AU2016204336A1 - Apparatus and methods for crushing a material - Google Patents

Abstract

The present invention provides a geological material processing apparatus for use in mining and similar activities. The apparatus comprises a separating component, and a crushing component, wherein the apparatus is configured such that geological material larger than a predetermined size is preferentially fed from the separating component to the crushing component. The apparatus may be in portable form (having wheels, skids or tractors), and may be operable on less than about 200 kW of electrical energy. ~~o

Description

APPARATUS AND METHODS FOR CRUSHING A MATERIAL FIELD OF THE INVENTION 2016204336 24 Jun2016 5 The present invention relates to industrial scale machines and methods configured to reduce the piece size of geological materials such as rocks, and particularly machines and methods used in mining.

BACKGROUND TO THE INVENTION 10

In mining, it is typical for rock material removed from a mine to be in a form unsuitable for further processing. For example, explosives may be used to fracture rock, leading to the generation of relatively large rock pieces. In order to effectively extract a target material from the rock pieces, it is often necessary to crush the relatively large pieces into relatively small 15 pieces. Smaller rock pieces may be desired to facilitate handling by downstream machinery, or to provide rock pieces having higher surface area to volume ratio required for the efficient chemical and/or physical treatments required to extract the target material.

In mining operations, rock material is generally delivered to a primary crusher hopper by dump 20 truck, excavator or wheeled front-end loaders. A feeder device such as an apron feeder or conveyor controls the rate at which material enters the crusher. The raw material to be crushed may contain pieces of 150 mm in the largest dimension.

Reduction in the piece size of a raw material is typically achieved by a series of sequential 25 steps. Prior art methods typically treat raw materials in the following sequence: feeding, coarse crushing (producing particles of size <500mm), secondary crushing (producing particles of size <350mm), fine crushing (producing particles of size <25mm), coarse grinding (producing particles of size <10mm), fine grinding (producing particles of size <0.5mm), and -1- finish grinding (0.074mm). These steps are typically executed in a single location with each step carried out by a dedicated piece of machinery. Each piece of machinery is typically arranged such that intermediate materials can be conveniently passed from one machine to another. 2016204336 24 Jun2016 5

It is known in the prior art to dispose each piece of required machinery onto a single transportable platform to provide a mobile processing plant. A significant problem in material processing machinery (and particularly when in mobile form) 10 is the amount of input energy required to perform the various steps. For example, the crushing/grinding process described above requires about 1,400 kW input electrical energy.

Furthermore, prior art machines typically require a large number of separate sub-machines (such as various crushers and grinders) which take up space and are complex and difficult to I5 maintain and repair.

Yet a further problem in the art is that many machines can only treat materials with moisture content of less than 15%, thereby obviating use for materials having a high water content, or in wet weather conditions, or operation in coastal areas. 20

It is an aspect of the present invention to overcome or ameliorate a problem of the prior art. It is a further aspect to provide a useful alternative to prior art crushing machines.

The discussion of documents, acts, materials, devices, articles and the like is included in this 25 specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application. -2-

SUMMARY OF THE INVENTION 2016204336 24 Jun2016

In a first aspect, but not necessarily the broadest aspect, the present invention provides a 5 geological material processing apparatus comprising: a separating component, and a crushing component, wherein the apparatus is configured such that geological material larger than a predetermined size is preferentially fed from the separating component to the crushing component. 10 In one embodiment, the geological material processing apparatus is configured such that substantially mainly, or only, geological material larger than the predetermined size is fed from the separating component to the crushing component.

In one embodiment, the separating component is a combined feeder and separating 15 component.

In one embodiment, the separating component relies at least in part on vibration to feed and/or separate the incoming geological material. 20 In one embodiment, the separating component comprises a sieve.

In one embodiment, the crushing component is an impact crusher.

In one embodiment, the crushing component is configured so as to avoid or prevent blockage 25 blockage using high pressure air.

In one embodiment, the crushing component is devoid of a sieve at the discharge opening. -3-

In one embodiment, the geological material processing apparatus comprises means for conveying geological material processed by the crushing component away from the crushing component. 2016204336 24 Jun2016 5 In one embodiment, the geological material processing apparatus is in portable form.

In one embodiment, the geological material processing apparatus comprises wheels, skids or tractors. 10 In one embodiment, the geological material processing apparatus is devoid of any one or more of: a dedicated feeder, a dedicated separating component, a coarse crusher (such as a jaw crusher), a secondary crusher, a coarse grinder (such as a rod mill, or a ball mill).

In one embodiment, the geological material processing apparatus is operable on less than 15 about 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, 300, 200 or 100 kW of electrical energy.

In one embodiment, the geological material processing apparatus is operable on less than about 200 kW of electrical energy. 20

In a second aspect, the present invention provides a method for processing a geological material, the method comprising the steps of: providing the geological material processing apparatus as described herein, providing a raw geological material, and feeding the raw geological material into the feeding/separating component. 25

In a third aspect, the present invention comprises a method for processing a geological material, the method comprising the steps of: providing a raw geological material, separating geological material based on a determined size to provide an intermediate geological material -4- having a greater proportion of geological material greater than the predetermined size as compared with the raw geological material, and crushing only the output geological material to provided a crushed geological material. 2016204336 24 Jun2016 5 In one embodiment of the third aspect, the separating step is configured such that that intermediate geological material is substantially devoid of geological material less than the predetermined size.

In one embodiment of the third aspect, the crushing step is an impact crushing step. 10

In one embodiment, of the third aspect geological material less than the predetermined size which has been separated from the intermediate geological material is combined with the crushed geological material. 15 In one embodiment of the third aspect, the method is devoid of any one or more of: a a dedicated feeding, a dedicated separating step, step, a coarse crushing step (such as a jaw crushing step), a secondary crushing step, a coarse grinding step (such as a rod milling, or a ball milling step).

20 BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagrammatic lateral view of a preferred mobile processing apparatus of the present invention. 25 FIG. 2 is a diagrammatic top view of the apparatus of FIG. 1 -5-

DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS 2016204336 24 Jun2016

Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment 5 is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more 10 embodiments.

Similarly it should be appreciated that the description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and 15 aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby 20 expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention.

Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant 25 to be within the scope of the invention, and from different embodiments, as would be understood by those in the art. -6-

In the claims below and the description herein, any one of the terms “comprising”, “comprised of” or “which comprises” is an open term that means including at least the elements/features that follow, but not excluding others. Thus, the term comprising, when used in the claims, should not be interpreted as being limitative to the means or elements or steps listed 5 thereafter. For example, the scope of the expression a method comprising step A and step B should not be limited to methods consisting only of methods A and B. Any one of the terms “including” or “which includes” or “that includes” as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, “including” is synonymous with and means “comprising”. 2016204336 24 Jun2016 10

The present invention is predicated at least in part on the Applicant’s finding that effective crushing of rock, and other geological material is possible utilising an apparatus that is greatly simplified as compared with prior art apparatus as described in the Background section herein. In particular, use of a component capable of separating out larger pieces of material, with only 15 the larger pieces of material being passed to a crusher has been found to provide utility with only a fraction of energy use compared with prior art apparatus. The apparatus thus has less component machinery than prior art apparatus. Accordingly, in a first aspect the present invention provides a geological material processing apparatus comprising: a separating component, and crushing component, wherein the apparatus is configured such that 20 geological material larger than a predetermined size is preferentially fed from the separating component to the crushing component.

For the purposes of the present invention, the predetermined size of the material pieces may be decided upon by reference to a physical parameter of the raw material (such as hardness 25 or friability), or the moisture content of the raw material, or a characteristic of the crushing component into which the material pieces are to be passed. Given the benefit of the present invention, the skilled person is capable of deciding the predetermined size given any situation. -7-

The decision may be made on theoretical considerations, empirical considerations or a combination of both. 2016204336 24 Jun2016

In an exemplary embodiment, the separating component is configured to discriminate at a 5 material piece size the same or similar to the predetermined piece size. The predetermined piece size may be between about 100 mm and about 1000 mm. Preferably the material piece size is at least about 200, 300, 400, 500, 600, 700, 800 or 900 mm. In a highly preferred embodiment the material piece size is 350 mm. The separating component is chosen so as to align with the predetermined material piece size, as required for any particular application. I0

The size of the material piece may be measured according to the broadest measure across the piece of material under consideration.

The separating component is configured to separate out material pieces larger than the I5 predetermined size. This separation may be achieved by any useful method, although low energy methods are preferred. For example the separating component may comprise a sieve or any type capable of retaining larger pieces but allowing smaller pieces to pass therethrough. Thus, the retained pieces are passed to the crusher while the smaller pieces are optionally recombined with material processed by the crushing component, or are further processed or 20 utilised, or are discarded.

In some embodiments, size-based separation of the pieces may be effected by the use of a vibratory mechanism, such as a vibrating screen to assist in the agitation of the material and facilitate the smaller pieces passing through the screen. 25

It will be appreciated that a separating component of the prior art may be utilised, optionally with modification(s) so as to be operable in the context of the present apparatus. In particular, the separating component may be a combined feeder and separating component. By this -8- arrangement material is both (i) separated and (ii) fed into the crusher by a single component. Accordingly, a dedicated feeder component is not required and a dedicated separating component is not required. 2016204336 24 Jun2016 5 The combined feeder and separating component may comprise a bin-like reservoir capable of receiving the raw material, and holding the material for some time. The walls and/or floor of the bin-like reservoir may comprise openings (such as apertures or slats) sized so as to allow passage of the material pieces smaller than the predetermined size therethrough. Pieces larger than that of the predetermined size are retained within the bin-like reservoir and 10 eventually passed into the crusher.

In one embodiment, the walls of the bin-like reservoir are substantially continuous (thereby retaining virtually all material), and are sloped toward the floor of the bin-like reservoir. The floor of the bin-like reservoir comprises openings (and preferably elongate openings) capable 15 of retaining material pieces larger than the predetermined size.

Disposed beneath the bin-like reservoir may be a material collector region configured so as to collect material pieces smaller than the predetermined size which pass through the openings of the bin-like reservoir. The roll of the collector region is to channel the smaller material 20 pieces toward a destination via an outlet. Preferably, the destination is a conveyer disposed of the apparatus.

Larger material pieces (which are excluded from the openings) travel toward an outlet of the bin-like reservoir, for expulsion into the crusher. The remainder of the floor may be 25 substantially continuous. Typically, the outlet is disposed adjacent the crusher opening such that the larger material pieces fall directly from the outlet and into the crusher. -9-

In one embodiment, the outlet is disposed substantially above and adjacent to openings in the floor of bin-like reservoir. In this way, larger and smaller material pieces travel toward an end of the bin-like reservoir (the end being typically adjacent the crusher), and when toward that end the smaller material falls through the openings in the floor and the larger material proceeds 5 toward and through the outlet. 2016204336 24 Jun2016

Movement of the material toward the outlet, and also through the openings may be achieved by a movement of the bin-like reservoir. The movement may be a rocking movement, a horizontal movement, a vertical movement, a shaking movement or a vibration applied to the 10 bin-like reservoir. Movement of the material may be assisted by gravity where the bin-like reservoir, or at least a wall and/or floor of the reservoir is sloped downwardly, and/or toward an end of the reservoir. In this way, material is fed from an entry point (typically distal from the end adjacent the crusher) and toward the outlet (typically adjacent the crusher). 15 The material processing apparatus of the present invention may be configured to substantially or completely exclude pieces smaller than the predetermined size from the crushing component. In other embodiments, the apparatus is configured to completely exclude at least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% of all pieces smaller than the predetermined size from the crushing 20 component. The percentage may be calculated on a weight basis by reference to the material fed into the separating component.

The crushing component may be any contrivance capable of reducing the size of a piece of material, and preferably any material of the predetermined piece size (exemplary sizes being 25 recited supra). The crushing component may be configured to output material pieces of less than the predetermined piece size, and in some embodiments less than about 50%, 40%, 30%, 20%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, or 1% of the predetermined material piece size. Preferably, the crushing component is configured to output material pieces of less -10- than about 5%, and more preferably less than about 2% of the predetermined material piece size. 2016204336 24 Jun2016

In some embodiments, the crushing component is configured to output material pieces of less 5 than about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm, 50 mm, 40 mm, 30 mm, 20 mm, 10 mm, 9 mm, 8 mm, 7 mm, 6 mm, 5 mm, 4 mm, 3 mm, 2 mm or 1 mm. Preferably, the crushing component is configured to output material pieces of less than about 10 mm, and more preferably less than about 5 mm. I0 In one embodiment, the crushing component is an impact crusher. Impact crushers involve the use of impact (as distinct from pressure) to crush material. The material is commonly contained within a cage, with openings on the bottom, end, or side of a desired size to allow pulverized material to escape. The impact crusher may be a horizontal shaft impactor (HIS, also known as a hammer mill) or a vertical shaft impactor (VSI). It will be appreciated that an I5 impact crusher of the prior art may be utilised, optionally with modification(s) so as to be operable in the context of the present apparatus. HSI crushers break rock by impacting the rock with hammers fixed upon an outer edge of a spinning rotor. VSI crushers use a different approach involving a high speed rotor with wear 20 resistant tips and a crushing chamber designed to propel the rock against. Thus, VSI crushers utilize velocity rather than surface force as the predominant force to break rock. In its natural state, rock has a jagged and uneven surface. Applying surface force (pressure) results in unpredictable and typically non-cubical resulting particles. Utilizing velocity rather than surface force allows the breaking force to be applied evenly both across the surface of the rock as well 25 as through the mass of the rock. -11-

In one embodiment, the impact crusher is a fine impact crusher configured to output pieces of less than about 300 mm, 250 mm, 200 mm, 150 mm, 100 mm, 90 mm, 80 mm, 70 mm, 60 mm, 50 mm, 45 mm, 40 mm, 35 mm, 30 mm, or 25 mm. 2016204336 24 Jun2016 5 In one embodiment, the impact crusher is devoid of a sieve at the discharge opening. It is found that the removal of the sieve from the crusher decreases the probability, or substantially prevents blockage of the crusher.

In one embodiment, the present application further comprises conveyance means configured I0 so as to transport the crushed material away from the crusher. While the conveyance means will typically be a conveyor belt, any other means deemed suitable by the skilled artisan may be incorporated into the present apparatus.

Turning now to Figs. 1A and 1B there is generally shown a mobile material processing I5 apparatus 10, comprising a trailer platform 12 having wheels 14. Raw material (such as rock, not shown) is fed into the top of the vibrating feeder with sieve 16, having sloping walls 18 to funnel raw material to the floor region 20. The vibrations agitate the material such that smaller pieces fall through the screen 22. The screen 22 comprises spaces (two shown 24) sized to retain material pieces larger than about 350 mm. The larger pieces enter the chute 26, and 20 pass to the impact crusher 28 under gravity. The smaller pieces fall through the spaces 24 to enter the chute 30, and pass to the conveyor 32.

The impact crusher 28 is a standard impact crusher modified to station materials with a water content of greater than about 15%. The modified impact crusher has air injection means and 25 a high pressure air pump configured to direct high-pressure air about the discharge opening of the crusher. This arrangement allows for the direction of high-pressure air to dislodge high-viscosity materials which may block the opening thereby loosening and dispersing the material -12- causing blockage. Indeed, the use of high pressure air in this way is capable in some embodiments of preventing or inhibiting blockage of the opening. 2016204336 24 Jun2016

In another embodiment the sieve at the discharge opening is removed. The use of high 5 pressure air as described supra allows for high throughput of material, and the presence of a sieve may in some circumstances ameliorate that advantage. Furthermore, the relatively fine particles output by the crusher are unlikely to cause any blockage and so throughput may be improved where a sieve is not used. Air injection and/or the lack of a sieve can allow for throughput of up to 200 tonnes/hour and may save power of over 1200 kW. I0

Once passed to the impact crusher 28, the larger pieces are crushed to a size of about 5 mm. The crushed pieces drop onto the conveyor 32. Thus, the conveyor carries away a mixture of crushed pieces (of size less than about 5 mm, and in some instances down to about 0.07 mm) and also the material which passes though the vibrating feeder with sieve 16 (of size less than I5 about 350 mm).

Electrical components of the apparatus are powered and controlled by means well known to the skilled artisan, by way of power supply and control box 34. 20 This preferred apparatus is operable with very low power consumption. Reference is made to the Table below showing a comparison of the energy consumption of a typical prior art apparatus. -13- 2016204336 24 Jun2016

Component Model Number* Discharge grain size (mm) Throughput (t/h) Power consumption (kW) Prior Art Power consumption (kW) Apparatus of Fig. 1 Vibrating sieve YK1545 60-270 30 N/A Coarse crushing: Jaw crusher ΡΕΥ900χ1200 160-350 132 N/A Secondary crushing: vortex strong impact crusher PFQ1313 <40 225 200 N/A Fine crushing PCWK1415 <6 210 380 N/A Fine Crushing (28) Modified crusher <6 210 N/A 132 Coarse grinding: high efficiency energy saving rod mill or GWB2136 2.5-0.2 35-14.8 200χ 6 N/A Coarse grinding: high efficiency ball mill GMQG3240 <3 210-22 630 N/A Vibrating feeder ZSW420x 110 150-280 15 N/A Vibrating feeder/sieve (16) Modified combination apparatus 150-280 N/A 11 TOTAL 1957-1387 143 *Products of Luoyang Dahua Heavy Type Machinery Co. Ltd; Luoyang City, China. 5 From the Table, it can be calculated that the prior art apparatus energy consumption is between 1387 and 1957 kW, while that of the apparatus of Fig. 1 is only 143 kW. Thus, the -14- apparatus of Fig. 1 uses only between about 7.3% and about 10.3% of the energy consumed by prior art machines. 2016204336 24 Jun2016

In the description provided herein, numerous specific details are set forth. However, it is 5 understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

In the following claims, any of the claimed embodiments can be used in any combination. I0 -15-

Claims (20)

1. THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

   1. A geological material processing apparatus comprising: a separating component, and a crushing component, wherein the apparatus is configured such that geological material larger than a predetermined size is preferentially fed from the separating component to the crushing component.
2. 2. The geological material processing apparatus of claim 1, configured such that substantially mainly, or only, geological material larger than the predetermined size is fed from the separating component to the crushing component
3. 3. The geological material processing apparatus of claim 1 or claim 2 wherein the separating component is a combined feeder and separating component.
4. 4. The geological material processing apparatus of any one of claims 1 to 3, wherein the separating component relies at least in part on vibration to feed and/or separate the incoming geological material.
5. 5. The geological material processing apparatus of any one of claims 1 to 4, wherein the separating component comprises a sieve.
6. 6. The geological material processing apparatus of claim any one of claims 1 to 5, wherein the crushing component is an impact crusher.
7. 7. The geological material processing apparatus of claim any one of claims 1 to 6, wherein the crushing component is configured so as to avoid or prevent blockage using high pressure air.
8. 8. The geological material processing apparatus of claim any one of claims 1 to 7, wherein the crushing component is devoid of a sieve at the discharge opening.
9. 9. The geological material processing apparatus of claim any one of claims 1 to 8, comprising means for conveying geological material processed by the crushing component away from the crushing component.
10. 10. The geological material processing apparatus of any one of claims 1 to 9, in portable form.
11. 11. The geological material processing apparatus of claim any one of claims 1 to 10, comprising wheels, skids or tractors.
12. 12. The geological material processing apparatus of claim any one of claims 1 to 11, devoid of any one or more of: a dedicated feeder, a dedicated separating component, a coarse crusher (including a jaw crusher), a secondary crusher, a coarse grinder (including a rod mill, or a ball mill).
13. 13. The geological material processing apparatus of any one of claims 1 to 12, operable on less than about 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, 300, 200 or 100 kW of electrical energy.
14. 14. The geological material processing apparatus of any one of claims 1 to 13, operable on less than about 200 kW of electrical energy.
15. 15. A method for processing a geological material, the method comprising the steps of: providing the geological material processing apparatus of any one of claims 1 to 14, providing a raw geological material, and feeding the raw geological material into the feeding/separating component.
16. 16. A method for processing a geological material, the method comprising the steps of: providing a raw geological material, separating geological material based on a determined size to provide an intermediate geological material having a greater proportion of geological material greater than the predetermined size as compared with the raw geological material, and crushing only the output geological material to provided a crushed geological material.
17. 17. The method of claim 16 wherein the separating step is configured such that that intermediate geological material is substantially devoid of geological material less than the predetermined size.
18. 18. The method of claim 16 or claim 17 wherein the crushing step is an impact crushing step.
19. 19. The method of any one of claims 16 to 18 wherein geological material less than the predetermined size which has been separated from the intermediate geological material is combined with the crushed geological material.
20. 20. The method of any one of claims 16 to 19 devoid of any one or more of: a dedicated feeding step, a dedicated separating step, a coarse crushing step (such as a jaw crushing step), a secondary crushing step, a coarse grinding step (such as a rod milling, or a ball milling step).