roll crushers are they give a very fine product size distribution and they produce very little dust or fines. Rolls crushers are effectively used in minerals crushing where the ores are not too abrasive and they are also used in smaller scale production mining of more abrasive metal ores, such as gold. Coal is probably the largest user of roll crushers, currently, though. Coal plants will use roll crushers, either single roll or double roll, as primary crushers, reducing the ROM coal. Usually, these crushers will have teeth or raised forms on the face of the roll. ( used for minerals and metal ores have smooth faced rolls.)

Roller mills

Figure : Schematic Layout of a High-Speed Attrition Mill

Roller mills use cylindrical rollers to grind all sorts of materials rather than crushing them or grinding them between stones such as in a traditional grains mill. Roller mills are usually used for industrial grain milling (Agriculture) and for grinding gravel into smaller rocks or pulverizing them. The roller mill is a relatively new kind of large scale power mill which is designed specially to solve the problems of low capacity and high consumption of industry mills. It is a necessary equipment for the high production of mineral powder in the non-metal mine industry and large scale powder making in many other industries. The product size is adjustable in the range of 02.8mm.

Working principle
While working, motor drives the hanger of the grinding roller to rotate through V pulley and centre bearing. The roller, which is hung by bearing and pendulum shaft, will roll along the inner circle of the roll ring while the hanger is rotating. A dust removal blower will generate negative pressure at the inlet and outlet of the grinder to prevent dust and radiating the heat in the machine.