46-CoalCrusher

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Introduction to Osborn Coal Crushers

INTR

ODUCTIONTOOSBO

RNCOALCRUSHERS

As the ROM coal is received from the Mine, the preparation process commences with the crushing and breaking of

the coal and the removal of any unwanted material found in the coal feed by the use of the Rotary Breaker.

This machine is designed to reduce the ROM coal from mined lumps into a more manageable size for further

processing through the plant.

The sized coal produced by the Rotary Breaker can then be fed into a Rolling Ring Crusher which works on aHammermill principle with a rotor spinning at high speed delivering heavy blows to the coal lumps through impact whilst

it is in suspension causing the material to be thrown against a breaker plate to reduce it to a size that will pass through

the breaker plate.

For more specific and smaller sizing of the coal the Double Roll Crusher is generally the chosen machine particularly for

processing the sizes required for power stations and for export coal sizing where specifications are more precise.

Osborn manufactures all the types of coal crushers mentioned here with a broad range of sizes to meet relevant

product size requirements.

Serving the South African coal industry for more than 50 years, Osborn coal crushers have proved to be highly reliable

and have gained popularity as far afield as Australia and Turkey and closer to home with our neighbours Zambia

and Zimbabwe.

Osborn Rotary Breakers

The Rotary Breaker works on a gravity method to break the coal in a very efficient manner. Material is continuously

introduced at the feed end, repeatedly raised by the lifters and dropped until it is broken to size and falls through the

perforations in the screen plates to a collection hopper below.

Mine rock , refuse and other uncrushable debris is automatically carried to the end of the drum and discharged through

a chute.

Due to variations in the types of coal being processed, capacities and power requirements will vary from Mine to Mine.

Osborn Rotary Breakers are capable of processing up to 2000tph with a maximum feed size of 1200mm depending on

the type of coal to be processed.

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FEAT

URESOFTHEOSBORNROTARYBREAKE

R

Features of the Osborn Rotary Breaker

1. The Rotor Cage is constructed with high strength steel longitudinal beams with extra peripheral segmental ties ,

situated between each row of grids, thereby ensuring robustness of the rotor cage and elimination of distortion of the

longitudinal beams along the weak axis. In the event of a longitudinal beam requiring replacement, all beams on the

Osborn Rotary Breaker are fitted with a flange at each end drilled to provide a bolted connection to the end plate. The

longitudinal beam is machined and also the flanges to ensure a perfect mating connection. This entails a major strip.

2. Screen Plates are of the patented fabricated type.

3. Adjustable angle lifter bars facilitate control of retention time and are of a deep profile design to assist with the

breaking and lifting of large size lumps.

4. Special alloy steel tyres are shrunk onto the machined end plates of the drum which run on steel support rollers

incorporating self-aligning spherical roller bearings .

5. Osborn Rotary Breakers are generally fitted with chain type drives.As an optional extra, higher specification trunnion

mounted girth gear and pinion drives (Mill type) are available.

6. A hand operated clutch disengages the main drive and switches to the barring drive to facilitate simple maintenance

procedures. The drives are electrically interlocked to prevent accidental starting and thus ensuring absolute safety

during servicing.

7. A dust tight housing incorporating hinged access doors are fitted to both sides. The top section is manufactured

from non-skid type plate with a removable hatch cover to provide crane access when required.

8. The entire Rotary Breaker can be mounted on a rigid base frame ready for site installation after workshop running

and testing. This is an optional extra.

Dimensional Data (Two Styles)

MODEL

CHAIN DRIVEA

B

C

D

E

F

G

H

J

K

L

M

N

P

Q

1020 5084 3050 3050 3200 3000 1040 2250 2340 2134 1076 980 150 1524 980 6860

1024 6284 3650 3650 3200 3000 1040 2250 2340 2134 1076 980 150 1524 980 80601227 6858 4115 4115 3700 3000 1345 2438 2949 2134 1127 1050 150 1270 1050 8850

1328 7278 4330 4330 4167 2800 650 2800 4000 2438 1422 1035 150 2438 1035 9348

MODEL

GIRTH GEAR &

PINION DRIVE

3.0 X 4.5 4500 3005 2745 3000 1900 994 2020 1950 1500 860 680 150 1230 910 6090

3.0 X 6.7 6740 4165 3905 3000 2550 994 2020 1950 1500 860 720 150 1230 950 8410

4.2 X 9.0 8970 4845 5250 4200 2500 1500 2620 2550 2100 1017 1000 150 1750 1000 11385

3.6 X 6.7 6730 4330 4070 2200 1605 2360 2090 1028 975 150 1185 8890

3.6 X 7.6 7600 4765 4505 2200 1605 2360 2090 1028 975 150 1185 9760

3

All dimensions are indicative only and should not be used for layout purposes. Contact Osborn for certified G.A. drawing.


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FEAT


R

4

Fabricated screen plates are

manufactured as welded box section.

The coal lumps are lifted and

dropped onto the screen plates

minimising the amount of fines

passing through the square

apertures.

Cage fitted with lateral beam for

stiffness. Square aperature screen

plates with hole sizes to suit product

required.

Segmented drive sprocket bolted to

machined end disc.

Special wide faced trunnion rollers support

the breaker cage. Rollers are housed in self-

aligning spherical roller bearings.


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FEAT


R

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Replacable steel alloy tyres shrunk onto the

machined end disc.

Uncrushable objects in the feed are passed

through an outlet scoop into a collecting bin.

Thrust Rollers positioned at each and of the Rotary Breaker to

prevent excessive axial float.

Osborn Rotary Breakers can accept a feed size of 1200mm of Coal

and are high capacity units up to 2000tph

Simplistic design and extremely durable and is the equipment of

choice in coal processing.


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Osborn Rolling Ring Crushers

OSBORNROLLINGR

INGCRUSHERS

This hammermill design has the capability to reduce a coal feed size of 500mm to 25mm in one pass. Capacities are

in excess of 2000tph dependant upon rotor speed, percentage lump in feed, hardness, structure and moisture. The

crushers are fitted with cleanout doors to remove tramp iron and uncrushable materials from the metal trap at the

rear of the machine.

Construction Features

1. ROTOR

Machined from heat-treated steel to minimize deflection.

Designed with excess on safety factor for critical speed

requirements.

2. FRAME

The housing is fabricated from top quality steel plate and

stress relieved prior to machining.

3. BREAKER PLATE

Pre-screens undersize material through breaker grate to

minimize fines production, alleviate dusting and decrease

wear on crusher.

4. ADJUSTABLE DROP CAGE

The machine is furnished with a drop cage. This feature

produces absolute size control within the product range

of the machine. It also permits quick cleanout in the event

of a power failure and blockage.

Adjustment of the American Rolling Ring Crusher (ARRC)

can be performed in 3 different ways.

(1) By the hand wheel

(2) By the handwheel

(3) By motorised gearbox

BEARINGS (NOT SHOWN)

Heavy-duty anti-friction bearings, which are enclosed

in dust and oil tight pillow blocks. The pillow blocks are

mounted and dowelled on machined surface. Split

bearings are optional.

5. LINERS

The liners are of high impact and wear-resistant plate.

The liners can be easily replaced without dismantling

the machine.

6. SHREDDER RINGS

Each ring has multiple cutting edges and is reversible.The rings revolve at slow speeds and split the coal,

instead of crushing it, producing a granular product with

minimum fines. If rings encounter tramp metal, they are

free to deflect on their shafts.

The Shredder Rings can be changed either through the

rear inspection panels or from the top of the machine

whereby the complete shaft assembly can be lifted out.

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3

2

6 1

5

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OSBORNROLLING

RINGCRUSHER

7

Access door for

shredder ring

change and metal

trap clean out.

Hand wheel (and gearbox

on large machines) for drop

cage adjustment.

Breaker plate, screen plates and rotor assembly.

Breaker plate

adjustment screw.

Both sides.

Heavy duty bearing and

plummer blocks for rotor shaft.

Pivot arrangement for ease of access is anoptional extra on all machines.

Access for inspection of drop cage

and screen plates.

General product grade analysis @ 400RPM.

Crushing medium, hard bitumous coal.

Note:Crusher output gradations and

tons per hour products may change due

to variations in operating conditions and

application of the crushing equipment. This

information does not constitute an expressed

or implied warranty or guarantee, but shows

results of test crushing of samples provided

by customers. This is guideline information.

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OSBORNDOUBLEROLLCRUSHER

Double Roll Crusher

99

Crushing Rolls and Drive

Osborns Double Roll Crushers can be used for primary and secondary crushing. Generally regarded as a 4:1 feed to

product ratio although in some instances, dependant upon material friability and hardness, it is possible to achieve a 6:1

crushing ratio. The feed material should enter the centre of the gap between the two rolls and spread across the full

roll width for maximum efficiency to obtain a uniform product size distribution.

Each roll assembly comprises renewable and reversible toothed segments bolted and keyed to a robust hexagonal hub

with the nuts inside the hub. Locking nuts are securely located in fabricated pockets in the drum. This enables removal

and replacement of segments to be done from the outside using only one tool (Allan Key). Bolt heads are protected

from excessive wear, being sunk in recesses in the segments. Teeth are disposed in circumferential bands, so that

teeth from the opposing roll can freely move in the space between adjacent bands. Tooth proportions are designed to

provide the particular product required.

The rolls are separately driven by two identical motors, through sets of vee belts which are connected from the motor

pulley to grooves machined in the flywheels. The drive arrangement is free standing with the electric motors mounted

on adjustable base plates.

Frame and Canopy

The main frame members which support the rolls are fabricated box beams. Machined pads on low friction polymer

are provided for the sliding of the bearing pedestals of the moving roll and the fixed roll bearing pedestals. The low

friction polymer slide pads provide ease of adjustment. Large area feet permit mounting of the machine directly onto a

concrete foundation with grout. Separate sections over each roll are bolted to a f ixed central section. Quick releasing

inspection doors are provided between both rolls and also at the roll ends on the non-drive side. A flange is provided on

the top for connecting a feed chute.

Release Mechanism

Pressure springs are fitted at one end of the unit and act on the bearing housings of one roll only. Spring compression

bolts and carrier plates are fitted for adjusting spring pressures. Uncrushable material entering the rolls will load the

springs causing them to compress and allow rapid movement of the roll and passing of the non- crushable objects.

Hydraulic roll adjustment and force relief cylinders can be supplied instead of the springs as an optional extra.

For the best results in sizing of materials, the Osborn Double Roll Crusher is particularly suitable for the Coal industry

where product sizes are often to a required specification. It is important to understand the material characteristics as

the type of coal will often vary considerably. Hardness, rock content, friability, moisture content are the major

factors that need to be known together with the crusher capacity, maximum lump size, required product size and the

amount of fines that are acceptable.

Efficient crushing will lower the power

requirements and the life of the crusher

segments will be increased when the

correct crushing ratio is used and the

optimum roll diameters are selected so that

the segments grip the feed material and do

not allow these pieces to roll on top of thesegments due to the incorrect nip angle.

Osborn has a wide selection of segments

tooth profiles which are asymmetrical in

order to allow the teeth of the one segment

to run in the valley of the opposing segment.


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Application Data Sheet - Osborn Roll Crusher

APPLICATION

DATASHEET-OSBORNDOUBLEROLLCRUSHER

Dimensions - Double Roll Crushers

CrusherModelDia x Width

A B C D E F G H J K

610 x 760 2760 915 610 260 840 670 658 851 634 748

(24 x 30)

610 X 1220 2760 920 610 260 1260 1270 873 1066 1530 748

(24 x 48)

760 x 910 2910 1500 620 345 1104 964 725 918 757 748

(30 x 36)

760 x 1520 2910 1600 620 345 1700 1550 980 1230 N/A N/A

(30 x 60)

760 x 2000 2510 1000 600 345 2030 2190 1230 1315 N/A N/A

(30 x 80)

1220 x 1220 3350 2400 1300 220 1400 1040 920 1122 799 750

( 48 x 48)

Dimensions subject to change. Please consult Osborn for confirmation of dimensions

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Double Roll Crusher - Product Analysis: Approximate

In MTPH and based on Material at 800Kg/mProduct Sizesmm

Setting of Crusher mm - Peak to Valley

175 150 125 100 75 50 38 25 150

- 200 + 150 14% 8%

-150 + 100 36% 34% 26% 18%

-100 + 75 20% 22% 31% 32% 18%

- 75 + 50 14% 16% 20% 22% 32% 16% 9%

- 50 + 38 6% 10% 8% 10% 13% 20% 12%

- 38 + 25 4% 4% 7% 8% 12% 34% 34% 26%

- 25 + 10 4% 4% 5% 6% 13% 18% 18% 50%

-10 + 0 2% 2% 3% 4% 8% 12% 16% 24%

NOTES These percentages are approximate only and are shown as a general guide Tests were based on crushing medium - hard bituminous coal at a roll speed of 110rpm Crusher used was a 760mm dia x 910mm In a lower speed range of 55-65rpm the amount of fines will be

proportionally lower Power requirements will depend on capacity throughput required, hardness & reduction ratio

Double Roll Crusher - Capacity Schedule: Approximatein MTPH and based on Material at 800Kg/m

Crusher Size

Dia x Width mm

Nominal Product Size

19mm 25mm 32mm 38mm 50mm 75mm 100mm 150mm 150mm

610 x 760 (24 x 30) 45 60 80 95 125 190

610 x 1220 (24 x 48) 72 90 120 143 188 285

760 x 910 (30 x 36) 95 120 140 190 284 378 567

760 x 1520 (30 x 60) 160 197 236 315 470 630 945

760 x 2000 (30 x 80) 210 263 315 420 630 840 1260

1220 x 1220 (48 x 48) 608 812 1218

NOTES The capacities stated above are based on roll speeds of 110rpm and will vary proportionally with the selected speed The roll speed will influence the amount of fines generated Feed Size - depends on the product size required

Reduction ratios of 4:1 but not exceeding 6;1 are considered good practiceMaximum feed size at maximum settings should not be greater than the following sizes

Roll Diameter Maximum Lump Size 610mm 300mm

760mm 600mm1220mm 910mm

Tooth design on the renewable segments is selected according to product size required and feed size Customers feed chute should incorporate a removable vertical section of at least 1 metre prior to

entering the machine

CAPACITIESANDPRODUCTANALYSIS

-OSBORNDOUBLER

OLLCRUSHER

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Six sided drums for easysegment replacement.

Located nuts require one tool.

Bolting is from outside only.


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Ref No. CC/09/Rev 1

Osborn, Designers and Manufacturers of Bulk Materials Handling Equipment and Minerals Processing Plant and Equipment

Head Office:

PO Box 8182

Elandsfontein

1406

Johannesburg

South Africa

Tel: +27 11 820 7600

Fax: +27 11 388 1136

E-mail: [email protected]

www.osborn.co.za

Documents

46-CoalCrusher