WO2009154585A2

WO2009154585A2 - Screw effective mill and crusher

Info

Publication number: WO2009154585A2
Application number: PCT/TR2009/000077
Authority: WO
Inventors: Bingol Oz; Oguz Tac
Original assignee: Bingol Oz; Oguz Tac
Priority date: 2008-06-20
Filing date: 2009-06-22
Publication date: 2009-12-23
Also published as: WO2009154585A3

Abstract

This present invention related to Screw Efffective Mill and Crusher designed for crushing and/or grinding till micronized powder of every kind of material to be size reducted. Abstract of invention is characterized by having material feeding chute (1,41), moving roller (2,42) and fixed roller (3,43), hydraulic system cylinder (4,44), drive unit (5,45) for rollers, machine housing (6,46), bearing blocks (7,47), sliding coupling (8,48) for moving roller, motor security coupling (9,49), material draw blades (10,50), material outlet chute (11,51), screw form projection (12,52) and screw form indentation (13,53) of rollers.

Description

DESCRIPTION SCREW EFFECTIVE MILL AND CRUSHER

Related Field of invention This present invention related to screw effective mill and crusher designed for crushing and grinding of every kinf of material to be size reducted, mainly stone, ore, sand medical material, grain etc.

Background of Invention (Prior art) Size reduction by crushing of material is well known and there are many type of machines and processes existing. In the same manner size reduction of materiel till powder form (micronizing) with known process name as grinding is vital part of many field of industry.

Related to developed present of invention said Screw Effective Mill and Crusher, basics of grinding applications are described below.

• Tube mills,

• Compression process mills.

TUBE MILLS

Tube mills rotate around their axis positioned by their bearings. As supported by bearings from both end, material inside the tube mill lifted continiously depending rotational movement and thrown away towards inside of mill at the definitive point of the movement.

Thrown material inside the mill starts the same movement effeccted by rotation and this cycle repeats continiously.

Generally tube mills utilise balls (23) as grinding media. Depending on process type some tube mills make grinding by utilising material and balls together. This type of tube mills are named as semi autogenius mills. If grinding is done only by self size reducton of material itself this type of tube mill named as autogenous mills. In tube mills material to be ground enter from one end of mill and leave from other end as¹ ground. In dry grinding process powder material conveyed mechanically or by air sweeping. In wet process outlet is slurry and conveyed in this form.

Depending on process tube mills may have one grinding section or multiple grinding sections (24) (25). In the first section (24) large diameter balls used for rough grinding or for pre-crushing, in the second section (25) small diameter balls are used for fine grinding.

Sections are seperated by a partition wall (diaphragm) (26) allowing material and air passage but avoiding passage of grinding balls .

Depending on the rotational movement of tube mill, material inside the mill pile up at one side. As a result of this movement center of gravity of the inside material shifts towards piling side and power demand of mill increases. To achieve physical balance and to turn the mass in rotation of mill, a moment necessary. Magnitude of this moment becoming the eccentric shifting distance of center of gravity of inside material multiplied with the weight of this material. This is the one of the weakest point of tube mills. Also it is necessary to overcome friction resistance of bearings and internal firiction of material.

Direction of material flow and direction of grinding geometry are not the same in tube mills. Almost perpendicular to each other.

In tube mills process air flow direction is perpendicular to grinding geometry inside. Air pass through grinding process cross-section of material. In case of drying of material, it is necessary to use additional drying chambers or separate equipment

Preliminary restrictive factors of tube mills are rotational speed of mill and required grinding volume. If the speed of the mill exceeds a certain limit whic is expressed as critical speed, throwing of material inside mill cannot be done. Centrifugal force overcomes the gravity and material inside forced against inner wall of mill without throwing and grinding. If the speed is low, throwing can not be possible and the efficiency of grinding drops a lot. For this reason dimension of mill should have enough volume for required product output which corresponds to certain cost and power consumption.

Typical cross section of tube mills and the motion inside shown at figure 15 and at figure 16. COMPRESSION PROCESS MILLS

Compression process mills could be collected under three main group depending on their widespread application.

• Vertical roller mills

• Roller Presses.

• Compression bed roller mills.

VERTICAL ROLLER MILLS Compression process mills are generally vertical roller miils. Material leaved on a rotating table (15) spreads outward by rotation of table and grinded by compression between grinding rollers (14) and table (15). To make contribution to that process, grinding rollers are forced against table by mechanical or by hydraulic system.

Compared to tube mills, specific power consumption of compression process(with roller)mills are much lower.

As the grindability of the material gets harder, hyraulic pressure apllied increases. As the result mechanical properties of rollers and table stressed depending on external pressure. Materials of table and rollers to be used should be special.

Material bed between table and roller should be continious and smooth in compression grinding. Damaging impacts occur on roller and table if the composition of grinded material changes, portion of coarse and hard material increases or unwanted metallic parts enter to grinding system.

In vertical roller mills force exerted from rollers to table is considerable. Cross section of vertical roller mill is shown in figure 10.

ROLLER PPRESSES

Roller preses are machines which grind material between two rollers by compression. Material fed into gap between rollers wich rotate in reverse direction according to each other. Material compressed between rollers as proceed down and crushed and grinded in this place. Grinding rollers are pressed to each other by a mechanical or hyraulic system to help the process.

Compared to tube mills, specific power consumption of roller presses are much lower.

In compression grinding as the grindability of the material gets harder, hyraulic pressure apllied increases. As the result mechanical properties of rollers and table stressed depending on external pressure. Materials of table and rollers to be used should be special.

Material bed between table and roller should be continious and smooth in compression grinding. Damaging impacts occur on roller and table if the composition of grinded material changes, portion of coarse and hard material increases or unwanted metallic parts enter to grinding system

In roller presses force exerted by rollers to each other is considerable. Cross section of rolles prress is shown in figure 11.

COMPRESSION BED ROLLERMILLS Characteristics of compression bed mills is grinding process realized in between cylindrical surfaces which are one inside the other. Material grinding is smooth and easy in these mills. This form which makes possible in wide band of compression for material is named as compression bed. By utilizing this compression bed, it is possible to develop much wider compression band and required compression pressure is less comparing with vertical roller mills and roller presses.

Vertical type compression bed mill is shown in figure 12. In this machines rollers (16) are connected in vertical position to balance arm (19) which is connected to a vertical shaft of drive unit (18). Compression force of rollers is the result of centrifugal effect of rotation. Rollers exert force on iner walls of cylindrical casing and rake whole walls circumferencially. It is the weak point of these machines to push and to hold material in between vertical cylindrical casing and rollers which rotate around vertical axis even against gravity. Throwing shovels (20) are used for this purpose. Compression force of rollers are limited since there is no additional hydraulic press applied.

Compression bed mill rotating around horizontal axis is shown in figure 13. It is possible to exert hydraulic press on rollers (21) rotating abut horizontal axis and entering of material in between roller and cylindrical casing (22) is more easy by the effect of gravity. Such mills are with fixed casing type or with rotating casing type. Fine grinded material should be used together with coarse material as filler to fill gaps in¹ between coarse particules to allow single direction pressure exertion efficiency. This operation increases overall material circulation of the grinding system. Considerable portion of fine grinded material stay as filler material in the system. Compression dynamics of compression process mills are shown in figure 14.

Compression band in roller presses are the narrowest since it is in between two convex surfaces. Compression band in vertical roller mill is a little bit wider since it is in between cylindrical convex form of roller and flat surface of table. Compression band in compression bed mills are in between convex form of cylindrical roller and concave form of casing and generates the widest compression band in this field.

Related to present invention developed and said screw effective mill and crusher, basics of existing crushing applicatons are described below.

As many types of crushers are in practice, they may be summerized in two main groups

IMPACT CRUSHERS

Impact crushers generally operates with principle of utilising rotational movement of crushing componenets which transfers power to material to be crushed. Crushing power exerted to material in different ways. Brief description of impact crushers are as follow. Hammer crusher; Material goes under size reduction by Impact of hammers (28) installed on rotor (27) . Material than pass through a grate (29) of which gap between grate bars adjusted. Finally leaves the crusher as size reducted.

In fig 25 hammer type of crusher is shown.

Impact bar crusher; Material goes under size reduction by Impact of impact bars (31) installed on rotor (30). Than pass through a passage between impact bars and impact wall (34) as size reducted.

In fig 26 impact bar type of crusher is shown.

Vertical shaft impact crusher; Material fed from top into crusher rotor (33) which turns with high speed around vertical axsis, than accelerates horizontally and thrown by centrifugal force to stationary material bed (34). First size reduction occur at the maximum speed point by hitting of tool bit (35) fastened to rotor, later another size reduction done by impact on material bed and dropped material get out of crusher. Very high speed necessary since hitting on material is not by the impact of crushing componenet. Depending on high speed and heavy wear of componets tool bits are manufactured from superior material like tungsten carbide which is very costly

In fig 27 vertical shaft impact crusher is shown By impact crushing material gets mostly regular prismatic form and if it is preferred for the end using, impact crushers preferred too.

As noted for all impact crushers, components like hammer, impact bar, tool bit are necessary. Components like grate, impact wall, material bed installed against working of impact componenets complete the system. Impact components wear out in time. In the same way stationary componets like grate, impact wall wear out too. As the result of this wearing, efficiency of impact componenes decreases, the working gaps between rotational and stationary componenets increase and overall crushing efficiency of the equipment decreases. Especially wearing of crushing componenets reduce the efficiency of crushing process considerably after certain point and it becomes necessary to replace worn out componenets. Worn sections of crushing componenets compose few portion of component mass. Since the whole component to be replaced, components manufactured from special material bring considesrably cost.

Another weak point of impact crushers are eventual breakdowns which are the result of continious impact effect on equipment. Realization of such risk brings considerably procuction lost and repair costs.

COMPRESSION EFFECTIVE CRUSHERS

This type of crushers make size reduction by applying compressive pressure on material. Basic principle is to get the material in crushing chamber which narrows gradually. As material compressed in this gradually narrowed geometry at the same time additional compression applied. Operation of this tye of crushers described below.

Conical crusher; Material fed to crushing chamber between rotor (36) and statioary housing (37) and goes downwards in gradually narrowed cross section. Rotor (36) rotates eccentricly with respect to vertical housing axis and makes narrowing of cross section in horizontal plane. Hydaulic system (38) pressure applied on rotor and the gap between rotor and housing decreases. Hence hydraulic compressive force exerted on material to be crushed. Material compressed both by mechanical and hyraulic forces get out from bottom of crusher. In fig 29 conical crusher is shown.

Cyindrical crusher; Shape and function is the same as roller press. Required crussing pressure is less than grinding. Material passing between rollers which rotate against ecah other is curshed by mechanical or hydraulic press In fig 28 cross section of rollers of cylindrical crusher is shown.

Jaw crusher; Compressive pressure and impact effect both applied at the same time on material dropping throug gradually narrowed gap between eccentrically driven and elipticallly reciprotated mobile jaw (41) and stationary jaw (42). Size reducted material get out from bottom of crusher. In fig 30 jaw crusher is shown.

Compression effective crushers consume less power for the same operation compared to impact crushers. On the other hand crushed material is not regularly prismatic, rather having less prismatic shape formed by decomposition of material from its natural breaking planes and lines. Compression type crussers are widely used, if this prismatic property is not required by the process or if this property is not definititve at that stage of size reduction.

Wearing of componenets is an important factor in compression type crushers since moving and stationary componenets are always in contact with material and by hydraulic system an additional pressure occurs on these componenets. Working gap increases because of wearing of crushing componenets and efficiency of crusher decreases considerably. After certain point it becomes necessary to replace worn componenets. Worn sections of crushing componenets compose few portion of componenet mass. Since the whole component to be replaced, components menufactured from special material bring considerable cost.

Rotating componeents under hydraulic pressure sometimes go under high impact effect. This impacts ends with equipment breakdown resulting considerable production loss and high repair cost.

Aims Of The Invention

There are many types of mills for grinding, crushers for crushing, having many different process type and equipment design of existing technique of today, as explained before. Two main process type is to grind and crush either by impact or by compression effect. Screw effective mill and crusher developed as;

• the result of investigagiton of compression type process of both processes used by industry

• studying of process process possibilities • establishing of weak points

• Result of establishing of alternative solution searching according to these weak points

Aims of this invention are; • More effective process efficiency,

• Possibility of different rotational speeds depending on size of material to be ground and depending on dimension of system.

• Production economy and efficiency.

• More simple and economic equipment operation

General Properties Of The Invention

General properties of screw effective mill and crusher developed by this invention are as follow;

• There is no restriction of size. • Operates with very simple principle and could be designed for various sizes ranging from too small to too big sizes.

• It is possible to operate continious or intermitttent way for prosess wise. It is possible to crush/grind certain amount of material at one side or it is possible to gring continiously by air draft. • Material to be grinded size reducted to smaller micronized size.

• There is no speed restriction. Capacity increases with speed increase. Speed increase dos not change the main dynamics of movement achieved in the screw effective mill and crusher. • Force exerted on the material to be size reducted is combination of hyraulic press on rolle'rs of this operation and the screw effect generated between the rollers. Material is subjected to hydraulic compression pressure and on the other hand proceeds at right angle to hydraulic forces in screw spiral and goes under two dimensional size reduction. This combined motion increases the efficiency of size reduction.

• Characteristics of process is to reduce power consumption.

COMPARISON OF THE INVENTION WITH EXISTING TECHNIQUE COMPARISON WITH TUBE MILLS Comparison Screw effective mill and crusher developed by this invention with tube mills described as foollows;

• Screw effective mill and crusher operates with lower power cost compared to tube mills as the other compressipn process mills do.

• Screw effective mill and Crusher allows more possibilities considering the parameters which affect the process. It is possible to reach different process results by changing the geometry of roller. In tube mills modification on main process parameters are very limited such as throwing speed of material and grinding balls, iner volume of mill etc.

• Humidity of the material is not important in Screw Effective Mill and Crusher. Size reduction by compression is done in very short time and material dos not get hot. Retention time of material in tube mills is too long and it gets hotter and hotter as size reducted in the friction enviroment of material and grinding balls. This point is very important for the process which do dot allow heating and deterioration of material.

COMPARISON WITH COMPRESSION PROCESS MILL Comparison screw effective mill and crusher developed by this invention with compression process (with roller) mills described as follows;

• Screw effective mill and crusher basically looks like cylindrical roller system named as roller press. Size reduction is realized by passing of material between the cylindrical formed rollers. Main difference of screw effective mill and crusher is additional mechanical compression coming from screw spiral geometry in which material has to move in continious compression between concave and convex curved surfaces, hence achieving size reduction by the most efficient way of compression bed of thies field. Progressive decreasing of gap between rollers in screw spiral direction is also one of main the difference of screw effective mill and crusher compared with other compression process mills. This characteristics is described in detail at coming paragraphs.

• Mechanical screw help; Material captured by srew form spiral has to proceed absolutely in this direction. In this way another movement happens in addition to main material flow direction between the rollers. This two directional movement and pressure application makes possible crushing in multiple planes and required pressure of one way compression becomes less. Decreased pressure decreases mechanical failures and increases efficient lifetime of rollers.

• Compression bed formation. Best geometrical form in compression process size reduction is to hold the matrerial to be size reducted between concave and convex forms. This geometry achieved in compression bed mills and in conical crusher at limited way, on the other hand in screw effective mill and crusher it is possible to get different curved forms for application.

• Progressiverly Decreased compression gap. The gap beween rollers could be applied as progressively decreased in the course of screw spiral. This narrowing increases the compression and crushing effect for more size reduction along the screw spiral.

• By the effect of scew spiral and progresssively compression gap, it is not necessary to fill the gap between coarse particules with fine grinded particules as in other compression process mills. Circulation load of the system decreases by this characteristic • Choise of operation with impact effect. Compression pressure is build by hydraulic system at crushing and compression process. In Screw Effective Mill and Crusher an additional impact circuit in hydraulic ststem enables to increase the effect of size reduction by compression. Description Of Figures

For better explanation of the screw effective mill and crusher developed by this invention, figures prepared are described as below

Figure 1 - Isometric view of the screw effective mill and crusher. (Grinding)

Figure 2- Vertical cross section of process of the screw effective mill and crusher. (Grinding) Figure 3 - Top view of screw effective mill and crusher with material draw section.

(Grinding)

Figure 4- Top view of screw effective mill and crusher with material draw section. (Double sided Grinding)

Figure 5- Vertical cross sections of the screw effective mill and crusher. Vertical model

(Grinding)

Figure 6- Screw effective mill and crusher. Cross section of rollers (grinding) Figure 7- Screw effective mill and crusher. Cross section of process of rollers (grinding) Figure 8- Screw effective mill and crusher. Cross section of rollers

(grinding with low compression ratio) Figure 9- Screw effective mill and crusher. Cross section of rollers

(grinding with high compression ratio)

Figure 10 - Cross section of vertical roller mill (existing technique) Figure 11 - Cross section of roller press (existing technique)

Figure 12- Compression bed vertical mill. Verical and horizontal cross sections

(existing technique).

Figure 13- Compression bed horizontal mill (existing technique) Figure 14- Compression process compression geometries (existing technique) Figure 15- Transverse cross section of tube mill (existing technique)

Figure 16- Longlitidunal cross section of tube mills having two section (existing technique) Figure 17- Isometric view of the screw effective mill and crusher. (Crushing) Figure 18- Vertical cross section of process of the screw effective mill and crusher.

(Crushing ) Figure 19- Top view of screw effective mill and crusher with material draw section.

(Crushing) Figure 20- Top view of screw effective mill and crusher with material draw section.

(Double sided Crushing) Figure 21- Vertical cross sections of the screw effective mill and crusher. Vertical model

(Crusher)

Figure 22- Screw effective mill and crusher. Cross section of rollers (Crushing) Figure 23- Screw effective mill and crusher. Cross section of rollers

(crushing with low compression ratio) Figure 24- Screw effective mill and crusher. Cross section of rollers

(crushing with high compression ratio) Figure 25- Hammer crusher cross section (existing technique) Figure 26- Impact bar crusher cross section (existing technique)

Figure 27- Vertical shaft impact crusher cross section (existing technique) Figure 28- Cylindrical crusher cross section(existing technique) Figure 29- Conical crusher cross section (existing technique) Figure 30- Jaw crusher cross section (existing technique)

Description of parts and sections of the invention

For better explanation of the screw effective mill and crusher developed by this invention, each part and section of figures prepared are given a seperate number and described as below. 1. Material inlet chute

2. Moving roller (grinding)

3. Fixed roller (grinding) 4. Hydraulic system cylinder (grinding)

5. Drive unit of rollers (grinding)

6. Machine frame (grinding)

7. Bearing block of roller (grinding) 8. Sliding coupling of moving roller (grinding)

9. Security coupling of drive motor (grinding)

10. Draw blades for material (grinding)

11. Material outlet chute.(grinding)

12. Screw form projection of roller (grinding) 13. Screw form indentation of roller (grinding)

14. Grinding roller (existing technique)

15. Rotating table (existing technique)

16. Vertical compression bed mill roller (existing technique)

17. Vertical compression bed mill casing (existing technique) 18. Vertical compression bed mill drive group (existing technique)

19. Vertical compression bed mill balance arm (existing technique)

20. Vertical compression bed mill shovel (existing technique)

21. Horizontal compression bed mill roller (existing technique)

22. Horizontal compression bed mill casing (existing technique)) 23. Balls (existing technique)

24. First section of tube mill (existing technique)

25. Second section of tube mill (existing technique)

26. Partition wall of tube mill (Diaphragm) (existing technique)

27. Hammer crusher rotor (existing technique) 28. Hammer crusher hammers (existing technique)

29. Hammer crusher grates (existing technique)

30. Impact bar crusher rotor (existing technique) 31. Impact bar crusher bars (existing technique)

32. Impact bar crusher impact wall (existing technique)

33. Vertical shaft impact crusher rotor (existing technique)

34. Vertical shaft impact crusher material bed (existing technique) 35. Vertical shaft impact crusher tool bit (existing technique)

36. Cone crusher rotor (existing technique)

37. Cone crusher housing (existing technique)

38. Cone crusher hydraulic system (existing technique)

39. Jaw crusher moving jaw (existing technique) 40. Jaw crusher fixed jaw (existing technique)

41. Material inlet chute (crushing)

42. Moving roller (crushing)

43. Fixed roller (crushing)

44. Hydraulic system cylinder (crushing) 45. Drive unit of rollers(crushing)

46. Machine frame (crushing)

47. Bearing block of roller(crushing)

48. Sliding coupling of moving roller (crushing)

49. Security coupling of drive motor (crushing) 50. Draw blades for material (crushing)

51. Material outlet chute (crushing)

52. Screw form projection of roller (crushing )

53. Screw form indentation of roller (crushing) Detailed description of invention

There are two functions of the screw effective mill and crusher developed by this invention;

• Grinding and • Crushing

In explanation, grinding function will be considered firstly.

Main componenets of the screw effective mill and crushern developed by this invention are;

• Material inlet chute (1,41) • Rollers (2,42 and 3,43) composed of; material draw baldes (10,50), roller screw form projections (12,52), roller screw form indentataions (13,53), and bearing blocks (7,47)

• Roller drive system (5,45) composed of; sliding coupling of moving roller (8,48) and motor security coupling (9,49) • Hydraulic system cylinder (4,44)

• Machine frame (6,46)

• Material outlet chute (11,51)

Grinding There are many types of grinding mills with different process type and with different equipment design. Two main process is to make grinding by impact and by compression.

Screw effective mill and crusher developed by this invention designed as

• investigation

• studying of process process possibilities • establishing of weak points

• establishing of alternative solution searching according to these weak points of existing mills and crushers, especially of compression type, used in industry Material to be ground enters in the mill through an inlet chute (1). Material fall into

Space iti between of rollers (2,3) which rotate against each other in the direction of rotataion. One of the roller is the moving roller (2) and the other is the fixed roller (3).

Material when passing through the gap in between of fixed roller (3) and moving roller (2), compressed and grinded in between roller screw form projection (12) and roller screw form indentation (13) by application of hyraulic pressure of hydraulic cylinder (4). At the same time crushed material moves in screw spiral generated by natural screw drawing in of rollers.

Direction of screw spiaral depends on helix angle of screws. Until leaving compression bed between rollers (2,3), movement in direction of screw spiral goes on. Material size reducted through rollers falls dawn and colllected by otlet chute (11) to outside of mill.

Gap between rollers (2,3) decreased in the direction of screw spiral if more effective grinding required. This gap is wider at material inlet section. Along screw spiral gap is decreased.

Caharacteristics of this process could be described as below. Advantageous compression geometry. Cross section of rollers (2,3) are shown in fig

6. Necessary compression pressure to be increased as the grindability of material becomes harder in such grinding systems. Compression pressure is build up according to compression geometry throuhg which material passing. Continious compression of material between concave and convex cylindrical surfaces is the best geometry in compression process grinding. One projection in one roller corresponds with one indentation of the other roller as screw forms of rollers meet each other. By this way it is possible to exert less compression pressure at wider surface on continiously compressed material in between concave and convex forms.

Advantageous compression geometry and and passage of material between the rollers is sown in figure 7

In this design roller cross section forms are arranged as asked by process requirements. For example more indented and projected forms are used for easy grinded material to keep more material inside, on the other hand less indented and projected forms are used for hard grinded material to get less material flow and to apply more grinding pressure.

Number of screw forms (12,13) and cross section of these screw forms (12,13) could be arranged as wanted. It is possible to arrange same number of and same shaped screw forms on fixed roller (3) and moving roller (2), it is also possible to apply different screw forms (12,13) on each roller or pattern of differnt screw forms (12,13) on each roller. Diameters of fixed roller (2) and moving roller (3) becomes different if differentt number of screw forms are used. Geometrical shapes of screw forms are, cylidrical, parrabolical, conical, patterned prismatic of flat surfaces etc. Cross section of one compression bed having low compression ratio and having maximum compression band is shown in figure 8.

Cross section of one compression bed having high compression ratio and having narrow compression band is figure 9.

Spiral helix angle of screw forms (12,13) on the roller are determined according to material to be ground. Higher spiral helix angle applied for easy grinded material to keep compression time shorter, lower spiral helix angle applied for hard grinded material to keep longer compression time.

Compression gap between fixed roller (3) and moving roller (2) arranged as progressively narrowed way along screw spiral. Material inside the screw forms to be drawn definitely since screw conveying is the process of positive deplacement movement. Material proceeds in screw spiral by this way. Gap between rollers decreased in the direction of progress. More grinding made on narrowed volume and grinding process becomes effective.

Movement of material is shown in figure 2. Projection of material at inlet an at outlet is not the same because of screw geometry. As shon in figure 2 and figure 7, basic requirements of compression process grinding;

• Provision of required compression and grinding pressure,

• Provision of enough contact area for particles to contact each other

• Provision of relative movement of grinded particles with respect to each other, are realized advantageously. Grinding pressure is build on compression bed which is the best convinient geometry of this field and also maximum material contact realized as the advantage of this geometry. Relative movement of particles to be ground is convinient and smooth by screw spiral motion.

Hydraulic system (4) is used to get required compression pressure. Hydraulic cylinders (4) apply the hydraulic pressure on moving roller (2). Hydraulic pressure builds additional compression force. Classical accumulator circuit hydraulic system to build and to maintain pressure is used as common in these system. Depending on perssure requirements, an impact circuit is added to hydraulic system. This additional impact circuit combines compression effect with impact effect on size reduction process and incresases efficiency of size reduction process considerably. Sliding coupling (8) of moving frame has characteristic which slides axial in the direction of the axis of drive shaft of roller to enable back and forth movement of moving roller (2) with respect to fixed roller (3). Both rollers (2,3) are driven by the same drive unit for not changing the coresponding screw position at normal design. While double output drive unit is enough for light and small systems, special drive units for torque dividing and equilizing are used for heavy and bigger systems. Special controls synchronizing two separate drive units keeping relative positions of rollers while turning could be used at specific design. There are security coupligs (9) at outlet of drive motors depending on heaviness of system and importance of componenets.

Rollers stand on the machine frame (6) by bearing blocks (7) using either roller bearings or journal bearings. Roller section of screw forms (12,13) are machined as separate part with hardfacing against wear and than passed over the rollers as separate part depending on process characteristics.

System could be constructed in differrent ways. Material draw section installed before compression spiral to increase roller efficiency as shown in figure 3. Material draw blades (10) at this section convey the material towards crushing spirals without applying compression on material. By this way screw spirals perform crushing function along the whole roller

In figure 4 material is fed from middle and drawn to both sides and pass through two roller group at left and at right. Angular force componenets coming from crushing load are balanced and excessive axial loads are avoided in this design.

In figure 5 vertical design is shown. Material flow and spiral movement is in same direction in this design. Feeding convenience and regularity targeted.

Machine frame (6) which supports all componenets is reinforced to whitstand forces coming from rollers and hydraulic system. Geared, guide piston type or similar mechanisms are used for combining bearing blocks (7) of moving roller to machine housing (6) to enable regular back and forth movement of moving roller.

After describing screw effective mill and crusher system and its componenets, general characterictics when used for grinding purpose are; • There is no restriction of size. Machine operates with very simple principle and could be

^• designed for various sizes ranging from too small to too big sizes.

• It is possible to operate continious or intermitttent way for prosess wise. It is possible to grind certain amount of material at one side or it is possible to grind continiously by air draft.

• Material to be grinded size reducted to smaller micronized size.

• There is no speed restriction. Capacity increases with speed increase. Speed increase dos not change the main dynamics of movement achieved in the screw effective mill and crusher. • There is no problem of material proceeding towards compression section where grinding done. Screw movement of rollers draw in material by itself.

• There will be considerable amount of power saving. In addition to one axis hydraulic pres, mechanical draw coming from screw movement in the second axis will make size reduction easy and less hydraulic pres will be necessary. • Impact circuit added on hydraulic system, will make compression process more easy.

• It composes operation convinience of roller presses with process advantage of compression bed rollers in the same machine.

Crushing Main design is the same for crushing process. Roller projections and indentations are voliminous to allow more material passage and to allow less energy requirement. Hydraulic pressure requirement is less too.

Material to be crushed enters in the mill through an inlet chute (41). Material fall into space in betten of rollers which rotate against each other in the direction of rotataion. One of the roller is the moving roller (42) and the other is the fixed roller (43). Material when passing through the gap in between of fixed roller (43) and moving roller (42), compressed and crushed in between roller screw form projection (52) and roller screw form indentataion (53) by application of hydraulic press of hydraulic cylinder (44). At the same time crushed material moves in screw spiral generated by natural screw drawing in of rollers. Direction of screw spiaral depends on helix angle of screws. Until leaving compression bed between rollers (2,3), movement in direction of screw spiral goes on. Material size reducted thruogh rollers falls dawn and colllected by otlet chute (51) to outside of crusher. Gap between rollers (42,43) decreased in the direction of screw spiral if more έffective crushing required. This gap is wider at material inlet section. Along screw spiral gap is decreased.

Caharacteristics of this process could be described as below. Advantageous compression geometry. Cross section of rollers (42,43) are shown in fig 22. Necessary compression pressure to be increased as the material becomes harder in suchh crushing systems. Compression pressure is build up according to compression geometry throuhg which material passing. Continious compression of material between concave and convex cylindrical surfaces is the best geometry in compression process crushing. One projection in one roller corresponds with one indentation of the other roller as screw forms of rollers meet each other. By this way it is possible to exert less compression pressure at wider surface on continiously compressed material in between concave and convex forms.

In this design roller cross section forms are arranged as asked by process requirements. For example more indented and projected forms are used for easy crushed material to keep more material inside, on the other hand less indented and projected forms are used for hard crushed material to get less material flow and to apply more crushing pressure.

Number of screw forms (52,53) and cross section of these screw forms (52,53) could be arranged as wanted. It is possible to arrange same number of and same shaped screw forms on fixed roller (43) and moving roller (42), it is also possible to apply different screw forms (52,53) on each roller or pattern of differnt screw forms (52,53) on each roller.

Diameters of fixed roller (42) and moving roller (43) becomes different if different! number of screw forms are used. Geometrical shapes of screw forms are, cylidrical, parrabolical, conical, patterned prismatic of flat surfaces etc.

Cross section of one compression bed having low compression ratio and having maximum compression band is shown in figure 23.

Cross section of one compression bed having high compression ratio and having narrow compression band is figure 24. Spiral helix angle of screw forms (52,53) on the roller are determined according to material to be crushed. Higher spiral helix angle applied for easy crushed material to keep compression time shorter, lower spiral helix angle applied for hard crushed material to keep longer compression time. Compression gap between fixed roller (43) and moving roller (43) arranged as progressively narrowed way along screw spiral. Material inside the screw forms to be drawn definitely since screw conveying is the process of positive deplacement movement. Material proceeds in screw spiral by this way. Gap between rollers decreased in the direction of progress. More grinding made on narrowed volume and grinding process becomes effective.

Movement of material is shown in figure 18. Projection of material at inlet an at outlet is not the same because of screw geometry.

As shon in figure 18 and figure 22, basic requirements of compression process grinding; • Provision of required compression and crushing pressure,

• Provision of enough contact area for particles to contact each other

• Provision of relative movement of crushed particles with respect to each other, are realized advantageously.

Crushing pressure is build on compression bed which is the best convinient geometry of this field and also maximum material contact realized as the advantage of this geometry. Relative movement of particles to be crushed is convinient and smooth by screw spiral motion.

Hydraulic system (44) is used to get required compression pressure. Hydraulic cylinders (44) apply the hydraulic pressure on moving roller (42). Hydraulic pressure builds additional compression force. Classical accumulator circuit hydraulic system to build and to maintain pressure is used as common in these system. Depending on perssure requirements, an impact circuit is added to hydraulic system. This additional impact circuit combines compression effect with impact effect on size reduction process and incresases efficiency of size reduction process considerably. Sliding coupling (48) of moving frame has characteristic of slidin axial in the direction of the axis of drive shaft of roller to enable back and forth movement of moving roller (42) with respect to fixed roller (43). Both rollers (42,43) are driven by the same drive unit for not changing the coresponding screw position at normal design. While double output drive unit is enough for light and small systems, special drive units for torque dividing and equilizing are used for heavy and bigger systems. Special controls synchronizing two separate drive units keeping relative positions of rollers while turning could be used at specific design. There are security coupligs (49) at outlet of drive motors depending on Heavine'ss of system and importance of components.

Rollers stand on the machine frame (46) by bearing blocks (47) using either roller bearings or journal bearings. Roller section of screw forms (12,13) are machined as separate part with hardfacing against wear and than passed over the rollers as separate part depending on process characteristics.

System could be constructed in differrent ways. Material draw section installed before compression spiral to increase roller efficiency as shown in figure 19. Material draw blades (50) at this section convey the material towards crushing spirals without applying compression on material. By this way screw spirals perform crushing function along the whole roller

In figure 20 material is fed from middle and drawn to both sides and pass through two roller group at left and at right. Angular force componenets coming from crushing load are balanced and excessive axial loads are avoided in this design. In figure 21 vertical design is shown. Material flow and spiral movement is in same direction in this design. Feding convenience and regularity targeted.

Machine frame (46) which supports all componenets is reinforced to whitstand forces coming from rollers and hydraulic system. Geared, guide piston type or similar mechanisms are used for combining bearing blocks (47) of moving roller to machine housing (46) to enable regular back and forth movement of moving roller.

General caharacteristics of screw effective mill and crusher whwn used as crusher,

• Crushing by compression system; especially producing material to be obtained from secondary and tertiary crushers

• Wide band wearing tolerance; Rapid wear of compression componenets and related performance lost is the general problem of compression process crushers. Wearing band is much more wider in screw effective mill and crusher. Local wearing of rollers does not effect crushing efficiency considerably since material compressed proceeds at the same time and does not move at the same place of rollers. Local wearings are one of the main problems in compression process crushers and are the reason for considerable drop of efficiency.

• No problem of capacity; Simple and reliable sysem design offers wide range of product capacity. It is possible to make production at too low and too high capacities.

Claims

1. A Screw effective mill and crusher, characteristics composed of: material feding chute (1,41), A moving roller (2,42) and a fixed roller (3,43), Hydraulic system cylinder (4,44), Drive unit (5,45) for rollers, machine housing (6,46) and bearing blocks (7,47), Sliding coupling (8,48) for moving roller and motor security coupling (9,49), Material draw blades (10,50), Material outlet chute (11,51), Screw form projection (12,52) and screw form indentataion (13,53) for rollers.

2. A Screw effective mill and crusher as claimed in claim 1, wherein has an inlet chute (1,41) to convey material to be grand or crushed into mill.

3. A screw effective mill and crusher according to any one of claims above wherein has a moving roller (2,42) which performs grinding and crushing by hydraulic press build by hydraulic system cylinder (4,44), rotating motion given by dirve unit (5,45) of rollers, back and forth motion enabled by sliding coupling (8) of moving roller. 4. A screw effective mill and crusher according to any one of claims above wherein has a fixed roller (3,43) making grinding and crushing of material together with moving roller (2,42).

5. A screw effective mill and crusher according to any one of claims above wherein has an hydraulic system cylinder (4,44) applying hydraulic pressure on moving roller (2,42) and if necessary furnished with hydraulic impact circuit to ensure more effective crushing and grinding of material.

6. A screw effective mill and crusher according to any one of claims above wherein has a drive unit (5,45) of rollers turning moving roller (2,42) and fixed roller (3,43) together without changing screw positions. 7. A screw effective mill and crusher according to any one of claims above wherein has a machine frame (6,46) carrying all componenets and reinforced to whitstand forces coming from rollers and hydraulic system.

8. A screw effective mill and crusher according to any one of claims above wherein it has bearing blocks (7,47) engaging rollers (2,42 and 3,43) to machine frame (6) either by roller bearings or by journal bearings.

9. A screw effective mill and crusher according to any one of claims above wherein has sliding coupling (8,48) enabling back and forth movement of moving roller (2,42).

10.A screw effective mill and crusher according to any one of claims above wherein has security coupling (9,49 ) of drive motor enabling required safety at motor outlet depending on size of the system and importance of componenets. ll.A screw effective mill and crusher according to any one of claims above wherein has material draw blades (10,50) conveying material to screw formed crushing spirals of rollers (2,42 and 3,43) where crushing and grinding realized wihout building pressure on material.

12.A screw effective mill and crusher according to any one of claims above wherein has an oulet chute at outlet enabling material collection at outlet and conveying out of mill. 13.A screw effective mill and crusher according to any one of claims above wherein has roller screw form projections (12,52) and roller screw form indentations (13,53) for crushing and grinding of material by taking material between them.

14.A screw effective mill and crusher according to any one of claims above wherein roller screw form projections (12,52) and roller screw form indentations (13,53) could be same numbered and shaped or could be as different numbered and shaped at each roller.

15.A screw effective mill and crusher according to any one of claims above wherein rollerscrew form projections (12,52) and roller screw form indentations (13,53) has cross section geometry as cylindrical, parabolical, conical or prismatic which is succesive pattern of flat surfaces. 16.A screw effective mill and crusher according to any one of claims above wherein spiral helix angle of roller screw form projections (12,52) and roller screw form indentations (13,53) on rollers (2,42 and 3,43) are determined as wide or narrow according to material to be ground.