Republican Unitary Enterprise "SPA "Center"
The equipment to obtain cubiform crushed rock of enhanced durability
Minsk
UE «SPA «CENTER»
The equipment for obtaining cubiform crushed rock: - the content of plate-like and prickly form particles is below 15%; - the increase in durability of crushed rock; - the reduction in consumption of binders; - the improvement of quality and the extension of service life of a road surface.
The equipment to process siftings of crushing: - the obtaining of small-sized crushed rock fractions, sand, mineral additives into asphaltic concrete, ruberoid grit, etc.; - de-dusting of crushed rock.
The Unitary Enterprise «SPA «Center» manufactures mills to obtain fine dispersed powders (fine material, mineral additives, etc.) 19, Sharangovich st., 220018, Minsk, Belarus Tel. (017) 252-46-41, 252-20-13, fax: 258-45-60 E-mail: crushtech@telecom.by www.npo-center.com
Cubiform crushed stone When manufacturing concrete and asphaltic concrete road surfaces as well as building constructions, the shape of fine material particles is of great importance. The approaching of the particle shape to that of regular and cubiform and a drop in the amount of particles of weakened shape increase the durability of concrete and asphaltic concrete constructions and extend their service life. Particularly important is the shape of small-sized crushed rock of 3-5, 5-10, 10-15 mm which is used for the upper strengthening layer of a road surface which defines the longevity and quality of roads. The application of cubiform crushed rock at road building makes it possible: - to reduce crushed rock consumption by 15-20% and binders (bitumen, cement) - by 30-40%; - to bring the compacting factor of road concrete mix to one which provides not only longevity of a road surface but frost resistance as well; - to reduce time and labour input on placing the asphalt coating to 50%; - to extend the service life of a road surface; - to increase the coefficient of adhesion up to 0,65-0,71. The particle shape of crushed stone depends directly on the mode the rock is crushed. The most promising line in technology of crushing is to break the material by impact which is realized in SPA «Center» centrifugal crushers. This technology permits obtaining of crushed material having high consumer properties: - the content of plate-like and prickly shaped product commonly makes up 2-7% and safely does not exceed 15% which corresponds to the 1-st group crushed rock according to the State Standard 8267-93; - the strength of the crushed rock is 10-15% higher than that of source material; - the dustiness of the finished product fractions does not exceed 1%; - siftings (0-5 mm fraction) which are obtained at product crushing are an excellent fine material for the road concrete mix as regards their granulometric composition and an isometric shape of the grain. - Centrifugal impact crushing makes it possible to get crushed rock of high quality from both high-strength materials (basalt, granite, diorite, porphyrite, etc.) and weakened materials (dolomite, limestone) which after treating in centrifugal-impact crushers acquire characteristics permitting a considerable widening of the area of their application. The research done on crushing the dolomite crushed stone with obtaining 5-10 and 10-20 mm fractions employing SPA «Center» crushers showed that the type of crushed stone crushability increased from 400-600 up to 1000 while the content of grains of plate-like and prickly form amounted to 8,2 % for 5-10 mm fraction, for 10-20 mm fraction - 6,8 % which corresponds to the 1-st group crushed rock according to the State Standard 826793. Crushed rock of such characteristics can be applied for the asphalt concrete road surface of all the road categories unrestricted. The layout of the line to obtain cubiform crushed rock is given in Fig. 4.
Centrifugal-impact crusher The basis of construction of centrifugal machines which our association produce is a supporting assembly “on an air cushion” developed at our enterprise, the latter permitting the rotation of big masses at a high speed and with a high degree of unbalance. This made it possible to create a range of equipment with high technical properties as well as a qualitative product which is obtained via this equipment. The equipment is noted for a stable work under the most unfavourable distribution of the material in the accelerator, a high maintainability and low expenses for installation and operation. Centrifugal-impact crushers are intended to break both ore materials and nonmetallic materials. In a centrifugal crusher the failure of the material takes place through the impact of the material against the impingement elements at its speeding up in the field of centrifugal forces in the rotating accelerator. Both this and the fact that that the original support-rotor system provides a low level of vibration make it possible: - to increase significantly a degree of crushing and to widen the range of controlling the content of fractions in the product; - to reduce capital costs at the expense of a low specific consumption of materials and the absence of foundations; - to reduce working costs; - to obtain a stable granulometric composition of crushed product not depending on the wear of lining elements; - to exclude a dynamic balancing of accelerators; - to work without vibrations at imbalances reaching 1 kg, while with similar foreign impact crushers a limiting level of imbalance is 20 g. A basic scheme to crush the material in a centrifugal-impact crusher is given in Fig. 1. Table 1 Technical features of centrifugal crushers Operation factors Capability, t/h, up to Maximal lump feed size, mm Electric motor power, kW, up to Length Overall dimensions, Width m Height Mass, t
ДЦ-0,63 20 25 55 2,1 1,6 2,2 2,5
ДЦ-1,0 40 40 110 2,7 2,2 2,4 5,0
ДЦ-1,25 160 60 200 3,2 2,8 3,0 9,0
ДЦ-1,6 300 70 315 3,7 3,2 3,6 13,0
Mass and overall dimensions of the crushers may vary depending on the power of the electric motor, productivity, composition of the set and constructional execution. SPA «Center» manufactures crushers with the capacity from 20 to 300 t/h.
Fig. 1 A schematized crushing of material in a centrifugal-impact crusher: 1 – feed hopper; 2 – distribution cone; 3 – accelerator; 4 –crushing chamber; 5 – rotor; 6 –stator; 7 – supercharge chamber; 8 – fan; 9 gimbal drive; 10 – expanding clutch; 11 – electric motor of the drive.
Fig. 2 A schematized distribution of source product in accelerator. Source material supply into accelerator
Source material supply into accelerator
Crushing chamber
The product after crushing
Self-lined bed
The product after crushing
Impingement plate
Fig. 3 Versions for the crushing chamber construction.
The equipment to separate siftings SPA «Center» has developed and manufactured the line to obtain commercial products from the crushed rock siftings, the size being less than 5 mm. The basis of the technological line is a multi-product air cascade-gravity classifier (КГ) which is intended to separate material in the air flow by size or density of particles in the size range from several millimeters to 0,1 mm. The classifier makes it possible to separate the siftings into the required number of fractions with specified fractional compositions (e.g. 5-2, 2-1, 1-0 mm). This allows the obtaining of building materials (sands of a prescribed size modulus, fine material for concrete and asphalt, ruberoid grit, abrasive powders, etc.). In the design of the machine there has been realized a cascade scheme of separation: the process of classification has a multi-step nature. This permits a high precision of separation to be achieved. The direction of the movement of particles in a classifier is defined by the relationship between the force of gravity and the force of air drag from the side of an air flow. The fine product of separation deposits in cyclones. A basic scheme of the line to separate siftings of crushing is given in Fig.5. The classifier is characterized by a wide range of controlling the size of separation products which can be performed during the operation as well as by high working reliability and a very simple maintenance. Technical features of some cascade-gravity classifiers manufactured by SPA «Center» are given in Table 2. Table 2 Technical properties of some cascade-gravity classifiers Description Productivity, t/h Source product size, mm
КГ–3.006 35 -5
КГ–3.008 30 -5
КГ–2.001 40 -5
Separation products, mm
2-5; 0,63-2; 0-0,63
2-5; 0,16-2; 0-0,16
1,5-5; 0-1,5
20000 2,3 2,2 7,0 2,5
25000 1,6 1,9 6,4 1,5
Air consumption, m3/h
28000 length 2,2 Overall dimensions, width 2,0 m height 7,0 Mass, t 2,3 * The size of separation products can be regulated.
КГ–4.001 5 -5 2,5-5; 1,25-2,5; 0,63-1,25; 0-0,63 6500 1,4 0,7 4,1 0,7
The application of cubiform crushed rock in road building At present more than 80 crushers for obtaining crushed rock from granite, porphyrite, diorite and other materials operate at the enterprises of Belarus, Russia, Ukraine and Kazakhstan (see Table 6). According to the data presented by a building organization «Minskobldorstroy» which since 1997 has been applying cubiform crushed rock obtained via SPA «Center» centrifugal-impact crushers in highway engineering and repair works, the adoption of new technologies and materials made Cubiform crushed rock obtained via a centrifugal-impact crusher it possible to achieve the following results: 1. Improvement of road safety. A current coefficient of adhesion between a car wheel and the surface of a roadway covering as regards the Republican highways (according to systematic actual tests carrying out by a Research Institute «BeldorNII») is 0,33-0,48; when treating the surface with emulsion and cubiform crushed rock of 6,3-10 mm fraction, the coefficient of adhesion is 0,6-0,71, but with the crushed rock of 2-4 mm fraction this coefficient reaches the value of 0,9. Factual rise of safety factor is 50%. Besides, a possibility of skidding sharply goes down as well as the loss of control over the car at abrupt braking and speed-up on a wet pavement. 2. Reduction of noise level caused by moving traffic through populated areas. Table 3 The level of noise of the moving traffic through the populated areas Type of a road surface Noise level Asphaltic concrete 80 dB (A) The treatment of surface by the crushed rock of 5-20 mm frac88 dB (A) tion (the crushed rock is obtained via cone and jaw crushers) The treatment of surface with emulsion and cubiform crushed 77 dB (A) rock of 6,3-10 mm fraction 3. Extension of service life of a road surface: «taking root» of the crushed rock has run to 95-97% at the service life of 5 years (the inter-repair standard is 4 years). All in all during 5 years «Minskobldorstroy» gave surface treatment by cubiform crushed rock to 2800 km of roads. All these advantages made it possible for «Minskobldorstroy» to have a saving of 1,5 million USD. Comparative cost of 1 m2 of traffic-bearing surface at different ways of its treatment − with the application of materials after cone and jaw crushers and with the use of the crushed rock obtained via centrifugal crushers of SPA «Center» production − is given in Tables 4 и 5.
2
Table 4
The comparative cost of 1 m of roadbed at surface treatment Consumption Saving Crushed rock after Cubiform crushed rock Material per 1 m2 % cone & after impact-centrifugal Absolute jaw crushers crushers Crushed rock, kg 20 8,5 11,5 57,5 Bitumen, kg 1,2 0,77 0,43 35,8 Cost, conventional 0,63 0,34 0,29 46 unit 2
Table 5
The comparative cost of 1 m of road bed at membrane technology Consumption Saving Crushed rock after Cubiform crushed rock Material per 1 m2 cone & after impact-centrifugal Absolute jaw crushers crushers Crushed rock, kg 114 64 50 Bitumen, kg 17,2 7,1 10,1 Mineral powder, kg 24,8 0 24,8 Cost, conventional 5,31 3,28 2,03 unit According to ÂŤMinskobldorstroyÂť estimation, the period of recoupment for an impact-centrifugal crusher is 1 year.
% 43,8 58,7 100 38,2
THE LINE TO OBTAIN CUBIFORM CRUSHED STONE Source material Fraction up to до 100 mm, up to 40 mm 100 % Feeder Fraction up to 100 mm Cone crusher Fraction up to 40 mm
Impact-centrifugal crusher Return of material Fraction 20-40 mm Unbalancedthrow screen
Fraction 10-20 mm
Fraction 0-5 mm Fig. 4
Fraction 5-10 mm
THE LINE TO PROCESS SIFTINGS OF CRUSHING Siftings of crushing 0-5 mm
Feeder
Classifier
Fan
Cyclone
0-0,2 mm
Fig. 5
0,2-2mm
2-5 mm
Table 6
SPA "Center" crushers being in operation with the customers N
Customer
Crusher
Amount
Material
Productivity, t/h
Power, kW
Delivery year
Russia 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Krasnoyarsk, Chemical plant Krasnokamensk, "Priargunskoye enterprise" Sverdlovsk region, the village of Polunochnoye, "Rudoupravleniye" Krasnodar, Integrated works for nonmetallic materials Cheliabinsk region "Maly Kuibas" Kursk, the firm KBS Cheliabinsk region, The town of Anbash The village of Polunochnoye "Uraltranssgaz" Revda (Izhevsk) "Udmurtavtodor" Kemerovskaya oblast, Mozzhukhino Kemerovo, Granite quarry Sverdlovsk region, "Volkovsky mine" Yekaterinburg, "Uralnerud" Nefteyugansk, "Pervouralskoye rudoupravleniye" Nizhnevartovsk, "Severavtodor" Surgut, "Severavtodor" "RAOhimprom", Ltd. Lebedinsky ore-dressing & processing plant Ufa, "Sangalyksky quarry" Yekaterinburg, "Gorny Ural", Ltd. Magnitogorsk, Closed Corporation "Ural-Omega" Cheliabinsk region, Snezhinsk Ulianovsk, Closed Corporation "BelTEN" Smolenski branch of Closed Corporation "Trud" Orsk, "Orskoye karyeroupravleniye", JSC The town of Asbest, "Uralasbest", JSC Cheliabinsk region, "Minyarsky quarry " Kaluga, "Pilon-plius", Ltd. Pervouralsk, "Pervouralsky dinasovy plant", JSC Kurganskaya oblast, "Kataisky shchebenochny plant", Ltd.
ДЦ-2,5
1
Limestone
150
315
1989
ДЦ-1.25
1
Zeolite
50
160
1989
ДЦ-1.25
1
Manganese ore
100
132
1997
ДЦ-1.25
1
Pebble
90
132
1998
ДЦ-1.6
2
Porphyrite
200
250
1998, 2001
ДЦ-1.25
1
Granite
100
132
1999
ДЦ-1.25
1
Granite
100
132
1999
ДЦ-1.6
1
Granite
250
250
1999
ДЦ-1.6
1
Granite
250
250
1999
ДЦ-1.6
1
Granite
200
250
2000
ДЦ-1.6
1
250
250
2000
ДЦ-1.6
1
Granite Sandstone, Limestone
250
250
2002
ДЦ-1.6
1
Granite
250
250
2000
ДЦ-1.6
2
Granite
230
250
2000
ДЦ-1.25
1
Hornblendite
100
132
2001
ДЦ-1.25
2
Hornblendite
100
132
2001, 2002
ДЦ-1.25
1
Hornblendite
100
132
2001
ДЦ-1.6
1
Granite
250
250
2001
ДЦ-1.6
2
Granite
250
250
2001, 2003
ДЦ-1.6
1
Diabase
250
250
2002
ДЦ-04
1
Different Materials
3
11
2002
ДЦ-1.6
1
Granite
250
250
2002
ДЦ-1.25
1
Granite
100
132
2003
ДЦ-1,6
1
Granite
250
250
2003
ДЦ-1,6
1
Granite
250
250
2003
ДЦ-1.25
1
Serpentinite
120
132
2004
ДЦ-1,6
1
Limestone
250
250
2004
ДЦ-0,63
1
Crushed stone
15
45
2005
ДЦ-1.25
1
Non-metallic raw product
120
132
2005
ДЦ-1.25
1
Granite
120
132
2005
N 31 32 33 34
35 36 37 38 39 40 41 42 43 44 45 46 47 48
49
50 51 52
53
Customer Sverdlovsk region, "Pervouralskoye rudoypravleniye", Ltd. Uchaly, "Bashkirskaya goldmining company" Moscow, "Moscow Institute of Steal and Alloys" Cheliabinsk region, Magnitogorsk, Closed Corporation "Modulservice" Samarskaya oblast, Otradny, "TD "Remetall-S", Ltd. Asbest, Closed Corporation"BestGranite" Sverdlovskaya oblast, Asbest, "Uralasbest", JSC Cheliabinsk region, Satka, "YuzhUralPromSnab", Ltd. Kazan, "Kazdorstroy", JSC The republic of Dagestan, Kizilyurt, "Stroitel-7", Ltd. Orenburgskaya oblast Orsk, "Orskoye karyeroupravleniye", JSC Magnitogorsk, "Magnitogorsky shchebenochny plant", Ltd. Novosibirsk region, the village of Gorny "Kamenny quarry " , JSC Sverdlovsk region, Kachkanar "Monolit", Ltd. Sverdlovsk region, Asbest "Uralasbest", JSC Permskaya oblast, Chusovoy, "Chusovsky metallurgical works", JSC Cheliabinsk region, Satka, "NPK "Magnezit", Ltd. Kemerovskaya oblast, Novokuznetsk "Yevrazruda", JSC Amurskaya oblast, Blagoveshchensk Closed Corporation "Asphalt" Krasnoyarsk, State Enterprise "Krai DEO" Yekaterinburg, "Uralizvest", Ltd. Moscow, "Energoalliance", Ltd. Orenburgskaya oblast, the town of Yasny, "Kiyembayevsky ore dressing & processing plant "Orenburgskiye mineraly" JSC
Crusher
Amount
Material
Productivity, t/h
Power, kW
Delivery year
ДЦ-1,6
1
Hornblendite
250
250
2005
ДЦ-1,6
1
250
250
2005
ДЦ-0,4
1
1
7,5
2006
ДЦ-0,63
1
Mulit-corundum brick
10
45
2006
ДЦ-0,63
1
Aluminium industry slag
15
45
2006
ДЦ-1.25
1
Gabbrodiorite
110
132
2006
ДЦ-1,6
1
Chrysolite, asbestos
200
250
2006
ДЦ-1,6
1
Granite
250
250
2006
ДЦ-1.25
1
Granite
120
160
2007
ДЦ-1,6
1
River pebble
250
250
2007
ДЦ-1,6
1
Granite
250
250
2007
ДЦ-1,6
2
Granite
250
250
2007
ДЦ-1,6
2
Albitophir
250
250
2007
ДЦ-1,6
1
Gabbrodiabase
250
250
2007
ДЦ-1,6
1
Gabbrodiorite, serpentinite
300
315
2007
ДЦ-1,6
1
Blast-furnace slag
200
250
2007
ДЦ-1,25
1
Fused magnesia
10 по классу 0-8 мм
110
2007
ДЦ-1,6
1
Primary concentrate
300
315
2007
ДЦ-1,6
1
Gabbrodiabase
250
250
2008
ДЦ-1,25
3
Quartz porphyrites
100
200
2008
ДЦ-1,25
1
Gabbrodiabase
100
132
2008
ДЦ-1,6
1
Granite
200
250
2008
ДЦ-1,25
1
Chrysolite, asbestos
150
200
2008
Gold-bearing ore Different Materials
N 54 55 56 57 58 59 60 61 62
63
64
65 66 67 68 69 70 71 72
Customer Chuvash Republic, the village of Churachiki "Voldorstroy", Ltd. Leningrad region, the town of Tikhvin, Closed Corporation "TFZ" Sverdlovsk region, Asbest, "Uralasbest", Ltd. Krasnodar, "Dorstroyservice", Ltd. Krasnodar, "Kubanskiye Engineering Technologies", Ltd. Russia, Makhachkala, "Stroitel-7", Ltd. Orenburg, "Gazpromdorstroy", Ltd. Moscow region, the town of Naro-Fominsk, "DSK "Avtoban," JSC Amurskaya oblast, Blagoveshchensk, Closed Corporation "Asphalt" Cheliabinsk region, the town of Kyshtym, "Kyshtymski ogneuporny zavod", JSC Altaiski krai, the town of Rubtsovsk, Closed Corporation "Transservice – Yug" Cheliabinsk region, the village of Kvarttsytny, "Bobrovsky kvartsit", Ltd. (for "Lizing-M", Ltd.) Kemerovskaya oblast, Novokuznetsk, "SМTS", Ltd. The town of Vladivostok, Closed Corporation "DeltaLizing" Krasnodar, "Kubanskiye Engineering Technologies", Ltd. Krasnodar, "Kubanskiye Engineering Technologies" Orenburg region, the town of Yasny "Kiyembayevsky oredressing & processing plant", JSC Sverdlovsk region, Yekaterinburg, "Trest Uraltransspetsstroy", JSC
Crusher
Amount
Material
Productivity, t/h
Power, kW
Delivery year
ДЦ-1,25
1
Granite
150
250
2008
ДЦ-1,25
1
Granite
150
200
2008
ДЦ-1,6
1
Serpentinite, gabbro, diorite
300
315
2008
ДЦ-1,6
1
Gravel
220
250
2008
ДЦ-1,6
1
Gravel
250
250
2008
ДЦ-1,6
1
Pebble
230
250
2008
ДЦ-1,6
1
Barite ore
160
200
2008
ДЦ-1,25
1
Slag of ferrochrome industry
140
200
2008
ДЦ-1,6
1
Gabbro-diabase
230
250
2008
ДЦ-0,63
1
Scrap pf fire brick
20
55
2008
ДЦ-1,6
1
Gravel
250
250
2008
ДЦ-1,0
1
Quartzite
50
90
2008
ДЦ-0,63
1
Chamotte brick
15
55
2008
ДЦ-1,0
1
Gravel
60
110
2009
ДЦ-1,6
1
Gravel
200
250
2009
ДЦ-1,25
1
Granite
150
200
2009
ДЦ-0,63
1
20
55
2009
ДЦ-1,0
1
60
90
2009
ДЦ-1,25
1
100
160
2009
Chrysotileasbestos Chrysotileasbestos Gabbro
Ukraine 1 2 3 4 5 6 7 8
The town of Ovrutch, PO "Kvartsit" Zhitomir, DP"Shpat" The town of Klesovo, "Tekhnobud", Ltd. Dnepropetrovsk, "Avtodorservice", Ltd. Dnepropetrovsk, "Kvartsit DM" The town of Krivoy Rog, "Eco-Tekhnologiya" Kiev, "Rosukrkaryer", Ltd. Rovenskaya oblast, Sarnenski
ДЦ-1.6
2
Quartzite
150
200
2001, 2007
ДЦ-1.25
1
Feldspar
50
132
2002
ДЦ-1.6
2
Granite
300
315
2003
ДЦ-1.6
1
Granite
250
250
2003
ДЦ-1,6
1
Quartzite
250
250
2005
ДЦ-1,6
1
Iron ore
250
250
2005
ДЦ-1.6
1
Granite
220
250
2006
ДЦ-1,6
1
Granite
300
315
2008
N
Customer
Crusher
Amount
Material
Productivity, t/h
Power, kW
Delivery year
50
75
2006
district, Klesov, " KKNI Tekhnobud", Ltd.
Estonia 1
"Tallinnskaya Slantsevaya kompaniya"
ДЦ-1,0
2
Shale
Uzbekistan 1 2
Tashkent, "Asia-Granite" Company The town of Zarafshan, "Navoiyski ore-dressing & processing plant"
ДЦ-1,0
1
Crushed stone
40
75
2006
ДЦ-1,6
1
Gold-bearing ore
150
315
2009
Belarus 1 2 3 4 5 6 7 8 9 10
Minsk, "Minskobldorstroy" Grodno, "Grodnoobldorstroy" Homel, "Homelobldorstroy" Minsk, "Avtomagistral" The town of Mikashevichi, Republican Unitary Production Enterprise "Granite" Soligorsk, RUP "PO "Belaruskaliy" Minsk, "Makrodor", JSC The town of Mikashevichi, Republican Unitary Production Enterprise "Granite" Minsk, "BelTEN" Stock Company Glushkovichi village, Lelchitski district, Shchebzavod"Glushkovichi"
ДЦ-1.6
4
Granite
220
250
1996–1998
ДЦ-1.25
5
Granite
100
132
1997–1998
ДЦ-1.6
3
Granite
220
250
1998-2003
ДЦ-1.25
1
Granite
100
132
1998
ДЦ-1.25
5
Granite
200
200
2002-2003
ДЦ-1.25
4
Potassium chloride
150
110
2004–2005
ДЦ-1.6
1
Diorite
250
250
2006
ДЦ-1,6
2
Diabase
250
250
2007
ДЦ-1,25
2
River pebble
100
132
2008
ДЦ-1,6
1
Granite
250
250
2008
Kazakhstan 1 2 3 4 5 6 7 8 9
Aktobe, Mugodzharskiy quarry Karaganda, TTO GRK "KarRuda" Karaganda, "Karaganda Nerud" The village of Arshaly, "Arcada-industry" The town of Kaskelen,, Closed Corporation"ZHOL" Kostana, TOO "Kostanashcheben" Aktobe, JSC"KoktasAktobe" Pavlodar, Stock Company "Transsnerud-KZ" Akmolinskaya oblast, Yenbekshilderskiy district, Atansor village, ТОО "Orken"
ДЦ-1.6
1
Diabase
250
250
2001
ДЦ-1.6
1
Porphyrite
250
250
2002
ДЦ-1.6
2
Porphyrite
250
250
2002, 2003
ДЦ-1.6
2
Granite
250
250
2003, 2006
ДЦ-1,6
1
Granite
250
250
2003
ДЦ-1.6
1
Granite
250
250
2004
ДЦ-1.6
1
Granite
250
250
2006
ДЦ-1.6
1
Granite
250
250
2007
ДЦ-1,25
1
Porphyrite
150
250
2008
300
315
2007
Vietnam 1
Hanoi, International Investment Construction Corporation
ДЦ-1,6
2
Basalt
N
Customer
Crusher
Amount
Material
Productivity, t/h
Power, kW
Delivery year
150
250
2009
Mongolia 1
Ulan Bator, Bayanzurkh district, "BOR-Undur" oredressing and processing plant, KOO "Mongolrostsvetmet"
ДЌ-1,6
1
Copper ore
The Republic of Belarus
SCIENTIFIC AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE «SPA «CENTER»
EQUIPMENT AND TECHNOLOGIES
Minsk 2009
ABOUT OUR
ENTERPRISE
Director of SPA”Center” Borodavko Vladimir Ivanovich
Scientific and Production Republican Unitary Enterprise SPA “Center” was established in 1981 on the basis of a scientific subdivision of the Academy of Sciences of BSSR which was engaged in research of new technological processes. Within a short period of time the enterprise turned into a scientific and research, experimental and production centre to create a new generation of equipment for aviation, space and atomic industries. At that same time work was begun on creating the technological equipment for ore-dressing and processing industries. Even first models of crushers, mills, classifiers and centrifuges of centrifugal principle of operation proved to be a promising streamline. At present «SPA «Center» is both one of the biggest manufacturers of equipment for crushing, breaking and classifying different materials and a leading producer of centrifugal machinery in CIS countries territory. A high scientific and technical potential of the enterprise and great experience in development and adoption of new technologies make it possible to create new equipment irreplaceable in many branches of industry. Basic models of equipment, key technical solutions and developed manufacturing processes are patented and have no analogs. Production facilities supplied with modern equipment furnishes an opportunity to perform all kinds of metalworking, to provide for manufacturing of large-size and advanced complexity constructions, production lines and complexes. The enterprise has the certificate on DIN 18800-7 class Е confirming the right to manufacture and supply for export welded metal constructions.. In 2007 SPA “Center” got the certificate of conformity of quality management system to engineer and manufacture centrifugal machinery, medical refrigerator and laboratory centrifuges in compliance with STB ISO 9001-2001 requirements. More than 200 units of crushers, mills, size-reduction complexes, classifiers and classifying complexes which are made in SPA “Center” are being successfully operated at the enterprises of Belarus, Russia, Ukraine, Estonia, Kazakhstan, Uzbekistan, Viet Nam. Within a period of more than 25 years a united team has been formed which comprises not only workers of the enterprise but our customers and partners as well. At present our company is a reliable partner for more than 100 CIS countries enterprises which identify us as a progressive, actively developing plant where advanced technologies are being developed and applied both in manufacture of modern equipment and in business management system.
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ABOUT OUR
ENTERPRISE
SPA «Center» renders a full range of services associated with the application of our equipment and technologies: - preliminary and laboratory testing on breaking, classifying and dewatering of your material with the run of our equipment which permits the optimal modes of operation of the equipment to be set and the actual results of this work to be presented to the customer with the characteristics of obtained material; - the elaboration of the technological part of a production project; - engineering, manufacturing and supply of equipment; - installation and commissioning, training of operating personnel; - warranty and extended guarantee, manufacture and supply of spare parts and lining elements. High skill and a long standing working experience of SPA “Center” specialists give warranty to our clients for a qualitative execution of works and reliability of delivered equipment. We are always individually working with each customer and elaborate equipment and technological lines which correspond as much as possible to your exactly requirements. The enterprise is always open for a mutually beneficial partnership and businesslike co-operation. A vivid example of such a co-operation is Scientific and Research Association «Ural-Center» which was established in 1991. It comprises: - SPA «Center» (Minsk); - Public Corporation «Ural-Omega» (Magnitogorsk); - Joint-Stock and Production Centre «Uralmekhanobr-Engineering» (Yekaterinburg). Scientific and technical co-operation of the three enterprises makes it possible to carry out efficiently before contract studies on the customer’s material, to solve the problems of a comprehensive design taking into account both the demands of our customers and fitting out of the complexes with all the auxiliary systems. In so doing delivery on turn-key basis is provided as well as a prompt solution of warranty and after-sales service problems.
3 3
м
CRUSHERS
The impact mode for breaking down materials which is realized in centrifugal crushers and mills has great reserves for the increase in productivity of the processes of crushing and milling, the improvement in quality of the product, the reduction both in power consumption and in specific consumption of materials. In impact-centrifugal crushers the breakage of materials takes place through the impact of material against the impingement surface at its speedup in the field of centrifugal forces in the rotating accelerator. The process of breakage of the material by impact mode in comparison with the breakage due to shear stresses which takes place in cone and jaw crushers has a number of advantages: obtaining of the material mainly of regular cubical shape; improvement in strength of crushed material; selectivity in opening; a high degree of mechanical activation of freshly ground material.
Impact-centrifugal crushers make it possible to perform the operations of crushing of any hardness materials, abrasive difficult-to-machine materials including. The basis of SPA “Center” crushers’ construction is a supporting assembly "on an air cushion" which enables the self-balancing system of the working unit of the crusher to be created as well as the stable work of the equipment to be maintained at considerable unbalances arising from the uneven wear of the working parts and the uneven distribution of the material. This gives decisive advantages to our crushers in comparison with both centrifugal crushers having supporting assemblies of rolling and conventional crushing equipment – cone, jaw, hammer and rotary crushers. The most considerable advantage is low capital and working costs which are under the influence of the following factors: to mount the crushes it is not required to have special foundations, they can be installed on an even site and at any level of a production building; the design itself secures simplicity and conveniences to do the job on the replacement of the lining elements in the accelerator due to unconventionally made assemblies and fastenings; it is not required to do a dynamic balancing of the accelerator after the lining elements have been replaced; the crushers show stable work without vibrations at unbalances reaching 2 kg; the cost of the lining elements is 3-4 cents per ton of the material being crushed; the grain composition of crushed material does not depend on the wear of the lining elements. The general principle of operation of an impactcentrifugal crusher is shown in Fig. 1. By a high-pressure fan (8) in the chamber (7) the air pressure necessary for the «floating» of the rotor and for forming an air gap between the rotor (5) and stator (6) is generated. The origiFig 1 nated air cushion under the rotor fulfils the role of a gas bearing. The unique construction of the crusher’s working body is a self-balancing system and it secures a stable work of the equipment. Through funnels (1) the source product is fed into the separating cone (2) which distributes the product evenly along the channels of the accelerator (3). Having got in the rotating accelerator peripheral velocity necessary for the ejection and respectively kinetic energy, the source material strikes against the crushing chamber surface (4) and breaks down. (See Fig. 2).
Fig 2
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CRUSHERS Technical properties Description Model Throughput capacity, t/h Max linear size of the feeding lump, mm Electric motor power, kW Length Overall Width dimensions, m Height Mass, t
Value ДЦ-0,63
ДЦ-1,0
ДЦ-1.25
ДЦ-1.6
5-15 25 22-55 2,1 1,7 2,2 2,5
15-60 40 45-132 2,8 2,4 2,4 4,8
60-150 60 110-200 3,2 2,8 3,0 9
150-300 70 160-315 3,7 3,2 3,6 13
Impact-centrifugal crushers make it possible: to break materials of any strength and hardness; to increase considerably the degree of crushing and to extend the range of controlling the fractions’ content in the product; to redistribute the correlation of crushing and milling operations towards the increase of the former and to reduce the total costs for obtaining the final product; to reduce the feed-size of the comminuting equipment at further stages of the process of concentration and thereby to raise the productivity of comminuting redistribution by no less than 30%; at the cost of selectivity of impact breakage to start beneficiation at the stage of crushing; to obtain crushed rock with high consumer properties: - the content of prickly and plate-like particles in crushed stone corresponds to group I in compliance with State Standard 8267-93; - the strength of crushed stone is 10-15% higher than the initial strength; - the dustiness of finished fractions after screening does not normally exceed 1%; - the riddling (0-5 mm) which is obtained at screening of crushed product in its granule composition and isometric grain shape can be either an excellent filler material for road concrete mix or feedstock for obtaining high quality building materials.
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CLASSIFIERS Classifiers are intended to separate materials by size or density of the particles in the air flow. Our classifiers are characterized by: a high separation accuracy a possibility to provide the operation in a closed circuit without the removal of dust into the atmosphere; stability to obtain a pre-assigned granule composition; a possibility to regulate the borderlines of separation of the source product within a wide size range during the operation; low metal consumption and low power intensity.
Centrifugal classifiers Air-centrifugal classifiers with a dynamic area of separation (КЦ) are applied to obtain fine-dispersed powders of a prescribed fractional composition within 10 up to 80 mkm sizerange. The operation of a classifier is based on separation of material into coarse and fine fractions at the cost of interaction between the field of centrifugal forces and the air flow. The regulation of separation products size is done by variation in rotating speed of the accelerating rotor and also by change of the amount of the air flow. Classifiers of this type are used to obtain high quality filler materials, pigments, high-brand cements, micro-talc and other materials. The running of classifiers during a number of years has shown their high effectiveness, reliability in operation and simplicity in servicing.
Air-centrifugal classifiers with a static area of separation (КС) are applied to obtain fine-dispersed powders of a prescribed fractional composition within 63 up to 400 mkm size-range. The separation of material takes place owing to the interaction between the centrifugal force and that of aerodynamic resistance which have an influence upon a particle of the material. Going through the tangentially installed blades a powder-gas flow begins to twist. Coarse particles are thrown off on to the periphery of a classifier under the influence of centrifugal forces and then they are sinking along the walls whereas fine particles are carried away from the classifier by the air flow and then they deposit in cyclones. The regulation of separation products size is done by the change in the angle of installing of adjustable blades and in the amount of the air flow. Classifiers of this type are applied, as a rule, in combination with the mills for the reduction of ore materials and non-metallic materials. Technical properties Description Model Productivity, t/h, not more than Borderline size of separation products, mm Air consumption, thou. m3/h Hydraulic resistance, kPa Installed capacity, kW length Overall width dimensions, m Height Mass, t
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Value КЦ-0,3-1 1
КЦ-0,4-2 2
КЦ-0,6-5 5
КЦ-0,8-20 20
КС-2.001 5
КС-2.002 20
0,05-0,01
0,05-0,01
0,05-0,01
0,07-0,02
0,4-0,063
0,4-0,063
2 1-3 2,2 1,4 1,2 2,2 0,35
5 1-3 7,5 1,4 1,4 2,2 0,44
8 1-3 11 1,7 1,6 2,3 0,8
20 1-2,5 15 2,3 2,0 2,5 1,3
6 1-2 1,2 1,1 2,2 0,8
22 1-2 2,4 2,3 5,8 1,5
CLASSIFIERS Cascade-gravity classifiers Cascade-gravity classifiers are applied to separate coarse-dispersed materials into the pre-assigned fractions in the size-range between 0,16 up to 5,0 mm. The separation of material is accounted for by the interaction of gravitational forces field and the air flow. There has been realized a cascade system of separation in the design of the machine when the process of classification has many times repeating nature which makes possible a high precision of separation to be gained. The advantages of cascade-gravity classifiers comparing to those of traditional sieves are in the absence of expensive wearing close-meshed sieves and vibration mechanisms at separation. They make it possible to separate wastes of crushing into two, three and more fractions (see the Table). As a result building materials are obtained such as small-size cubiform crushed rock, building sands of specified fineness modulus, fine fillers for concretes and asphalts, filter and abrasive powders, etc. Long-term running of SPA “Center” air cascade-gravity classifiers demonstrated their high effectiveness, reliability, simplicity in maintenance and a possibility to control fractional composition in a wide sizerange without stopping the production. Classifiers can be applied both independently and together with crushing and sorting lines which is more promising and makes it possible to provide non-waste production.
Technical properties of some classifiers Description
Value
Model The number of separation products
КГК-2.001
КГ-3.006
КГ-3.011
КГ-3.012
КГ-3.013
КГ-3.014
2
3
3
3
3
3
Capacity as to charge, t/h
60
35
40
10
40
60
The size of separation products (can be regulated), mm
5-2 <2
5-2 2-0,63 < 0,63
5-2,5 2,5-0,16 < 0,16
5-2,5 2,5-0,16 < 0,16
5-1,2 1,2-0,16 < 0,16
5-2 2-0,16 < 0,16
Air consumption, thou. m3/h
30
28
25
9
25
31
Hydraulic pressure, kPa
2,5
2,0
2,5
2,5
2
2,5
length
2,5
2,2
3,0
2,4
3,6
3,8
width
3,2
2,0
2,4
1,6
2,4
2,6
height
5,5
7,0
7,6
5,8
8,2
8,3
4
2,3
3,5
1,6
4
4,2
Overall dimensions, m Mass, t
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MILLS Mills and grinding-and-classifying complexes to reduce ore materials and non-metallic materials The process of fine grinding of ore materials and non-metallic materials in traditionally applied ball grinders and rod mills is characterized by high materials consumption and power-consuming. The grinded product obtained in these mills is characterized by a wide grain composition while its particles have a gravel shape which reduces physicochemical activity of the finished product. Impactcentrifugal mode of grinding which is realized in SPA “Center” mills (grinding complexes) is considerably devoid of these drawbacks. Classifiers which are a part of the mills serve to withdraw the material of a required size from the zone of grinding and to return the underground product for re-crushing. Such a layout permits cost-effectiveness of grinding and qualitative indices of obtained product to be significantly improved. The end-product size can be regulated in operation without shutting down the equipment. The material obtained through SPA “Center” mills is distinguished for a narrow granulometric composition, a low content both coarse and fine fractions. Particles possess a uniform isometric shape with a well developed surface. It contributes to the obtaining of durable and qualitative goods at the reduction of material costs (binders, water) and power inputs. Depending on the properties of materials, feed size and product size, productivity, requirements for mass and overall dimensions the mills can be of three design versions: - with a built-in classifier; - with a singly standing classifier; - with a built-in and singly standing. Basing on centrifugal mills SPA “Center” specialists developed different types of grinding complexes (КИ) representing a modular system of appliances (mills, fans, cyclones, filters, systems of automation and control) which are arranged and integrated in the most optimal way to secure high operational indices, simplicity and convenience in servicing, small occupied space and low power intensity.
Technical properties Description Model Productivity, t/h Feed size, mm, up to The size of grinded product (is regulated), mm, not more than Installed capacity, kW, Not more than Overall dimensions, m, not more than: length x width x height Mass, t
8
Value КИ-0,4 0,05-1,0 10
КИ-0,63 0,5-5,0 20
КИ-1,0 1,5-10,0 25
КИ-1,25 3,0-20,0 25
КИ-1,6 5,0-25,0 25
0-0,02…3,0
0-0,02…3,0
0-0,02…3,0
0-0,02…3,0
0-0,02…3,0
40
160
290
430
520
5,0х4,0х4,1 3,5
11,0х4,0х8,7 14,5
14,0х7,0х9,0 21
15,0х8,0х10,0 40
15,0х8,5х11,0 50
MILLS Flow diagram of the grinding complex КИ-1,25
Mills for food industry Centrifugal mills for food industry are used to grind sugar, non-fat spices, cacao, coffee beans, herbs, dry fruits, farm grain products for mixed fodder, whole flower as well as to obtain powders from different materials of medium hardness, the initial size being up to10 mm. With these mills the product of various fineness of grind can be obtained depending on the installed rotor system (agreed with customer). The machines have batching devices protecting the motor against the overload and improving the quality of milling of the product. The product can be discharged into bags, containers, bins, etc. The mills are easy to maintain, are reliable in service and they require minimal installation costs.
Technical properties Description
Value
Model
ДЦ-9613
ДЦ-9717
ДЦ-9612
Productivity, kg/h
200...500
до 2000
до 6000
8000
The size of milling, mm
0,05-0,315
0,1-2,0
0,1-2,0
0,1-2,0
diameter, m
0,34
0,46
0,6
0,8
rotational speed, min-1
6000
5300
3000
3000
Installed capacity, kW
7,75
15-18,5
56,5
75
Rated voltage, V
380
380
380
380
0,91х0,56х1,3
1,3х0,55х0,9
0,9х0,9х1,7
1,1х1,1х1,7
0,20
0,50
1,00
1,25
Rotor:
Overall dimensions, m: length x width x height Mass, t
ДЦ-08
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CENTRIFUGES
Centrifuges for filtration and dehydration Centrifuges are a kind of equipment intended for filtration and dehydration of suspensions. The application of highly productive centrifuges contributes to the production process intensification. Centrifuges are easy to integrate into the technological lines: on processing ore materials; on processing suspensions of micro-biological and cellulose industries; on processing food products; on treating the runoff of industrial plants and recovering industrial wastes.
The automatic centrifuge with side filtration and batch-type inertial discharge of sediment The automatic centrifuge with side filtration and batch-type inertial discharge of sediment is intended for dehydration of hard-to-filtrate suspensions in food industry (suspensions of milk sugar, casein, maltresidue, potato, etc.), in chemical industry (ammonium sulfate), in mining industry (fluorite, quartz) and in other industries. The possibility to detain the material in the centrifugal field at separation factor up to1500 g provides the obtaining of a required quality product as well as the treating of suspensions with S:L phase correlation = 1 : 2 – 1 : 50 and with the size of particles of the solid phase = 10 - 3000 mkm. Liquid phase withdrawal is done uninterruptedly in the course of charging whereas the discharge of dewatered material, filtration and finishing squeezing – periodically. The rotor filter element has a possibility of centrifugal regeneration of a filtering partition in the course of rotor discharge. Any type of a filter fabric as well as a metal net can be used as a filtering partition. On the basis of these centrifuges there have been developed complexes to process potato, fruits and vegetables into dry semifinished products. The application of this equipment provides a 4 6 times reduction in energy expenses to dry the product, the increase in quality and product output and the reduction in metal consumption. A wide application of such technologies will make it possible to reduce greatly fruits and vegetables storage losses.
Technical properties Description Model Productivity on sediment, kg/h Rotor: diameter, m rotational speed, min-1 Installed capacity, kW Power consumption, kW Pressure in pneumatic system, atm Overall dimensions, m: length x width x height Mass, t
10
Value ФВП901К up to 600 0,9 1500 30,5 17-18 3-6 2,13x1,8x1,8 2,3
CENTRIFUGES
In modern practice the obtaining of milk-protein concentrates assumes more and more importance. The appliance of centrifugesits obtaining makes it possible: to reduce protein losses by 70%-90%, to increase the yield of finished product by 8%-10% while producing wet milk-protein concentrates. When producing dry concentrates - by 18%-20%; to use an effective method to clarify whey and then make it ready for further processing as well as to expand its area of application; to perform sewage treatment.
Automatic centrifuges of blade type with inertial discharge of sediment Automatic centrifuges of blade type with inertial discharge of sediment are designed to de-water coarse-dispersed materials in potash, mining, chemical, building and other industries. At separation factor 300 – 1100 g centrifuges permit suspensions to be treated with phase correlation S : L = 1 : 1 – 1 : 5, the size of solid phase particles being from 10 mkm. The centrifuges provide productivity as to sediment up to 50 t/h. For suspensions with S : L phase correlation above 1 : 5 the suggested scheme of separation allows to use the centrifuges as continuous thickeners.
Technical characteristics Description
Value
Model
ФЦ 921
Productivity as to sediment, t/h
ФЦ 844
10
50
Rotor: diameter, m rotational speed, min-1
1,0 1500
2,0 640
Installed capacity, кВт
37,5
215
Overall dimensions, м: length x width x height
2,8x1,8x1,5
5,0x3,6x2,4
1,60
15,00
Mass, t
The original supporting and rotor system of centrifuges provides a low level of vibration to give a possibility of carrying out their erection without special foundations on any level of a production area while arranging the technological lines. The centrifuges feature stable work at the most unfavourable distribution of the material in the rotor, high maintainability and low capital and operating costs.
Sedimentation continuous scroll-discharge centrifuges Sedimentation continuous scroll-discharge centrifuges are designed mainly to separate suspensions with an insoluble solid phase. They are applied to treat asbestos fibers, aluminum bromide, crystals of bi-aqueous gypsum, diatomite, carbongraphite dust, calcium-sulfate colloids, carbamide, molybdenum acid, sodium sulfate, chalk, potash, starch, polyvinylchloride, sodium carbonate and other materials. This centrifuge is intended to separate suspensions with solid phase of small and medium concentration, the size of particles being more than 5 mkm and the difference in density
11 11
CENTRIFUGES
between solid and liquid phase being more than 20 kg/m3. When the centrifuge is operating a rather pure clarified liquid results as well as sediment of small humidity . The centrifuges differ from currently available equipment by the drive in which gear belt transmissions are applied instead of a planet gear. The centrifuges are easy to operate and maintain.
Technical properties Description
Value
Model
ЦОГШ-0,36.01
ЦОГШ-0,5.01
Productivity as to suspension, m /h
3-6
15
Operating body: Inner diameter, m Rotational speed, min-1
0,36 3385
0,5 2650
3
Installed capacity, kW Factor of separation, g Overall dimensions, m: length x width x height Mass, t
30
37
2300
1950
2,5x1,6x0,8
2,3х1,8х1,2
1,50
2,00
The centrifuge for liquid classification For liquid classification in the field of centrifugal forces of synthetic micro-powders and natural diamonds, titanium carbide and other materials there has been developed the centrifuge РВК-01. The centrifuge control system assures a smooth speedup with a specified rate – from 10 to 45 revs/sec, spin stabilization with ±2 % accuracy in holding the rotating speed as well as a smooth braking. The control system is interference resistant, operates successfully at ±15 % fluctuation of supply system and it does not require special skills in controlling and maintaining. Thanks to nearly total absence of vibration on the shell of the unit, the best chosen radius of the rotor and diameter of the glasses there is an increase in assured yield of components amounting to 25% as compared to any other analog. The unit is made complete with four quick-change inserts made from food stainless steel. The system keeps workability within the temperature rate of +5 - +50 oC and at humidity up to 80%.
Technical properties Description The highest fill volume, l Rotational speed of the operating body, min-1 The highest factor of separation, g Period of speedup as far as max rotational speed, not more than, min Period of rotor braking from max rotational speed, min, not more than
6,4 500 - 3700 4500 4 5
The number of glasses in the operating body, pieces.
4
The number of quick-change inserts, pieces.
4
Density of classified disperse medium, not more than, g/cm3 Duration of one cycle of centrifuging, min
1,6 0,1 - 99,5
Power consumption, not more than, kW
2,2
Max permissible balance weight of the glasses, g.
80
Overall dimensions, mm: length x width x height Mass, t
12
Value
990х780х870 0,33
CENTRIFUGES
For more than 10 years SPA "Center" has been engaged in development, production, servicing and maintenance of medical and laboratory centrifuges. Proper certificates and licenses of the Republic of Belarus are available.
Refrigerating and laboratory centrifuges At present refrigerating centrifuges ЦР-01 and ЦР-02 and laboratory centrifuge ЦР-02Л are produced in lots. They are intended for blood and its components fractionation as well as for a biochemical research. ЦР-01 и ЦР-02 refrigerating centrifuges are designed both for blood and its components fractionation and for a biochemistry research. ЦР-02Л laboratory centrifuge is intended for a biochemical, laboratory and clinical research. The centrifuges are fitted with micro-controller modules providing the following functions: a smooth controlled rotor speedup, spin stabilization with ±2% accuracy and braking with a specified rate; control over the operational period of the centrifuge with the precision of ±1 sec; all required protection levels in case of emergency. Refrigerating centrifuges have the function of temperature control inside the unit with the preset accuracy from ±1 ° С up to ±3 °С. The workability of both the centrifuges and their control systems survives within + 5 - + 50°С temperature range. There are additional service functions: memory for 20 programmes of operating modes; the diagram for the current operating mode of the unit displaying the state of work; a possibility to convert the rotational speed into the separation factor and vice versa; a possibility to convert time into the integrated factor and vice versa.
Technical properties Description Model
Value ЦР-01
ЦР-02
ЦР-02Л
Rotational speed of the operating body, min-1
500 – 3200
500 – 6000
500 – 3600
Working range of chamber thermostating depending on the rotational speed, ºС
-10 - +25
-10 - +25
-
3145
6700
3100
The highest factor of separation, g
(4-glass rotor)
3700 (6-glass rotor)
Power consumption, kW, not more than
5,5
4,0
1,5
The highest fill volume
9,6 l
9,6 l
60 test tubes with up to 18 mm diameter
960х740х910
960х740х910
670х525х516
250
250
80
Overall dimensions, not more than, mm: length х width х height Mass, kg, not more than
13
CENTRIFUGES ЦВ-01 high-speed centrifuge The centrifuge is intended for the research of physical properties of proteins, nucleic acid and different biological substances. The centrifuge can be equipped with an angle rotor and a bucket rotor.
Technical properties Description
Value
Model
High-speed centrifuge ЦВ-01
Rotational speed of the operating body, min-1
500 – 15000
The highest factor of separation, g
30000
Period of rotor braking from max rotational speed, not more than, min Duration for one cycle of centrifuging, min
3 1 – 60
Working temperature range of chamber thermostating, °С Permissible balance weight, g
-4 - +20 2
Power consumption, not more than, kW
2.0
Max rotor capacity, ml
600
Overall dimensions, not more than, mm: length х width х height
670х525х516
Mass, not more than, kg
100
OUTFIT Unbalanced-throw screen SPA «Center» constantly improves and increases the range of output. One of the new developments of the enterprise is ГИ-0.1 (ГИС-43) unbalanced-throw screen. It is designed to separate mechanically crushed-rock, gravel-sand stuff and other loose materials into fractions. The screens can be used both independently and form a part of technological lines for crushing and classification which are designed by SPA «Center».
Technical properties Permissible load, t/h Max size of the material, mm
70
The sizes of screening surface, m2
6,7
The number of decks of the screen
3
The size of meshes of the screens *, mm Slope angle, ° Power of a drive, kW Overall dimensions (length/width/height), mm
* Can be changed on the customer’s demand 14
180
5,10,20 15±5 11 5650 × 2300 × 3010
OUTFIT Air filter Air filter is designed to clean non corrosive, non explosive, indisposed to adhesion and to condensate generation gas from fine-dispersed dust at a temperature up to 100 о С. Regeneration system of filter elements is fitted to the filter employing air pressure and offering freedom of compressed air supply.
Technical properties Productivity as to the gas being purified, m3/h, not more than
8000
Area of filtration, m2
120
Permissible pressure (discharge) inside the filter, kPa
5,0
Inlet mass concentration of dust g/m3, not more
50
Installed capacity, kW, not more
2,0
Degree of cleaning, %, not less
99,5
Hydraulic resistance, kPa
2,0
Overall dimensions, mm length width height
4550 2450 6200
Масса, кг, не более
4400
Automated complex for plasma cutting The complex is intended for the automated figured and linear cutting of sheet metal-roll from corrosion-proof metals, ferrous and nonferrous metals. It features a high productivity as well as a guaranteed quality. Gases in use: - the mode of gas cutting – acetylene, propane, natural gas - the mode of plasma cutting – О2, Ar/H2/N2, Ar/N2, Ar/H, air
HiFocus Plus cutting techniques. The deviation of both edges of the cut from perpendicular is within -1 up to +2о. Enhanced tightness of the arch. Improved quality of the cut.
FineFocus Plus cutting techniques. The deviation of the right edge of the cut from perpendicular is from -1 up to +2о
Technical properties The width of the bench for cutting, mm
2000 (2500, 3000)
The length of the bench for cutting, m
3-12
Max speed of cutting, mm/min
8000
Cut accuracy Thickness of the metal being cut: - plasma - gas welder Angle of inclination, degree
A EN ISO 9013 0,5-80 20-250 0-45о
Depending on the customer’s requirements plasma cutting complexes of other types and sizes can be made to solve different technological problems.
15
TEST
STANDS
Ц CENTRIFUGAL TEST STANDS The stands are intended to test for strength and endurance the items of both rocket-space and aviation engineering. The application of original design supporting assemblage makes it possible to test different forces at their simultaneous effect and at any of the combinations: linear accelerative forces, vibration and vibro-impact loads, changing climatic and environmental conditions, additional movements in different planes. It is possible to simulate intensive flight loads in ground-based conditions for large-size and heavy items.
Technical properties Description
Value СЭ-2,5
СЭ-4
СЭ-5А
СЭ-5В
СЭ-5-10 (small rotor)
СЭ-5-10 (big rotor)
Diameter of the base, m
2,5
4
5
5
5
10
Mass of the item under test, kg
100
200
300 -1000
1000
1000
3000
Overload, units g
500
320
250 -300
200
250
100
Specific power, kW/kg
0,29
0,2
0,49
0,4
0,5
0,3
Reheat temperature of the test item up to the temperature, оC
-
-
1200
1200
1200
1200
The set up vibration frequency range, Hz
-
-
10 -2500
10 -2500
10 - 2500
10 - 2500
Model
STANDS FOR TESTING MATERIALS FOR EROSION The stands are intended to test materials and protective coats applied in rocket-space and aeronautic engineering for resistance to erosion. Tests on erosion breakdown are carried out under the influence of two-phase streams (airwater, air-dust) in mostly close to real conditions. Main parameters: - linear velocity, m/sec 700 - 1500 - angular velocity, rpm 10000 - 15000 - the distance between rotational axis and item axis, mm 700-1500
THE STAND TO TEST MICROCIRCUITS AND ELECTRONIC COMPLETE PARTS The stand is intended to test for strength and reliability the parts of electronic engineering applied in control systems subjected to extreme actions (firing off, impact and so on). Main parameters: - overload, units g up to 20000 - angular velocity, rpm up to 9000 - linear velocity, m/sec up to 250 - the number of test microcircuits, units/h up to 6000
16
TECHOLOGIES
Technologies to concentrate minerals The most energy-intensive process at preparation of mineral raw materials to beneficiation is the process of comminuting. It is this process that defines a final performance of concentration as far as it has been at comminuting when the opening of minerals occurs while the quantity of unopened joints of both ore and non-metallic minerals defines the quality of the final concentrate. It is obvious that if at the stage of preparation of mineral raw materials to beneficiation, just at crushing and comminuting, there have been already created conditions for a selective opening of minerals then the effectiveness of the process of beneficiation itself will increase several times. In jaw and cone crushers, in ball and rod mills which are a traditional equipment for the most of oredressing and processing enterprises it is a problem to realize a principle of a selective opening of minerals because the failure of minerals in them takes place at the cost of static forces of crush, shear, attrition. At this mode of breakage a great number of joints survive which hinder the entire further process of beneficiation. Besides, this method is rather energy-intensive. The impact mode for breaking minerals embodies a great reserve in increasing the productivity of concentrating equipment, in improving the quality of final product, in reducing energy intensity and materials consumption of the process of beneficiation. In impact-centrifugal crushers the breakage of minerals takes place at the expense of a free impact of the material against the impingement surface. At this mode of comminuting: - the failure of the material is found along the micro-fissures, margins of cohesion. This implies that a selective comminuting of minerals which have a different resistance to impact takes place. The share of joints which sharply reduce the efficiency of beneficiation process is minimal therewith. - the overgrinding of the products as well as their sliming up does not take place which is typical for grinding in ball mills; a better opening of mineral grains is attained at more coarse grind as compared to a ball grinding. It is proved by repeated comparative tests at comminuting of ores of different metals; - the content of slime fractions (less than10 mkm) in the ground product significantly goes down which is conditioned not only by the increase in coarseness of grinding but by the impact mode to crush the material itself with the immediate withdrawal of the crushed product from the grinding chamber into the classifying zone. The increase in coarseness of the reduction product as well as a drop in the content of slime fractions make it possible to switch to a dry methods of beneficiation for a lot of minerals as well as apply more widely gravitation methods at the first stage of concentration which makes cheaper ore processing. With this water is excluded from the technological process as well as the operation on dehydration. Air classifiers can be used to extract minerals into concentrate at the stage of comminuting, to separate into wastes small fractions of the ground ore with a dump content of useful components. As a result the necessity to locate the additional equipment stands no longer while the quantity of the material arriving for concentration reduces. Similar technologies have already been introduced at a lot of enterprises of ore-dressing industry. Positive results have been obtained on applying SPA â&#x20AC;&#x153;Centerâ&#x20AC;? equipment in the technological lines at dry methods of concentration.
Iron ore concentration For concentrating mills with the combined methods of concentration the application of dry methods at early stages makes it possible to separate up to 50% of dry dump wastes. The results of dressing of titanium-magnetite ores (Kachkanar ore-dressing and processing enterprise) by a combined method including impact crushing and dry magnetic separation of the ground material as well as by the current method are given in the Table.
17
TЕCHNOLОGIES
Products of concentration
Combined method
Current method
Yield, %
Content Fe, %
Extraction Fe, %
Yield, %
Content Fe, %
Extraction Fe, %
Concentrate 95% class 0–0,071 mm
16,56
64,3
69,05
15,91
62,8
64,83
Wastes of dry concentration
42,33
5,34
14,68
8,0
8,0
4,15
Wastes of wet concentration
41,11
6,1
16,27
76,09
6,28
31,02
Manganese ore concentration At present a concentrating mill for dressing carbonate manganese ores is operating in the village of Polunochnoye (the Northern Ural). It was engineered and built with the application of completely dry concentration technology. The application of this technology for carbonate manganese ores dressing made it possible to obtain the concentrate with manganese content of no less than 30% (in the source ore – as much as 19%), at it extracting into concentrate – 79% and tails with manganese content as much as 8 %. This technology is developed for the first time and is far superior in its parameters to the conventional patterns of concentration. The obtained concentrate is a conditional product for metallurgy industry while the concentration wastes are used building materials industry. The application of dry technology of electromagnetic concentration of oxidized manganese ores (the Southern Khingan, the content of manganese – up to 20%) made it possible to obtain the concentrate with 42-44% manganese content, at its yield up to 35%, with manganese extraction of about 75%. The obtained tails therewith in the amount of 64-66% have the content of manganese as much as 8%.
Beneficiation of gold-bearing ores In the flow-sheets to prepare auriferous ores for beneficiation the air classifiers are applied not only for size-separation of the material but for a prior concentration as well: the extraction of coarse gold into concentrate at the stage of comminuting, extracting into tails of small fractions of ground ore with waste content of useful components. As a consequence the necessity to install nugget traps stands no longer and besides the quantity of the material entering for beneficiation is going down. The studies carried out on gold-quartz and gold-sulfide-quartz ores showed that the application of impact-centrifugal crushers permits the share of the opened gold in the ground product to be increased from 5 up to 25% (relatively) as compared with the conventional crushers and mills. At the same time there is a cutting of capital and operational costs. There was also a research on dry concentration of auriferous ores of some deposits. Thus, for example, the analysis of the end products of concentration of Beriozovsky deposit (the Ural, Russia) by dry methods showed that the content of gold in the obtained concentrate came to 100 – 120 g/t at 95 – 98% extraction (the content of gold in source products - 8,3 g/t).
Technology to obtain cubiform crushed rock Owing to high consumer properties of the crushed rock obtained through impact-centrifugal crushers, its cubiform shape as well as the advanced surface activity of the particles, its application at concrete production, highway engineering, at manufacture of building constructions makes it possible to reduce significantly material and technical resources, to increase the quality of the articles produced. The technology in question as well as the equipment which is manufactured by SPA «Center» are successfully applied while producing cubiform crushed rock from porphyrite, diorite and other materials for highway engineering in Belarus, Russia, Ukraine and Kazakhstan.
18
TЕCHNOLОGIES The advantages of cubiform crushed rock application At highway construction: In road surface building of great and special importance is a shape of pebbles 2-5, 5-10, 10-15 mm in size which is used for an upper strengthening layer of the road surface. The layer defines the longevity and quality of the road. The application of cubiform crushed rock at highway engineering and manufacturing of building constructions makes it possible: to reduce crushed rock consumption; to reduce bitumen and emulsions consumption up to 30%; to reduce time and labour expenditures up to 50% at placing asphalt concrete surfacing; to reduce cement consumption; to increase several times the service life of a road surface; to increase a cohesion factor up to 0,65-0,71. In production of concrete To ensure a high quality of concrete of great importance is a shape of particles of coarse aggregate (crushed rock). It is not to have more than 15% (as to mass) of the grains having a plate-like and a prickly shape. The conducted tests showed that the application as aggregate of crushed rock obtained by impactcentrifugal crushing makes it possible: to reduce water requirement of concrete mix by 3% to reduce cement consumption by 5-10 kg/m3; to improve the strength of concrete; to cut energy expenses for manufacture by 2,5% on the average, to reduce concrete prime cost by 3% on the average. It was determined that the application of cubiform crushed rock resulted in the reduction of cement consumption per unit durability of concrete by12,5%.
Technological layout to obtain cubiform crushed rock
19
TECHNĐ&#x17E;LĐ&#x17E;GIES Technology to produce man-made sands from the siftings of crushing of the rock Sand is an indispensable component of practically all the building materials. The rate of growth of road building and the production of reinforced concrete constructions conditioned the rise in demand for construction sand. At the same time the extraction of natural sands often involves the disruption of environmental conditions of some areas. It also destroys the ecosystem of riversides, causes the washing out of the beaches, the formation of landslips, wedging out of the underground water. At quarrying the organizations pay the mining tax and conduct activities on environmental protection. In some countries of the world the natural sand production is under a ban at all. At the same time a great amount of siftings of crushing which result from the processing of the rock are not used in full and are often assigned to wastage. They are stored in slag-heaps and this leads to the environmental pollution while they could become marketable products which price is many times higher than that of the siftings. After the siftings are processed through the classifying complex it is available to obtain pebbles, construction sands, fillers and other materials. The essential part of the line for obtaining man-made fractionated sands is a multi-product air cascade-gravity classifier which makes it possible to separate the siftings into the required number of fractions. The installation of only one line on siftings classification permits the obtaining of about 200 thousand tons of commercial output per year. At present, man-made sands have already been successfully applied in manufacture of building materials. In so doing the quality of the materials based on man-made sands occurs in most cases higher than that of similar materials based on the natural sand. The carried out research showed that the bending strength of fine-grained concrete based on the sand crushed through the impact-centrifugal crusher outperforms by 36 % a similar index of the concrete based on the bank sand. With this, the concrete based on the sand crushed in the cone-inertial crusher has the excess in strength by 29 %. A similar relationship is true also for a durability factor of fine-grained concretes at compression resistance.
Structure chart of a classifying complex
20
TЕCHNОLОGIES The fractionation of powder aggregate is one of the promising aspects in improving the quality of building materials. It is found that fractionated sands permit the obtaining of the concrete which surpasses in durability the concrete with both bank sand and not fractionated crushed sand or to provide cement saving. Thus, to obtain concrete durability unit (1 MPa) with the crushed fractionated sand the demand for cement is 19 % less comparing to the concrete with the bank sand and 17 % less comparing to the concrete with the non fractionated crushed sand.
Technology to obtain cement of centrifugal-impact grinding The technology of milling of Portland cement clinker through КИ complexes provides the obtaining of ПЦ400 and ПЦ500 cement brands according to the State Standard 10178-85. The proposed technology has a number of advantages comparing to a ball milling: - specific consumption of electricity for milling of Portland cement clinker in a centrifugal-impact mill is 12-18% lower than that of a ball mill; - the concrete mixes based on cements of centrifugal-impact milling are characterized by lesser water requirement (by 4-6 l/m3) and by lesser cement consumption (by 7-13 kg/m3); - there is a possibility for centrifugal-impact mills to regulate the size of particles of the obtained product. The technology to obtain mixed Portland blast-furnace cements (Pbfc) is developed by Spa «Center» specialists, too. The performed tests on Pbfc in hard concretes of classes В 12,5 и В 7,5 showed that the concretes have standard physical & mechanical and operational characteristics. The proposed technology makes it possible to reduce significantly the cost price of produced material.
The technology to obtain mineral additives from the used agglutinant sand At foundries a great amount of the agglutinant (burnt) sand is generated which is unfit for further production. It is taken out to slag-heaps and is buried in special mortuaries. Enterprises bear great expenses in the form of payments both for the waste burial and for the transportation to the place of burial. The research done by the Byelorussian National Technical University in collaboration with the specialists of the Republican Unitary Enterprise «Belorussian Road Research Institute» and SPA «Center» made it possible to develop the efficient method to obtain the activated mineral powder by fine milling of the agglutinant sand. The mineral powder can be a full value equivalent for a dolomite mineral powder which is now used in highway engineering. The presence of organic binders on the surface of the powder affords 10-20% economy of bitumen and permits the process of bitumen aging to be slowed down. Roadway coverings built with the usage of quartz activated powders are more durable. Mineral powders are a scarce material which is used in the production of road concrete mix and that is why a considerable part of asphalt concretes is produced without them. It causes their high porosity and fast disruption especially due to the cycles of freezing-defrosting. All this leads to the improper state of roadway coverings and heavy expenses for their repairs. Hence the production of powders from the used agglutinant sand will make it possible to expand greatly raw materials base of highway engineering, to improve the quality and service life of roadway coverings. Besides, up to15 % of coarse mineral material (sand) obtained after comminuting can be used as a return material together with the supplied sand in foundry at preparing the agglutinant sand which will be rather economically effective. According to the calculations done by the Republican Unitary Enterprise «Minsk Tractor Plant» the period of recoupment of a complex to obtain mineral additives from the used agglutinant sands will be less than a year.
21
EQUIPMENT Outdoor advertising equipment and small architectural forms One more line of SPA «Center» activities is designing and manufacturing of outdoor advertising equipment and small architectural forms. Since 1995 the enterprise has produced more than 4000 units of this type of equipment: various billboards, two-side advertising displays with illumination, public transport shelters, different kiosks, telephone booths and so on.
Technological equipment and metalwork In recent years SPA «Center» has been actively developing the production of different technological equipment of both own design and according to the customer’s design. A case in point is a range of machines to manufacture plastic windows, the lines to shape metal sheets which are made in collaboration with a French firm «DUBUS»; mixers for food industry, УД-2500 hose sprinkler system, the mobile unit to utilize organic wastes. The enterprose manufactures different metalwork to put up and finish buildings and constructions. These articles were applied while constructing the buildings of the Railway Station, the National Library, Metro stations, sports structures, Minsk streets and squares as well as giving these projects an attractive appearance.
THE LINE TO SHAPE METAL SHEETS
MOBILE UNIT TO UTILIZE ORGANIC WASTES
УД-2500 HOSE SPRINKLER SYSTEM
MIXER FOR FOOD INDUSTRY
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ATTRACTIONS The groundwork and experience on designing and manufacturing of different centrifugal equipment, test stands to investigate the effect of overloads on materials and people in the outer space made it possible to master the output of attractions which are placed exacting requirements upon reliability and safety of their constructions. As for now, SPA "Center" has manufactured and installed more than 150 attractions which decorate a lot of parks in such cities of Belarus, Russia and other CIS countries as: Minsk, Moscow, Anapa, Pyatigorsk, Surgut, Stavropol, Novosibirsk, Akmola, Rostov-on-Don, Samara, Lipetsk, Karaganda, etc. Some attractions were sold to the countries of far abroad – the USA, Germany, the Netherlands. 6
MERRY-GO-ROUND "VZLIOT"
GIANT SWING "ZUBR"
WATER SLIDE «RUCHEYOK»
MONORAIL ROAD FOR VIEWING
MERRY-GO-ROUND "WALTZ"
CHAIN-TYPE MERRY-GO-ROUND
LOCOMOTIVE "EKSPRESS-SHOSSE 2"
PLEASURE TRIP COACH "ALYONUSHKA"
23
New technologies to concentrate minerals To rise the efficiency of concentrating industry it is required to develop and promote both new manufacturing processes and equipment providing high technical-and-economic indices under the conditions when the loss of quality of crude minerals is observed. One of the ways to solve the problem could be a wider application of dry methods of ore dressing and crude minerals concentration. These methods, unfortunately, find limited applications because of lack of the equipment which could permit reaching by dry methods such results as at wet methods. In SPA "Center" new types of equipment have been developed and are being manufactured now which are applied for crushing, milling, classification and dehydration. The equipment makes it possible to carry out the processing of minerals by dry methods with high technical-and-economic indices. The research done on application of impact-centrifugal crushers, mills and air classifiers gives grounds to speak of economic and technological expedience of their usage in the process of concentration of many ore and non-metallic materials. Centrifugal equipment makes it possible: - the materials of any strength and hardness to be reduced dry; - to increase significantly degree of crushing and widen degree of controlling the content of fractions in the product; - to redistribute the relation between crushing and milling operations in the direction of increasing the first one; to reduce total costs for manufacturing the end product; - to reduce feed size and by doing so to raise the productivity by no less than 20%; - to cut capital costs at the expense of low specific consumption of materials, lack of foundations and simplicity of maintenance; - to start concentration at the stage of crushing at the expense of selectivity of impact breakage; The impact mode of crushing admits of attainment of better opening of mineral grains at a more coarse grind as compared to a ball milling. The content of slime fractions (less than 10 mkm) in the broken product therewith essentially declines. The increase in size of the product admitting for concentration makes it possible: - to improve the results of conventionally applied methods of concentration; - to apply more widely gravity methods of concentration; - to shift to dry methods of concentration as for many minerals.
Concentration of Iron Ores For dressing plants, which apply combined methods of concentration, the application of dry methods at early stages allows up to 50% dry tailings to be separated. For instance, at titanium-magnetite ores concentration with application of impact crushing and dry magnetic separation of the broken product the following results were obtained: - the aggregate concentrate with the yield of 16,6-20%, with the content of iron of 59,7-64,3%, with the extraction of iron of 69,2-70,6%; - tailings of dry concentration with the yield of 36,6-44%, with the content of iron of 5-5,6%, with the extraction of iron of 11,2-14,7%; - tailings of wet concentration with the yield of 39,5-44,5%, with the content of iron of 6-6,9%, with the extraction of iron of 15,3-18,1%.
Concentration of Manganese Ore The scheme of a production process put forward for manganese ore concentration makes it possible to process carbonate, oxidized and mixed manganese ores by dry method and to obtain concentrate and tailings.
The application of this know-how at concentration of carbonate manganese ores made it possible to obtain the concentrate with manganese content no less than 30% (in the source ore – up to 19%), at its extraction into concentrate – 79% and tailings with manganese content – up to 8%. This manufacturing process is first developed and it far exceeds in its values conventional schemes of concentration. Testing of this method on oxidized manganese ores showed that there is a possibility to obtain the concentrate with manganese content of more than 40% (in source ore- up to 14%), at it extraction into the concentrate – no less than 70% and manganese content in the tailings – about 6%. The main advantages of this manufacturing process are: lack of water in the process of concentration, practically total absence of harmful impacts on the environment, the application of the equipment with low specific consumption of material and energy expenditure. All this favours the reduction of capital and working costs.
Auriferous Ores Concentration In auriferous ore dressing air classifiers can be applied not only for separation the material by size but also for previous concentration: separation of coarse gold into the concentrate at the stage of grinding, separation of small fractions of ground ore with waste content of usable components into tailings. As a result the necessity to install traps for native metal fades and the amount of metal admitting for concentration reduces. The increase of coarseness of the product due to a better opening of minerals at impact grinding and the reduction of slime amount allow gravity processes to be applied at the first stage of concentration. This makes cheaper ore processing. As far as the suggested grinding and classification are done dry it's expedient to apply dry methods of concentration regarding some types of auriferous ores (magnetic, electromagnetic and electrical separation). With this water is excluded from the manufacturing process and dehydration, too. Studies on dry concentration of some auriferous ores of a number of deposits were made. Thus, for example, the assay of the resulting product after dry concentration of Beriozovsky deposit ores (the Ural region, Russia) showed that gold clustered in sulfide concentrates and its content in them was 100-120 g/t at 95-98% of recovery (the content of gold in source products –8,3 g/t).
SPA "Center"
19, Sharangovich str., 220018, Minsk, Belarus Phone: (+375 17) 2524641 2522013 Fax: (+375 17) 2584560. E-mail: crushtech@telecom.by www.npo-center.com
SPA ÂŤCenterÂť
The equipment for minerals processing Crushing, grinding, classification
The equipment to produce building materials
Centrifugal-impact crushers
Mills and grinding complexes
Centrifugal and air-gravity classifiers
Auxiliary equipment (sizing screens, cyclones, bag filters, fans)
2
Centrifugal-impact crushers Make it possible to perform the operations on crushing the materials of any strength, hard-to-treat and abrasive materials including. •Low capital and operating costs; •To install the crushers there’s no necessity in special foundations, they can be installed on a flat ground at any level of a production building; •The construction itself provides simplicity and ease at the execution of works when replacing the accelerator lining elements of at the expense of the original execution of assembly units and fasteners; •The accelerator’s dynamic mass balancing is not required after the lining elements have been replaced; •All the wearing surfaces and parts are furnished with special wear-resistant elements; •Grain size composition of the ground material does not depend on the wear of the lining elements.
3
Centrifugal-impact crushers 1 2 3 4 5
Supply of source product into the accelerator
Supply of source product into the accelerator
Crushing chamber
The product after rushing
The bed which is being selflined
The principle of operation of a centrifugal-impact crusher By a high-pressure fan (5) the air-pressure is generated necessary both for the ÂŤfloatingÂť of the rotor and the creation of the air gap between the rotor (3) and the stator (4). The air-cushion which is formed under the rotor plays the part of a gas bearing. The unique design of a working part of the crusher is a self-balancing system which secures a steady operation of the equipment. Source product (1) is fed through the hopper into the rotating accelerator (2). Having got in the accelerator the necessary peripheral velocity for grinding and, consequently, the kinetic energy it strikes against the bumper surface of the crushing chamber and breaks.
Crushing chamber
The product after crushing
Impingement plate
4
Centrifugal-impact crushers
Description Model Throughput capacity, t/h Maximal linear dimensions of a feed lump, mm Electric motor power, kW Overall dimensions, m Mass, t
length width height
ДЦ-0,63 5-15
Value ДЦ-1,0 ДЦ-1.25 15-60 60-150
ДЦ-1.6 150-300
25
40
60
70
22-55 2,1 1,7 2,2 2,5
45-132 2,8 2,4 2,4 4,8
110-200 3,2 2,8 3,0 9
160-315 3,7 3,2 3,6 13
5
Technology to obtain cubiform crushed rock The technology is based on the application of SPA «Center» impact-centrifugal crushers at the last stages of crushing. It makes it possible: •to crush the materials of any strength; •to obtain the product in a wide size-range; •to obtain crushed rock which content of plate-like and prickly particles is within the range of 5-15 %; •o obtain freshly-crushed crushed rock with the enhanced activity of particles surface; •to increase the crushed rock strength by 15-20%.
Basic characteristic of crushing Feed size, mm
Particle size, mm
70 mm
40 mm
6
Technology to obtain crushed rock The technology can be realized in two stages: I - crushing; II â&#x20AC;&#x201C; the following classification of screenings
I
II
Source material Fraction 20-40 mm
Screenings of crushing Fraction 0-5 mm
Discharge of air Cyclonedischarger
Aspiration cyclone
Gravity classifier Centrifugalimpact crusher
Aspiration fan
Unbalancedthrow screen
Dust Return Fraction 20-40 mm
Screenings of crushing Fraction 0-5 mm
Fraction 5-10 mm
Fraction 10-20 mm
Fraction 0-0,63 mm
Fraction 2-5 mm
Fraction 0,63-2 mm
Transport fan
7
The application of cubiform crushed rock makes it possible 1. In highway engineering: - to enhance strength and and lifetime of pavement road surface; - to save binding materials and filling compound up to 30%; - to reduce labor expenditures on roadway surfacing up to 50%; - to increase the adhesive capacity up to 0,65-0,71; - to reduce moving transport noise level by 10-12%.
The content of platy shaped grains, %
Platy shaped grains content in the crushed rock of impact-centrifugal breaking 16 12,8
12,1 12 10
10
8,5 8
8,1
8
7 5,7 4
4
0 granite
porphyrite
quartzite
5 - 10 mm fraction
serpentine
jasper
10 - 20 mm fraction
8
Cubiform crushed rock in concrete production 2. The application of cubiform crushed rock in manufacture of concrete products makes it possible: - to increase the concrete products durability by10%; - to reduce the content of cement by 15%; - to reduce concrete mix water demand by 3%;
The impact of the mode of breaking of crushed rock on concrete strength
16,00
15,00
Energy expenditure, conventional fuel, kg/m3
Durability under compression, MPa
- to reduce energy costs for the production by 2,5% on the average.
The impact of a filler type on energy expenditure in manufacture of heavy concrete
120,0
15,31 14,90
14,85
116,3
116,0 111,7
112,0
14,00
13,51
109,0
107,9
108,0
13,00
104,0
12,00 Source porphyrite crushed rock
Broken porphyrite crushed rock
Source granite crushed rock
Broken granite crushed rock
100,0 Source porphyrite crushed rock
Broken porphyrite crushed rock
Source granite crushed rock
Broken granite crushed rock
9
Cubiform crushed rock in concrete production Fine-grained concrete which is obtained on the basis of crushed sand outperforms in its physical and mechanical properties similar concrete manufactured with the application of river sand. In ensuring concrete high quality of great importance is a shape of particles of coarse aggregate (crushed stone). It is not to have more than 15% (by mass) of grains having plate-like and prickly shape. This requirement is easy to carry out with SPA ÂŤCenterÂť crushing and grinding equipment.
10
The place of MIKASHEVICHI: crushing and screening complex
Crushing and screening complexes on the basis of centrifugal crushers provide the obtaining of high-quality crushed rock and sand in the volume up to 1 m. tons per year. 11
The place of GLUSHKOVICHI: crushing and screening complex on the basis of ДЦ-1,6
These complexes permit the obtaining of high consumer properties crushed material; flakiness does not exceed 10% and this corresponds to group I crushed rock according to State Standard (ГОСТ) 8267-93.
12
Gumbeika, Russia: crushing and screening complex on the basis of Đ&#x201D;ĐŚ-1,6
13
JSC Kiembaevsky Ore Dressing and Processing Plant In 2009 – 2010 the Enterprise «Orenburg minerals» (Russia) overhauled «JSC Kiembaevsky Ore Dressing & Processing Plant» on concentration of asbestos ores.
Before the reconstructi on
After the reconstruction
The amount of crushers
112 rotary crushers
39 ДЦ
The amount of the stages of crushing
5
3
Annual electricity consumption, MW
144 000
57 000
Manganese steel consumption (for quickwearing elements) reduced by 2700 t/year. 14
Centrifugal-impact mills Comparing to ball mills they make it possible: • • • • • •
to obtain the ground product of a narrow granulometric composition in a wide size-range; to control the size of the ground product in operation; to obtain the particles of material with the shape approaching cubiform; to obtain products with the enhanced surface activity of the particles; to reduce significantly the milling of metal into the finished product; to reduce energy costs on grinding by 10-12%.
15
Centrifugal-impact mills Finished product
Classifier Source material
Accelerator Crushing chamber
Air supply
Underground material
Classifiers which the mills comprise serve to Impingement ring
Air supply
Underground material
withdraw the material of the required size from the grinding zone as well as to return the underground product for re-grinding. Such a scheme permits both the substantial improving of the economic performance of grinding and the quality factors of the resulting material. The size of the finished product can be regulated in operation without the equipment shutdown. 16
Flow chart of the grinding complex
material
17
Grinding complex automated Control System
18
The application of the products from impact grinding •
when using cement to increase the strength of
concrete articles by 20-25% or to reduce cement consumption by 10-12%; •
when using sand and lime in the production of foam
concrete and cilica brick to enhance the strength of the articles by 40-50%; •
to obtain high quality building materials.
19
Centrifugal-impact mills The material obtained through SPA «Center» mills is distinguished by a narrow granulometric composition, by a low content of both coarse and fine fractions. The particles have homogeneous isometric shape with a well developed surface. It contributes to the obtaining of durable and qualitative articles and in so doing there is a reduction in material (binders, water) and energy expenditures.
Description Model Capacity, t/h Feed size, mm, up to The size of the ground product (can be regulated), mm, not more than Installed capacity, kW, not more than Overall dimensions, m, not more than:
length x width x height Mass, t
КИ-0,4 0,05-1,0 10
КИ-0,63 0,5-5,0 20
Value КИ-1,0 1,5-10,0 25
0-0,02…3,0
0-0,02…3,0
0-0,02…3,0
0-0,02…3,0
0-0,02…3,0
40
160
290
430
520
5,0х4,0х4,1 3,5
11,0х4,0х8,7 14,0х7,0х9,0 14,5
21
КИ-1,25 3,0-20,0 25
КИ-1,6 5,0-25,0 25
15,0х8,0х10,0 15,0х8,5х11,0 40
50
20
Homel Ore Dressing & Processing Plant: grinding complex to obtain powder quartz The results have shown that the obtained materials are in full compliance with the requirements of State Standard (ГОСТ) 9077-82.
Productivity: 2 t/h Product size: 50 μm Milling of metal, not more than: 0,02%
21
JSC «Polotsk-STEKLOVOLOKNO»: The complex to grind sand and erklez At the present time two complexes КИ-1,25 for sand grinding have been launched and are being in successful operation at JSC «Polotsk-Steklovolokno». The replacement of jet mills to grind sand and erklez for SPA «Center» grinding complexes in 2009 gave 50 thou. $ saving of the operating costs per month.
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В целях защиты вашей конфиденциальности автоматическая загрузка этого рисунка блокирована приложением PowerPoint.
«KOELGA-MRAMOR», Russia: the grinding of marble powder
At the present time up to 70 % of all the filling compounds on the basis of marble powders in CIS countries are produced with SPA «Сenter» equipment.
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Classifying equipment Gravity classifier
Cascade-gravity classifiers are applied for the separation of coarse-dispersed materials into the specified fractions in the size-range from 0,1 to 5,0 mm. The separation of the material takes place at the expense of the interaction of the field of the gravitational forces and the air flow. Cascade system of separation realized in the equipment construction permits the achieving of high precision separation.
Centrifugal classifier
Centrifugal classifiers are applied to obtain finedispersed powders of specified fractional composition in the size-range from 0,005 to 0,1 mm. The separation of the material takes place at the expense of the interaction of the centrifugal force field and the air flow. The size of separation products is regulated by the change in rotational speed of the speed-up rotor as well as by change in the amount of the air flow. 24
Centrifugal classifiers Classifiers of this type are used to obtain high quality filling compounds, pigments, highquality cements, micro-talc and other materials. The size of separation products is regulated both by change in the rotational speed of the rotor and by change in the quantity of the air flow.
Description КЦ-0,3-1 1
КЦ-0,4-2 2
Value КЦ-0,6-5 КЦ-0,8-20 КС-2.001 5 20 5
0,05-0,01
0,05-0,01
0,05-0,01
0,07-0,02
0,4-0,063
0,4-0,063
2
5
8
20
6
22
Hydraulic resistance, kPa
1-3
1-3
1-3
1-2,5
1-2
1-2
Installed capacity, kW length Overall width dimensions, m height Mass, t
2,2 1,4 1,2 2,2 0,35
7,5 1,4 1,4 2,2 0,44
11 1,7 1,6 2,3 0,8
15 2,3 2,0 2,5 1,3
1,2 1,1 2,2 0,8
2,4 2,3 5,8 1,5
Model Productivity, t/h, not more than Boundary size of the products of separation, mm Air consumption, thou. m3/h
КС-2.002 20
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Gravity classifiers Classifiers of this type can be applied both independently and as a part of crushing-and-sorting lines. The advantages of cascade-gravity classifiers in comparison with conventional screens lie in the absence of expensive quick-wearing fine-meshed screens and vibration mechanisms. Long-term of operation of SPA “Center" air cascadegravity classifiers revealed their high efficiency, reliability and simplicity in maintenance.
Description
Value КГ-3.011 КГ-3.012
Model The number of separation products
КГК-2.001
КГ-3.006
КГ-3.013
КГ-3.014
2
3
3
3
3
3
Productivity on loading, t/h
60
35
40
10
40
60
30
5-2 2-0,63 < 0,63 28
5-2,5 2,5-0,16 < 0,16 25
5-2,5 2,5-0,16 < 0,16 9
5-1,2 1,2-0,16 < 0,16 25
5-2 2-0,16 < 0,16 31
Hydraulic resistance, kPа
2,5
2,0
2,5
2,5
2
2,5
length width length
2,5 3,2 5,5 4
2,2 2,0 7,0 2,3
3,0 2,4 7,6 3,5
2,4 1,6 5,8 1,6
3,6 2,4 8,2 4
3,8 2,6 8,3 4,2
The size of separation products (can be regulated), mm Air consumption, thou. m3/h
Overall dimensions, m Mass, t
5-2 <2
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Classifying complexes permit the obtaining from
In the dumps of different
screenings of crushing the crushed rock fractions
enterprises millions of tons of
0-0,63 mm; 0,63-2 mm; 2-5 mm.
the screenings (fraction 0-5 mm) are stored. After the screenings are processed in the classifying complex small-sized crushed stone is produced as well as building sands, fillers and other materials the cost of which is incomparably higher than that of the screenings.
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Classifying complexes to separate screenings of crushing with the capacity of 80 t/h
Working as a part of crushing-and-sorting complexes they carry out waste-free processing of granite into high-quality commodity products. 28
Auxiliary equipment They are intended for the mechanical separation into fractions of crushed rock,
Unbalanced-throw screen
sandy gravel mass and other bulk. The screens can be applied both independently and as a part of technological lines of crushing and classification which are designed by SPA «Center».
The air filter is intended for cleaning of non aggressive, not explosive, not inclined to stick and form condensate gas mixtures from fine-dispersed dust at the temperature up to 100 °С. The filter can be completed with the systems of filtering elements regeneration which use both the atmospheric pressure and compressed air or the mechanical shaking up.
Air filter
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Auxiliary equipment Cyclones are intended to trap the suspended particles from gases. Depending on the requirements to gas cleaning, on the properties of the particles and their disperse content, the cyclones can be used separately or can be applied as the devices of the first and the second stages of cleaning in conjunction with other gas-purifying devices. The productivity of cyclones on gas can be from several hundred cubic meters per hour to hundreds of thousands. They can be used single and in group (2, 4, 6, 8 elements). The cyclones have the air shake system of the material in the bunkers for the sake of their complete discharge and for the prevention from the caking of the material. They also have bunkers level sensors. The cyclones have a lot of modifications as to bunker volume and the constructional execution. They can be manufactured according to the specific customer requirements. 30
Scientific and Production Republican Unitary Enterprise «SPA «CENTER»
More then 450 units of SPA «Center» centrifugal equipment successfully operate at the enterprises of Belarus, Russia, Ukraine, Kazakhstan, Azerbaijan, Uzbekistan, Estonia, Viet Nam, Iran and other countries. 31
SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
SPA “Center” was established in 1981 on the basis of a scientific subdivision of the Academy of Sciences of BSSR which was engaged in research of new technological processes.
At present «SPA «Center» is both one of the biggest manufacturers of equipment for crushing, breaking and classifying different materials and a leading producer of centrifugal machinery in CIS countries territory.
SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
В
More than 400 units of crushers, mills, size-reduction complexes, classifiers and classifying complexes which are made in SPA “Center” are being successfully operated at the enterprises of Belarus, Russia, Ukraine, Estonia, 2 Kazakhstan, Uzbekistan, Viet Nam.
SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
SPA “Center” performs: manufacturing and delivery
of the equipment; designing of new and
updating of now in force equipment contract supervision and
commissioning training of the maintenance
personnel
SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
ď Ž Production facilities supplied with
modern equipment furnishes an opportunity to perform all kinds of metal-working, to provide for manufacturing of large-size and advanced complexity constructions, production lines and complexes.
SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
ď Ž Unique equipment is available providing the manufacture of
the oversized constructions of higher than usual complexity, technological lines and complexes.
SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
The enterprise has the
certificate on DIN 18800-7 class Е confirming the right to manufacture and supply for export welded metal constructions.
НАУЧНО-ПРОИЗВОДСТВЕННОЕ РЕСПУБЛИКАНСКОЕ УНИТАРНОЕ ПРЕДПРИЯТИЕ «НПО «ЦЕНТР»
На предприятии имеется уникальное оборудование,
обеспечивающее изготовление крупногабаритных конструкций повышенной сложности, технологических линий и комплексов.
5-axis machining center FUQ-150VR/10
UE “NPO “Center“ has five-axis
machining center FUQ-150VR/10 - operational stroke in X-, Y-, Zaxis 9000x1500x2000 mm; - positioning accuracy: 20 microns; - contour milling; - boring; - drilling; - turning; - threading.
Universal milling CNC machine DMU-60 T
Vertical lathe
Shot-blasting machine and Spray cabinet
Shot-blasting machine GETRASUR BLASTECO PCBE 944C
SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
PLASMA CUTTING
PLASMA CUTTING UNDER WATER
WATERJET CUTTING
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Automated complex for plasma cutting
Waterjet cutting automated complex
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SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
PRODUCED EQUIPMENT
Impact-centrifugal mills
Impact-centrifugal crushers
Technical properties Model Throughput capacity, t/h
ДЦ-0,63 5-15
ДЦ-1,0
ДЦ-1.25
ДЦ-1.6
15-60
60-150
150-300
Max linear size of the feeding lump, mm
25
40
60
70
Electric motor power, kW
22-55
45-132
110-200
160-315
Mass, t
2,5
4,8
9
13
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SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
PRODUCED EQUIPMENT
CLASSIFIERS
SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER" RUPP Granit, Mikashevichi ДЦ-1,6 Milling and classifying complex provides an output of 1 mln ton of high quality cube-like crushed stone and sand per year
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SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER" RUPP Granit, Mikashevichi ДЦ-1,6 Centrifugal mill provides an
output of cube-like crushed stone of quality class 100, suitable for roads of any category, manufactured from low-grade dolomite rock
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SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
PRODUCED EQUIPMENT
Technological centrifuges
SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
PRODUCED EQUIPMENT
Medical and laboratory centrifuges
SCIENCE AND PRODUCTION REPUBLICAN UNITARY ENTERPRISE "SPA "CENTER"
PRODUCED EQUIPMENT
Centrifugal test stands