Osborne -Jaw Crushers

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handling source

OSBORN ENGINEERED PRODUCTS SA (PTY) LIMITEDShaping Materials Handling

Jaw Crushers fromOsborn South Africa

Your one stopmaterials

handling source

IntroductionIN

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Jaw Crushers are compression crushers consisting of a fixed jaw and a swing jaw and in a single toggle or a double toggle design.

The single toggle crusher is designed for a high capacity throughput due to the elliptical movement of the swing jaw which also assists in the discharge of the crushed material.

As the single toggle crusher will achieve far higher capacities than the double toggle design, they are often used as a primary crusher.

PRINCIPLES OF OPERATION - SINGLE & DOUBLE TOGGLE CRUSHERS

Jaw crushers process medium to hard quarry rock or other materials by compressing it between the fixed jaw and the swing jaw.

The swing jaw being the moving part is attached to a rotating eccentric shaft. The fixed jaw is an integral part of the crusher frame. Both jaws are fitted with manganese jaw liners that can be replaced or reversed when worn. During the crushing operation, the toggle plate which acts as a pivot point for the jawstock, controls movement of the lower part of the swing jaw. Although the toggle plate is designed to bend or break if uncrushable objects enter the crushing chamber, this is only applicable if these uncrushables are in the zone around the toggle plate. If uncrushable objects are at the top of the crushing chamber, it is likely that bearing failure can occur. Similarly, if the uncrushable object have managed to get below the toggle plate movement plane and sit at the bottom of the crushing chamber this could result in the bottom of the jawstock being broken. Hence, it is important to understand the limitation of a toggle plate when these other factors are present. As the swing jaw opens and closes , it compresses and crushes the material against the fixed or stationary jaw and the crushed material then drops to the discharge opening at the base of the crusher. This opening is adjustable by adding or subtracting shims between the toggle beam and the crusher frame. This adjustment is necessary when setting the different types of crushing requirements and to compensate for wear on the manganese jaw liners. The basic difference between the single toggle crusher and the double toggle is the movement of the jaws. The single toggle has an elliptical movement whilst the double toggle has a pendulum movement. A rule of thumb selection for either a single toggle or a double toggle is that when the material to be crushed has a compressive strength of up to 400Mpa and with a production capacity requirement of up to 1600tph, the correct machine would be the single toggle.

For much harder and highly abrasive materials with a compressive strength of up to 600 Mpa, the double toggle crusher would be the preferred machine.

The double toggle is capable of handling extremely hard rock and Ferro materials, but rate of feed and reduction ratio’s are restricted. With the top of the hinged swing jaw almost perpendicular to the crushing chamber, high compression is achieved by the linear stroke of the toggle movement thus minimising wear on the jaw liners.

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Jaw Crusher Components

Swing Jaw Moving weldment that crushes rock against the stationary jaw. Fits inside the main frame

Fixed Jaw An integral part of the crusher main frame

Jaw Liners Replaceable manganese wear surfaces fitted to the crushing faces of the swing and fixed jaws

Cheek PlatesReplaceable manganese wear surfaces bolted to the inner sides of the crusher frame

Toggle Plate Supports lower part of swing jaw and controls its movement

Tension Rod Assembly Provides tension that holds the swing jaw against the toggle plate

Toggle LeversOn double toggle crushers the system of toggle levers that connect to the Pitman

Pitman Main moving part in a jaw crusher connected to an eccentric shaft on the flywheel

Main Frame Bearing Rotational surface between the eccentric shaft and the main frame

Swing Jaw Bearing Rotational surface between the eccentric shaft and swing jaw

Eccentric Shaft A shaft machined with a portion of its axis off-centre to create the swinging (crushing) motion of the swing jaw

Flywheel - Grooved The input energy that drives the eccentric shaft through a series of vee belts

Flywheel - Flat face Helps maintain crusher speed as load conditions change.

The closed side setting (CSS) of the crusher will require adjustment dependant upon the required sizes of the crushed material. This is done by the use of shims at the discharge opening of bottom of the jaw. Hydraulic adjustment is another way of changing the CSS.

Single Toggle Jaw Crusher O

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Double Toggle Jaw Crusher

A - SwingstockB - Main frameC - Cheek platesD - Fixed jawE - Swing jawF - Toggle plate & beamG - Tension rod assemblyH - BearingsI - Bearing mountsJ - Eccentric shaftK - Flywheel

• The pitman runs on spherical roller bearings

• Swing jaw pivots with bronze bushes, on a concentric shaft

• Eccentric shaft actuates a vertical pitman connected to a pair of toggle plates, and is not directly exposed to crushing loads

JAW LINERS

BRONZE BUSHSWINGSTOCK

ECCENTRICSHAFT FLYWHEEL

SHIMS

TOGGLE PLATESPITMAN

TOGGLE BLOCK

TENSION ROD

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Osborn Hadfields Single Toggle - Heavy Duty

Model Kg Mass Kw RPM48” x 12” 11000 75 375

48” x 18” 16800 75 250

80” x 60” 180000 220 140

Screen Analysis

CLOSED SIDE SETTING OF CRUSHERPRODUCT SIZE

300 250 200 180 150 130 100 90 75 60 50 40 25 20

-400 100

-350 93

-330 89 100

-300 85 95

-280 78 90 100

-250 70 85 97 100

-230 63 78 91 98 100

-200 56 70 85 91 98

-180 49 60 76 81 92 100

-150 40 50 65 71 82 92 100

-130 31 40 51 60 70 80 95 100 100

-100 22 30 39 46 56 66 82 89 96

-90 20 25 33 39 48 58 73 82 90 100

-75 17 20 27 32 39 49 62 72 83 93 100

-60 14 17 22 26 31 39 52 60 70 81 95 100

-50 11 14 17 20 23 28 41 47 56 65 80 97

-40 9 10 12 15 17 21 28 33 40 48 63 80 100 100

-25 6 7 7 10 11 14 18 22 25 29 43 54 81 98

-20 4 5 5 7 9 11 14 16 19 22 30 38 61 80

-10 2 3 3 5 6 7 10 11 13 14 19 25 41 60

-5 1 2 2 2 3 3 6 6 7 7 8 12 16 20

Performance Schedule

CLOSED SIDE SETTING & CAPACITY (Depending on material type)

20 25 40 50 75 100 130 150 180 200 250 300

48” x 12” 15 30 55 70 110

Max Lump to to to to to

245mm 30 45 70 100 140

48” x 18” 70 110 150 200

Max Lump to to to to

370mm 100 140 190 260

80” x 60” 600 800 900 1000 1200 1400

Max Lump to to to to to to

1 220mm 680 900 1000 1100 1400 1600

SIZE OF FEED OPENING Width x Depth

Information for reading screen analysisTo illustrate the approximate screen analysis from an Osborn Hadfields Heavy Duty Jaw Crusher, the following results can be read from the relevant table.

Using a 48” x 18” as a typical popular crusher model and set at a 25mm CSS we can read off the screen analysis table that:

• 100% will pass through a 40mm square opening



• 41% will pass through a 10mmsquare opening


Note: On the Osborn Hadfields and Osborn Telsmith Heavy Duty Jaw Crushers, the CSS is measured from peak to valley.

The CSS on the Telsmith Std Heavy Duty Jaw Crusher is measured from peak to peak.

Data based on Dry Limestone @ 1.6t/m3. Performance schedule setting is Peak to Valley on Heavy Duty machines. Max lump not applicable to small settings. Crushing ratio = Feed size to CSS = 6:1 on mined ore.

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Osborn Hadfields Double Toggle - Heavy DutyO

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30” x 20” 19700 55 270

36” x 25” 23600 75 270


Screen Analysis

CLOSED SIDE SETTING OF CRUSHER

300 250 200 180 150 130 100 75 50 40 25 20

-400 100 100

-350 92 97 100

-300 82 92 97 100

-250 67 80 92 95 100

-200 57 67 78 89 95 100

-180 52 58 68 79 87 96

-150 42 49 59 69 77 90 100

-130 32 38 44 56 65 77 95 100

-100 22 27 32 41 52 63 81 95

-75 13 17 21 28 36 46 60 81 100 100

-50 7 9 13 18 22 24 38 54 80 88 100

-40 4 5 9 13 16 18 26 38 62 72 92 100

-25 2 2 6 9 11 12 15 23 38 46 72 92

-20 1 1 4 5 7 8 11 15 28 32 52 70

-10 0.5 0.5 2 3 4 5 6 9 18 17 32 35

-5 0 0 1 1 2 3 3 4 6 7 14 17

PRODUCT SIZE


48” x 42” 71000 110 185

60” x 52” 110 000 160 155



25 40 50 75 100 130 150 180 200 250

24” x 13” 15 25 40 55 70


265mm 25 35 50 65 80

30” x 23” 50 65 75 90


470mm 60 70 95 120

36” x 25” 95 110 140 180


600mm 120 150 200 250

42” x 32” 150 170 250 300


650mm 200 260 310 350

48” x 36” 300 440 540 600


730mm 440 540 640 700

48” x 42” 300 440 540 600


850mm 440 540 640 700

60” x 52’ 500 550 680 750 820


1 050mm 600 650 780 850 920


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Osborn Telsmith Single Toggle - Standard Duty

Model Kg Mass Kw RPM10” x 21” 2910 15 35010” x 30” 4000 18.5 32015” x 24” 5000 30 32020” x 32” 11034 55 27520” x 36” 12400 75 265

Screen Analysis


Data based on Dry Limestone @ 1.6t/m3. Performance schedule setting is Peak to Peak on Standard Duty machines. Max lump not applicable to small settings. Crushing ratio = Feed size to CSS = 6:1 on mined ore.

200 180 150 130 100 90 75 60 50 40 25 20

-330 100 -300 95 -280 90 100 -250 85 97 -230 78 91 100 100 -200 70 85 98 98 -180 60 76 92 91 100 -150 50 65 82 81 92 100 -130 40 51 70 69 80 93 100 100 -100 30 39 56 55 66 82 89 96 -90 25 33 48 47 58 73 82 89 100 -75 20 27 39 39 49 62 72 82 93 100 -60 17 22 31 31 39 52 60 68 80 93 100 -50 14 17 23 23 28 41 47 55 65 80 97 100-40 10 12 17 18 22 28 33 40 49 65 84 90-25 7 7 11 11 14 18 21 25 28 43 55 68-20 5 5 9 9 11 14 18 18 23 31 39 50-10 2 2 6 4 4 8 9 9 11 14 20 29-5 1 1 3 2 2 4 4 5 6 7 9 12

PRODUCT SIZE


25 32 40 50 64 76 90 100 130 152 178 20310” x 21” 13 15 17 Max Lump to to to 203mm 18 20 23

10” x 30” 21 26 32 Max Lump to to to 203mm 31 48 47

15” x 24” 24 27 35 45 50 Max Lump to to to to to 304mm 36 40 50 65 80

20” x 32” 30 40 50 60 70 Max lump to to to to to 406mm 60 70 90 100 120


22” x 50” 99 117 135 153 189 225 261 Max Lump to to to to to to to 447mm 148 171 198 225 283 333 396

25” x 40” 100 130 150 170 Max Lump to to to to 508mm 140 160 180 200


30” x 55” 175 200 230 250 Max Lump to to to to 608mm 270 280 300 340

36” x 48” 260 300 350 400 430Max Lump to to to to to731mm 320 360 400 480 550


Model Kg Mass Kw RPM22” x 50” 18800 90 26025” x 40” 16100 110 26030” x 42” 24100 132 25530” x 55” 26300 160 28036” x 48” 34800 160 230

SIZE OF FEED OPENING

Width x Depth

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Model Kg Mass Kw RPM12” x 8” 1300 7.5 345

24” x 5” 3700 22 350

30” x 42” 31700 132 250

42” x 48” 53000 160 220

50” x 60” 112000 220 180

Screen Analysis



300 250 200 180 150 130 100 90 75 60 50 40 25 20

-400 100

-350 93

-330 89 100

-300 85 95

-280 78 90 100

-250 70 85 97 100

-230 63 78 91 98 100

-200 56 70 85 91 98

-180 49 60 76 81 92 100

-150 40 50 65 71 82 92 100

-130 31 40 51 60 70 80 95 100 100

-100 22 30 39 46 56 66 82 89 96

-90 20 25 33 39 48 58 73 82 90 100

-75 17 20 27 32 39 49 62 72 83 93 100

-60 14 17 22 26 31 39 52 60 70 81 95 100

-50 11 14 17 20 23 28 41 47 56 65 80 97

-40 9 10 12 15 17 21 28 33 40 48 63 80 100 100

-25 6 7 7 10 11 14 18 22 25 29 43 54 81 98

-20 4 5 5 7 9 11 14 16 19 22 30 38 61 80

-10 2 3 3 5 6 7 10 11 13 14 19 25 41 60

-5 1 2 2 2 3 3 6 6 7 7 8 12 16 20

PRODUCT SIZE

10 20 25 40 50 60 75 90 100 130 150 180 200 230 300

12” x 8” 2 3 4 6


162mm 5 6 7 W9

24” x 5” 7 9 12 17


100mm 10 12 15 21

30” X 42” 180 220 260 300


608mm 210 250 290 340

42” X 48” 410 450 500 550 600 700

Max Lump to to to to to to

850mm 460 510 560 610 660 770

50” X 60” 580 600 640 740 820


1 015mm 640 680 720 810 890

How to determine maximum feed for a 3042 Jaw Crusher

Crusher Gape (smallest dimension of the feed opening)

30” (760 mm)

Maximum Feed

= 30” (760 mm) x 0.8

= 24” (600 mm)

30” 760 mm

600 mm

TOP

How to determine maximum Jaw Crusher Feed

Top Crushing leads to shaft and bearing damage. This is the weakest point of a Single Toggle Crusher.

30”

Matching the material to machine:Important ratios to remember

Feed to Closed Side Setting 6 : 1

Feed to Product 4 : 1

If you have gradings use:

F80

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6 : 1

Settings in above case is as follows600 mm Lump ÷ 6 = 100 CSS (F:CSS) 6 : 1

Yield 600 mm Lump ÷ 4 = 150 mm Product Lump (F : P) 4 : 1

When setting below this ratio effective manganese wear increases

This condition will also occur when too large a crusher is used with small feed size.

Only the extreme ends of the liners are used

These parameters are not applicable to ferrous metals crushing. Contact Osborn for more info.

Nip Angle The nip angle of the crusher jaw plates will determine the effectiveness of the machine.

The crushing action takes place low in the jaw cavity and is referred to as the choke point.

If the nip angle is too big then the jaws will not be able to grab the material and often in this case, the material is pushed upwards. This would result in extreme wear on the jaws and a significent production decrease.

When determining the nip angle, the type, bulk density and general material characteristics will be influential in the correct nip angle/crusher selection.

For optimum performance from a Jaw Crusher it is extremely important to pay attention to the way the machine is fed. As the design requires the Crusher to be choke fed, at least 80% of the chamber needs to be full at all times.

In other words, only about 20% of the top of the jaw liners should be visible.

In choke feeding, a heavy load of material is fed into the chamber to press down on the material being nipped.

It also extends the life of the manganese liners as much of the impact and abrasion from dribble feeding is eliminated.

Finally, with the fines removed from the feed material, and with a full chamber of material, efficient attrition will ensure production throughput is maximised.

Fines in crushing terminology is defined as material sized less than the CSS (closed side setting) and they should be removed by a Vibrating Grizzly Feeder/Scalper installed close to horizontal to keep discharge velocity into the jaw crusher at a minimum and to minimise high impact wear on the jaw liners.

The major point to fully understand in crushing materials is knowledge of the feed material. It is highly likely that material from a quarry in the north of a country is different from material blasted in the south of the country. Wherever possible, a feed gradation should be done to determine its suitability for crushing and for the intended use of the product.

A material analysis will also determine the abrasiveness and hardness of the material which would influence manganese liner life. Hardness of a material is generally referred to as the Bond Work Index and is a measure of grindability of a material and the higher the Bond Work Index (BWI), the harder the material is to crush. Therefore, as the WI increases, so does the power requirement.

More attrition crushing

Better grip, less slippage

InterparticleCompression

Feeding the Crusher

Ideal Feed Conditions – Choke fed

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Feeding the CrusherIncorrectly

Slippage,Percolation

Nip Angle

Nip Angle is the angle created between the fixed and swing jaw liners.

• Range 11˚- 23˚ optimal 19˚ for most material types

• Maximum nip angle occurs at minimum discharge setting with curved liners

• Discharge setting usually expressed as closed side peak to valley or peak to peak dimension

Nip Angle

Nip Angle

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Jaw Selection

Most commonly used profile

Deep Tooth Curved Jaw

This provides very good breaking over the sharp tooth

Reduced flat particles

The curved Jaw decreases the nip angle at the bottom of the crusher and moves the point of crush (choke point) higher

up in the chamber

Peak to Valley setting

Very hard or abbrasive material

Smooth Curved Jaw

Produces high percentage flat particles

Very good life but costly

Generally used in the Ferrometals Industry and Andesite Quarries.

Can mix smooth jaw with toothed jaw

Setting between tooth and flat jaw

Flat Tooth Small Curve

This provides longer life by virtue of more contact area of manganese at the

crushing zone

The small curved Jaw reduces the angle of nip through the full length of the crushing

chamber to a minimum degree at the discharge end

Jaw SelectionCurved Jaw

• Deep Tooth

• Smooth Tooth

• Square Tooth (flat)

• Fine Tooth (shallow)

Straight Line Jaw

• Deep Tooth

Jaw Crusher Discharge Settings

“X” dimension equals Peak-to-Peak measurement.

To set the Closed Side Discharge Setting, use a wood block with the same width as the desired setting. It should be

long enough to span most of the crusher’s discharge area.

NOTE: When the crusher is at rest, it is NOT in the closed position. Check your manual to determine the difference

between “closed position” and “at rest position”.

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Application Data Sheet - Osborn Jaw CrushersA

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Customer Contact Person

Phone No. Phone No.

Fax.No Date

MATERIAL

Type

Loose Bulk Density Kg/m³

Compressive Strength Mpa

Abrasiveness High Medium Low

Moisture Content % Max % Min

Shape of Material

DUTY

Capacity mtph

Max.Feed Lump Size mm

Min. Feed Lump Size mm

Feed Analysis Size - mm - mm - mm - mm

% Passing % % % %

Product Size Req’d mm

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

Head Office:PO Box 8182Elandsfontein

1406Johannesburg

South Africa Tel: +27 11 820 7600 Fax: +27 11 388 1136

E-mail: [email protected] www.osborn.co.za

Osborn Telsmith Single Toggle - Heavy DutyModel A B C D E F G H J K L

12” x 8” 1175 620 490 415 455 985 265 450 615 n/a 300

24” x 5” 1080 530 480 520 635 1220 445 735 1030 205 380

30” x 42” 2940 1995 1580 520 795 2650 745 1245 1635 350 400

42” x 48” 3860 2700 2145 875 965 3200 1015 1445 2210 480 455

50” x 60” 4215 2760 2345 1015 1365 3980 1120 1710 2660 540 510

Osborn Hadfields Single Toggle - Heavy DutyModel A B C D E F G H J K L

48” X 12” 1820 980 810 820 895 1625 770 1065 1690 50 400

48” X 18” 2260 1585 580 1055 1115 1755 770 1130 1700 100 230

80” X 60” 5470 4200 2615 1335 1685 4600 1500 1920 3310 750 800

Osborn Telsmith Single Toggle - Standard DutyModel A B C D E F G H J K L

10” X 21’ 1320 850 565 400 615 1070 380 655 865 n/a 305

10” X 30’ 1370 735 685 335 400 1170 510 815 570 100 200

15” X 24” 1735 1050 845 405 470 1380 500 770 1005 70 245

20” X 32” 2290 1455 945 540 605 1610 590 965 1310 90 950

20” X 36” 2080 1290 1250 620 470 1805 630 1100 1375 280 460

22” x 50” 2210 1375 1425 520 595 2100 845 2540 1810 200 250

25” X 40” 2300 1495 1450 460 535 2060 710 1185 1590 155 360

30” X 42” 2630 1680 1695 650 740 2525 735 1250 1645 395 635

30” X 55” 2630 1680 1695 650 740 2525 900 1415 1975 395 635

36” X 48” 2340 2150 1990 780 870 2950 815 2740 1795 175 150

Osborn Hadfields Double Toggle - Heavy DutyModel A B C D E F G H J K L

24” X 13” 1510 930 870 460 995 2370 445 790 1040 160 150

30” X 23” 1755 1235 1070 330 1070 2875 545 1050 1245 270 200

36” X 25” 2060 1550 1525 655 1340 3495 660 1025 1510 280 330

42” X 32’ 2085 2345 2310 780 1405 4040 737 1205 1745 300 350

48” X 42’ 2465 2540 2365 1170 1625 4445 890 1495 2045 455 535

60” X 52” 2930 2895 3240 1510 1825 5380 1045 1545 2275 555 580

NOTE: All dimensions are indicative only. Please consult Osborn for more information

COMPILED BY

Top of flywheel

Feed inlet

Telsmith Single Toggle

Drawbackrod clearance

AB

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Hadfields Double Toggle

Drawbackrod clearance

Top of flywheel

Feed inlet

A

DF E

B

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F

K

CL

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Osborne -Jaw Crushers