The fundamental goal for the design of a crushing plant is an installation that meets the required production requirements, operates at competitive cost, complies with today’s tough environmental regulations, and can be built at a reasonable price despite the rising

Cost of equipment energy and construction labor.

· Rising energy costs are causing owners to increase the integration of mine and mill design, so that they can identify ways of reducing overall electrical power consumption

· Electronic control of crusher discharge opening and feed rate. With adjustment of acrusher’s discharge opening, as the production continues through an on-line coarse size analysis of the crushed product (digital image analyses). Dance, A. 2001)

· More attention is being paid to the impact on crushing circuit design caused by variations in ore characteristics, size distribution, moisture content, ore grade and climatic conditions

1. An Introduction

· Basic definitions

· Minerals by value

· The process frame of minerals

· Mineral processing and hardness

· Size and hardness

· The stress forces of rock mechanics

2. Minerals in operation

· Operation stages

· Operation – dry or wet

· Mining and quarry fronts

· Natural fronts

· Size reduction

· Size control

· Enrichment – washing

· Enrichment – separation

· Upgrading

· Materials handling

· Wear in operation

· Operation and environment

· Operation values

3. Size reduction

· The size reduction process

· Feed material

· Reduction ratio

· The art of crushing

· Crushing of rock and gravel

· Crushing of ore and minerals

· Crushing – calculation of reduction ratio

· Selection of crushers

· Primary crusher

· Primary crusher – sizing

· Secondary crusher – type

· Cone crusher – a powerful concept

· Secondary crusher – sizing

· Final crushing stage – more than just crushing

· VSI – a rock protected impactor

· High Pressure Grinding Rolls (HPGRs) - HRC

· Final crusher – sizing

· Wet crushing prior to grinding

4. Size control

· Size control – introduction

· Size control by duties

· Size control by methods_ Screens Screening by stratification

· Screening by free fall Screen types

· Screen capacities_

· Selection of screening media

· Particle size – mesh or micron?

· Technical data: Single inclination screen – circular motion

· Technical data: Double inclination screen – linear motion

· Technical data: Triple inclination screen – linear motion

· Technical data: Multiple inclination screen – linear motion

· Classification – introduction

· Wet classification – fundamentals

· Hydrocyclone

· Spiral classifiers

· Dry classification – introduction_

· Static classifiers

· Dynamic classifiers

· Ancillary air solutions Dry grinding

· Size control in crushing and grinding circuits

5. Operations Design considerations

· Wet HGMS/F – magnet design

· Wet HGMS, HGMF – separator types

· Wet cyclic HGMS

· BASICS IN MINERAL PROCESSING

· Wet cyclic HGMS – process system

· Wet cyclic HGMS – operation

· Wet cyclic HGMS – applications

· Wet cyclic HGMS – sizing

· Technical data: Wet cyclic HGMS

· Wet cyclic high gradiant magnetic filter HGMF

· HGMF – applications.

6. Troubleshooting table for field types