Gormashexport Ltd (Novosibirsk, Russia):
Stepanenko A. I., CEO, goraexport@mail.ru
Malkov S. M., Chief Designer, stmgk@mail.ru

Crushers are usually designed with the use of the equations of Rittinger, Kick, Kirpichev, Bond, Svensson, etc. However, the first two laws have limitations on the grain size range, and the Bond law is an empirical dependence that may render significant errors in calculations. Due to the high degree of variability in crushability indicators available for the same rock types(depending on their composition and structure), certain data on energy intensity for the process and loads on operating components of the crushers may not always be strictly quantified through calculation. This article describes an applicable technique for physical modeling of the process with the use of an original pilot installation enabling collection of the basic data required for the design of industrial crushers. The peculiarity of the technique consists in the fact that all results obtained during the research maybe used in subsequent design work without scaling, since the pilot plant is essentially a segment of the industrial machine. This enables efficient prevention of errors and deviations associated with the selection of similarity criteria when moving from a model to the actual machine. The plant additionally enables the selection of the best tooth geometry and material. Special attention is paid to the major factors that determine the configuration of a crusher during its design. The applicability criteria for toothed screw crushers are considered. These criteria allow evaluating the performance of a specific crusher in the first approximation when selecting equipment for a given process task. Using the array of statistical data accumulated during decades-long laboratory studies of the crushing process for various materials, an estimate was made in the first approximation of the energy intensity of the toothed screw crushers designed.

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