Hammer Crusher Research Articles

Experimental Investigation of a New Modular Crusher Machine Developed for Olive Oil Extraction Plants.

The crushing system is crucial in the virgin olive oil (VOO) mechanical extraction process. The use of different crusher machines can highly influence the quality of the final product, mainly due to the phenolic and volatile content responsible for VOO sensory and health properties. An experimental investigation was conducted to evaluate the effect of the geometric features of a new model of crusher machine for olives. The crusher machine consists of interchangeable rotors: a rotor with hammers and a rotor with knives. The evaluation was carried out with the same fixed grid in stainless steel with 6 mm diameter circular holes. An evaluation was carried out on the impact of the crusher tools on the pit particle size and on the distribution of energy and temperature. The performance of the plant was also assessed in terms of process efficiency and olive oil quality. The results showed that the specific energy released by the tool per unit of product, calculated through both energy conservation and comminution theory, is about 25–27% higher in the case of hammers. Since the impact energy is mainly dissipated in the product as heat, the temperature reached during milling operations with the hammer crusher was also higher by the same percentage with respect to the knife crusher. This has important consequences on the quality of the product: the new knife rotor used in the crushing phase produced an improvement in VOO quality, relating mainly to sensory attributes and the health-enhancing properties of the final product. The ability of the crusher to break cell walls and vacuoles, thus releasing the oil contained therein, is comparable for the two different rotors.

Влияние окружной скорости молотков и диаметра рабочей камеры на величину эффективной мощности молотковой дробилки

The article presents the results of experimental studies to determine the effect of the speed of hammers and the diameter of the working chamber on the value of the effective power of the hammer crusher when grinding barley and feed grain mixture. The analysis of experimental data with an explanation of the obtained patterns is given. Keywords: HAMMER CRUSHERS, EFFECTIVE POWER, COMPOUND FEED, CIRCUMFERENTIAL SPEED, GRINDING MODULUS

Preparation of stem vegetable raw materials in the production of briquetted feed mixtures

To maintain the stable competitiveness of Russian agricultural products in the domestic and foreign markets, it is necessary to find reserves for the use of non-waste technologies using domestic raw materials in full. In the conditions of growing feed production, providing the feed industry with components of plant origin, an important role belongs to the use of inexpensive rough grass feed. Their use allows more rational use of plant stem forage, completely balances the diet of animals, mechanizes the distribution of feed, reduces its losses during transportation, distribution and eating, and thus significantly reduces the cost of livestock products. In connection with the production of new types of products in the form of briquettes, the production technology of which involves the introduction of stem plant materials, the process of their preparation is of great importance. Studies of the process of grinding stem plant raw materials with different moisture content on a hammer crusher were carried out, during which the optimal parameters of its operation were determined, which make it possible to reduce the energy intensity of the grinding process by 8.5-10.5% and improve the quality of the produced briquettes

Теоретические основы определения энергии перемещения кольцевого слоя в молотковой дробилке

In the course of a comprehensive analysis of the theory of the working process of hammer crushers, the insufficiency of theoretical studies of the processes occurring in the crushing chamber was revealed. One of the areas of theoretical research considered in this article is the determination of the displacement energy of the annular layer in a hammer crusher. Keywords: HAMMER CRUSHERS, ANNULAR LAYER, PASSABLE PARTICLES, ENERGY, SPEED, HAMMER, ROTOR, WORK OF DEFORMATION, POWER

Industry Scale Optimization: Hammer Crusher and DEM Simulations

The paper shows the preparation of the numerical models necessary for the simulation mapping of industrial-scale crushers of problematic material, such as copper ore with complex lithology. The crushers investigated in this work are located in the KGHM Polska Miedz S.A. copper ore processing plant. The complex ore consisting of sandstone, dolomite and shale is modeled using the Discrete Element Method (DEM) with Particle Replacement Model (PRM) that was chosen to simulate the crushing process. The article discusses the tests and calibration of material parameters and proceeds to test a breakage model in a laboratory-scale jaw crusher. The results are finally validated with the data from actual industrial-scale crushers and compared with the simulations. As an optimization option, the new shape of hammers is proposed and tested in a numerical environment. The performance of the newly designed hammers was examined using numerical methods. The numerical tests showed that the new design performed worse than the current solution. As a result, time and money were saved by avoiding industrial tests. In conclusion, the work shows how complex processes can be characterized in the numerical environment and used for further analysis.

The influence of the moisture content of the stem mass on the quality of grinding at using a hammer crusher

Purpose. Experimentally determine the influence of the humidity of the stem raw material during its grinding for further pelletization. Methods. When conducting research, monographic, calculation and construction methods were used. Raw materials obtained as a result of grinding were analyzed using sieve analysis. Grinding quality was assessed by the weighted average size of the particles. The methods of statistics, graphic and regression analysis were used in the processing and analysis of the obtained results. Results. The features of the sieve analysis of crushed stem materials have been specified, the weighted average particle size after crushing with a hammer crusher of wheat straw, rape stalks and corn at different moisture levels has been determined. Conclusions 1. Carrying out a sieve analysis of crushed stem raw materials requires compliance with DSTU EN 15149-2:2013 and careful observance of the sieving time of individual samples. 2. The dependences of the influence of humidity (in the range of 8–30%) of wheat straw, rape stalks and corn on the size of the particles, the weighted average length of which varies from 1.6 to 2.4 mm, were obtained when they were crushed with a hammer crusher. Keywords: hammer grinder, weighted average length of grinding, stem materials, humidity, dependence.

ПРЕВЕНТИВНАЯ СТРАТЕГИЯ ТЕХНИЧЕСКОГО ОБСЛУЖИВАНИЯ ДРОБИЛЬНОГО ОБОРУДОВАНИЯ

The research was carried out in order to develop a mathematical model and a diagnostic complex to determine the residual life of the rotor bearings of hammer crushers. Residual life information is essential for proactive maintenance and to prevent equipment crashes. To achieve this goal, Kazan State Agrarian University (Republic of Tatarstan) carried out calibration studies of the dependence of the diagnostic parameters of vibration on the value of the radial clearances of the bearings. 3610 bearings with different radial clearances (0.02 mm, 0.08 mm, 0.13 mm, 0.2 mm, 0.27 mm) were alternately installed on the rotor of the KD-2 hammer mill, from the drive pulley side and from the fan side) and recorded the vibration parameters. The information was read using a piezoelectric sensor. Signal processing was performed using a VVM-201 vibrometer. The results of mathematical processing of these data are presented in earlier publications. To determine the change in the value of the radial clearance from the operating time in hours, retrospective studies were carried out directly in the agricultural enterprises of the Republic of Tatarstan: “Shaimurzinskoe agricultural enterprise named after A.Sh. Abdreev” of Drozhzhanovskiy region, JSC “Kiyatskoe”of Buinskiy region, the agricultural production complex “Ural”of Kukmorskiy region, etc. The average operating time of the bearings of the rotor of the hammer-type KD-2 forage grinder before the onset of a pre-failure state on the drive side was 1900 ... 2000 hours, on the fan side - 2000 ... 2100 h. Based on the results of the research, the values of the radial clearances and vibration parameters of the rolling bearings of the rotor of hammer crushers were experimentally established, the regularities of the change in the radial clearance of the rolling bearings of the rotor of hammer crushers were revealed depending on the operating time. The developed mathematical models for determining the radial clearance in the rotor bearings of the hammer crusher by vibration parameters and calculating the residual life are implemented in a diagnostic complex consisting of a commercially available VVM-201 vibrometer and a residual life attachment

Studying the operational efficiency of the centrifugal-impact feed grain crusher of the new design

Crushing feed grain involves hammer crushers, which are characterized by high specific energy consumption and its uneven fractional composition. It is possible to obtain high-quality shredded grain with less energy when using a centrifugal-impact crusher of the new design with a hole in the loading neck to supply the chopping chamber with additional air at a rate of up to 4.8 m/s. An additional hole provides a 1.8...13-time increase in the airspeed through the unloading neck when the rotor’s rotation frequency changes from 3,750 to 2,250 min –1 , thereby enabling the timely evacuation of the shredded material from the crusher. The regression equations have been derived to determine the structural and regime parameters of the shredder, which ensure the maximal performance and minimal unit energy costs. The greatest impact on crusher productivity is exerted by the diameter of the sieve holes and the area of the bunker’s unloading window. The greatest effect on the specific energy intensity of the grinding process is exerted by the diameter of the sieve holes. The maximal performance of the crusher, 1,440 kg/h, and the minimal energy capacity, taking into consideration the achieved grinding degree, of 2.1 W∙s/(kg∙grinding degree unit), are observed when using a sieve with the holes’ diameter of 7 mm, the rotor’s rotation frequency of 3,500 min –1 , and the maximally open unloading window of the bunker, at F=1.458 m 2 ·10 –3 . The specific energy consumption for chopping barley is less by 1.22...1.89 times than that of the hammer crushers RVO 35, DB-5, KD-2A. The dust-like fraction is less than 5.74 %, which is half the amount of the hammer crusher DM-6. The rational crusher operation modes have been determined in order to prepare feed grain for feeding farm animals of different species and ages

ОПРЕДЕЛЕНИЕ РАБОЧЕЙ ПЛОЩАДИ ТОРЦЕВЫХ РЕШЕТ ДРОБИЛКИ ЗЕРНА С УВЕЛИЧЕННОЙ СЕПАРИРУЮЩЕЙ ПОВЕРХНОСТЬЮ

Hammer crushers are widely used for the destruction of grain in feed preparation. When they work in the grinding chamber, as a result of the rotor’s rotation, air flows arise that involve particles of crushed material and whole grains in motion, thereby creating an air-productive layer. These air flows are influenced by the shape and geometrical parameters of the blades, their location, rotor diameter and speed, and the parameters of the separating surface. Under the conditions of Knyagininskiy University, a hammer crusher with an enlarged separating surface was developed, the working chamber of which was formed by two end and one peripheral sieves. Angle hammers, straight hammers, or a combination of straight hammers and corner blades placed between them were installed on the rotor as working units. The study was carried out to study the effect of the type of working units and the area of overlapping of the edge sieve on the direction of air flows in the grinding chamber and to determine the working area of the edge sieve. Angle hammers are characterized by the movement of air flows in the axial direction and their following distribution: suction into the grinding chamber in the central part of the end sieve and ejection along the outer circumference of the sieve. Based on this, the entire area of the end sieve can be divided into three parts: the suction zone, the ejection zone and the transition zone. An increase in the length of the angular blades leads to an increase in the working area of the end screens, therefore, the use of combined working units is rational. Installation of working units in the form of straight hammers is impractical, since the working area of the end screens is minimal. It is also irrational to use working units in the form of angle hammers, since they are characterized by the maximum area of the retraction zone and a small working area of the end sieves

Comminution Characteristics for Recycling Waste Glass Bottle

To enhance the recycling rate of wasted glass bottles toward recycled aggregates, the study would decide optimal comminution equipment based on the particle size distribution, aspect ratio and equipment energy analysis. The impact, compress and abrasion is type of generated force by comminution. So, hammer crusher, shredder, roll crusher and ball mill have been selected because they have characteristic which is each type of force. As a result of the particle size analysis of each product, only the shredder product satisfied concrete and asphalt aggregate quality standard condition. Also, as a result of aspect ratio analysis using Imaging software program (Image J, National institute of health), most of size fraction is confirmed under 1.6 value. It was confirmed that the product has low dangerousness and satisfying to shpage index. Also, the particle reduction ratio against input energy of shredder product was the most high. Therefore, we can decide that the optimal equipment which applicable for comminuting waste glass bottle in certain particle size under 10mm is shredder. The result of study will make contribution to increasing energy efficiency of comminution processing and competitiveness of product.

Research of advanced crusher wood biomass for solid fuel production

The work deals with the crushing of recycled wood biomass for the production of pellets or briquettes to justify structurally-technological scheme and parameters of perspective crusher. The identified prospects solid biofuel production in terms of economy Analysis processes and designs devices for crushing biomass. Your rational type Hammer crusher without reshitnoyi for use in industrial complexes economy. Analytical studies demonstrated the feasibility of ram hammer crusher sieveless DMB-F (0.5-1.5) for crushing to pressing wood biomass in fuel products. The functional scheme of technical means, carried out engineering calculations modes and parameters of the crusher. The obtained results show the efficiency of the process of crushing raw wood at that mill.

DETERMINATION OF DUST EMISSION LEVEL FOR VARIOUS CRUSHING DEVICES

The paper concerns selected environmental problems of crushing devices operation. The main scope was to determine the dust emission level of hammer, cone and jaw crusher, operating in plant conditions. There were registered dust emissions for these crushers along with determination their distributions. There were also introduced indices that enable us to estimate environmental burdensome of particular crusher, with taking into account technological conditions (comminution ratio, throughput). It appeared that the jaw crusher, despite the highest dust emission level, turned out to be of less environmental nuisance, considering its throughput and achieved comminution ratio.

Analysis of simulation result by digital filtering technique and improvement of hammer crusher

This paper presents a method evaluating in numerical value the magnitude of vibration component contained in the rotor angular velocity of a hammer crusher and a new structure to remove them. In the hammer crusher, while rotating by the rotor, hammers are swinging around their pivots simultaneously. This swinging gives effect on the motion of the rotor, making vibration component contained in the rotor angular velocity. By simulating the rotating process of the hammer crusher, the rotor angular velocity and motor power are obtained, and by using the digital filtering technique, a method is developed to evaluate its magnitude in root mean square value by extracting vibration component contained in this simulation result. With this evaluating method is evaluated the simulation result on the motion process of various structures to find out a new structure model of very little value of vibration components in angular velocity and motor power.

Estimation on separation efficiency of aluminum from base-cap of spent fluorescent lamp in hammer crusher unit

In order to separate aluminum from the base-cap of spent fluorescent lamp (SFL), the separation efficiency of hammer crusher unit is estimated by introducing a binary separation theory. The base-cap of SFL is composed by glass fragment, binder, ferrous metal, copper and aluminum. The hammer crusher unit to recover aluminum from the base-cap consists of 3stages of hammer crusher, magnetic separator and vibrating screen. The optimal conditions of rotating speed and operating time in the hammer crusher unit are decided at each stage. At the optimal conditions, the aluminum yield and the separation efficiency of hammer crusher unit are estimated by applying a sequential binary separation theory at each stage. And the separation efficiency between hammer crusher unit and roll crush system is compared to show the performance of aluminum recovery from the base-cap of SFL. Since the separation efficiency can be increased to 99% at stage 3, from the experimental results, it is found that aluminum from the base-cap can be sufficiently recovered by the hammer crusher unit.

METHOD OF DETERMINING WEAR OF FAN BLADES CRUSHER GRAIN

It is scientifically proven that the main factors affecting the productive potential of the animals, are the structure of fodder farms, the quality of feed and methods of feeding. It is known that concentrated fodder are an important component in the diet of animals and contribute to a stronger manifestation of their productive potential. For grinding grain into livestock is usually used crusher with different working bodies. The most widely is spread hammer mill grain crusher. This happens due to the simplicity of their construction and relatively high resource of working bodies. Currently, for farmers are of great interest the small-sized feed factories and units, which include crusher grain with a fan. However, along with the obvious advantages of hammer crusher, like with forced feeding of material and with pneumatic, have a number of disadvantages, one of which is the increased wear of their working bodies: hammers, screens, fan blades. The greatest interest from the point of reducing wear represent fan blades, as changing their shape, it is possible to reduce or increase the intensity of wear. In addition, they are more prone to wear, since all of the crushed material passes through them with great speed, while in the grinding chamber, the amount of grain distributed over a larger number of hammers, and the relative velocity of grains in it decreases. The analysis showed that the intensity of wear of working surfaces of the blades of the fan depends on the coefficient of friction of grains on the blade, the angle of the blade to the radius of the rotor disc, and the greatest influence on friction force has a peripheral speed of the blades. To increase the service life of the blades and reduce the intensity of wear and tear it should be choosen the correct form of the smallest possible radius of curvature. The method is proposed on the basis of which it is possible to calculate the amount of wear of fan blades, taking into account its aerodynamic characteristics.

Influence of olive ripening degree and crusher typology on chemical and sensory characteristics of Correggiolo virgin olive oil.

In this study, two types of crusher, hammer and blade, were used to produce olive oils from cv. Correggiolo olives at four stages of ripeness, to analyse the effect of these two factors on oil quality indices (free acidity, peroxide value, UV absorption), on phenolic compounds content and sensory profiles. Differences in chemical and sensory data were analysed by two-way ANOVA. Ripeness exerted a stronger influence than the crushing equipment on quality indices, phenolic content and sensory evaluation; moreover the statistical significance of interaction between the factors considered suggests that they are intertwined. Differences in the texture of olive pastes obtained by squashing and crushing were clearly evident at the first stage of ripeness via observation with a scanning electron microscope. The stronger mechanical action of the hammer crusher also produced smaller pit fragments compared to the blade crusher, as shown by particle size analysis of the kernels fragments. Knowledge about the interaction between ripening and crushing will allow olive oil producers to pursue a product of the quality most suitable for a particular type of consumer. For example, bitterness and pungency, characters recently connected with health effects because sensory markers of extra virgin olive oil (EVOO) polyphenols, do not have a great sensory appeal for most consumers; however, there is a niche of gourmet estimators interested in these peculiar flavours and ready to pay a premium price for them. The producer will be able to customise the EVOO by modulating its chemical and sensory characteristics, especially the phenolic fraction, thus addressing the needs of consumers with different tastes. © 2016 Society of Chemical Industry.

Hard coal preparation in a single stage crushing circuit for gasification purposes

The article concerned the problem of coal preparation for gasification purposes. The main aim was to design the coal crushing circuit, which would produce the material within the particle size range between 0.5 and 5 mm. The one-stage crushing circuit based on hammer crusher was proposed. There laboratory tests of coal crushing in two circuits: one-stage circuit based on a hammer crusher and two-stage circuit based on jaw and roller crushers were also performed. The results showed that application of the one-stage circuit appeared to be more favorable both in terms of energy consumption and, if considered, the product particle size.

Study on diagonal hammer of three kind metals composite casting with block protecting handle

Hammer crusher is widely used in cement, ceramic, mining and electricityother industries, hammer head is one of important parts in crusher, its abrasion performance directly affects the service life of hammer crusher and economic cost. According to bimetalcomposite hammer head is often appear “Hammer handle wear and tear”,“Composite difficult” and the set of casting alloy block hammer head set piece of “come off” phenomenon, which design a set piece type bimetal composite casting straight diagonal hammer, make full use of high chromium cast iron wear resistance and the toughness of low alloy steel. Design a protect block structure reasonably that solve the hammer when the actual production of composite interface is difficult to control and “the problem of hammer head wear” for use. Solve the problem of hammer head wear actively, achieve “energy saving, emission reduction and environmental protection”.

К обоснованию количества граней корпуса безрешетной молотковой дробилки

К обоснованию количества граней корпуса безрешетной молотковой дробилки

Shelf life and quality of olive oil filtered without vertical centrifugation

This study evaluates the effect of filter press filtration on the shelf life of extra virgin olive oil (EVOO). Olives were harvested and processed on the same day by a continuous industrial plant equipped with a hammer crusher, a vertical malaxator, and a decanter. One part of the oil obtained was bottled in 0.5 liter dark‐green bottles with headspace representing a quarter of the bottle's volume (cloudy oil). The other part was filtered (using a filter press) directly after decanting and manually bottled using the same procedure (filtered oil). All samples were stored in a purpose‐built chamber and periodically analyzed. Samples were characterized by their water content, free acidity, peroxide value, specific extinction coefficients (K232 and K268), total chlorophyll, tocopherols, total phenolic compounds, HPLC phenolic profile, volatile compounds, fatty acid composition, and sensory analysis. Immediately after filtration, the only differences that could be detected were related to turbidity and total solids. In the subsequent analyses, filtered oil retained superior nutritional and sensory characteristics than cloudy oil. More importantly, the filtered oil remained at the standard required for categorization as “extra‐virgin olive oil” for longer.Practical applications: The article describes the effect of the filtration without vertical centrifugation on the olive oil quality. Shelf life tests have been performed to evaluate the changes in chemical and sensorial properties of olive oils. Since the filtration and its timing is controversial in the literature, a complete investigation, which considers the storage, is required. Furthermore, this is, to the best of authors knowledge, the first study focusing on the changes of oils produced without vertical centrifuge.This study evaluates the effect of filter press filtration on the shelf life of extra virgin olive oil (EVOO). Olives were harvested and processed on the same day by a continuous industrial plant equipped with a hammer crusher, a vertical malaxator, and a decanter. One part of the oil obtained was bottled (cloudy oil). The other part was filtered (using a filter press) directly after decanting and manually bottled using the same procedure (filtered oil). All samples were stored in a purpose‐built chamber and periodically analyzed. The results show a less degraded phenolic fraction in the filtered olive oils. In fact, compounds such as Tyrosol and Hydroxytyrosol, which are the final product of hydrolysis of secoiridoids, remain stable in filtered oils and increase in cloudy. Moreover, filtered olive oils have a better sensory profile than the cloudy along the shelf life. These data are confirmed by the GC‐MS analysis. The results confirm that filtration is essential in order to maintain the nutritional characteristics of the oil, and slow the onset of the main defects.