Gyratory Crusher

ThyssenKrupp Frdertechnik Excellence in Technology

Gyratory Crushers by ThyssenKrupp Frdertechnik: because its the perfected design that does the job
ThyssenKrupp Frdertechnik is one of the worlds leading manufacturers of machines and plants for the processing industry. Based on decades of experience, our engineers are engaged in research and development. The results have become an integral part of processing technology. Customers worldwide benefit from our innovations. Whether standard or customized designs ThyssenKrupp Frdertechnik always offer complete solutions often found in cooperation with the customer. Reliable, safe, profitable, innovative ThyssenKrupp Frdertechnik.

1 KB 63-89 in Iron Ore. Capacity: 6,200 t/h 2 KB 63-75 in Aggregates Capacity: 2,600 t/h

Fields of Application and Design Characteristics

KB 54-75 BK 54-67 KB 54-67

BK 63-75

KB 63-75 KB 63-89 KB 63-114

3 ThyssenKrupp Gyratory Crusher Product Range

The design of the gyratory crushers and jaw gyratory crushers is based on more than one hundred years of experience of ThyssenKrupp Frdertechnik in the manufacture of these machines. Changing mining and processing methods demand (besides new materials and design methods) a continual development of the products. ThyssenKrupp gyratory crushers represent todays leading crushing technology. They are designed for high performances at low operating and maintenance costs. Fields of application

Large scale hard rock ore mines Lime and cement works Open pit and underground
operations

4 KB 54-75 in Iron Ore

Aggregates industry
Design characteristics

Spiral bevel gear toothing Drive motors with heavy duty

ratings

Change of stroke through

adjustment of eccentricity torque facilitates start in case of emergency for wear compensation and overload protection

Direct drive for high starting

Heavy duty design Optimized crushing chambers

for direct feed

Hydraulic main shaft adjustment Low operating and

maintenance costs

High throughput rates Optimum crushing ratio

Includes Gyramatic PLC

Gyratory Crusher

Working principle The main shaft (B) of the crusher is radially guided in the spider bushing (A) and in the inner eccentric bushing (G). The thrust bearing assembly (J) arranged on the piston of the hydraulic cylinder (K) ensures the axial support of the main shaft. The rotation of the drive motor is transmitted via the transmission gear (H) to the eccentric bushing (G). This rotating eccentric bushing is generating the gyrating motion of the main shaft (B) which is characteristic of gyratory crushers. Consequently, the crushing gap between the stationary concaves in the crusher housing and the gyrating crushing mantle changes continuously. The feed material that enters the crushing chamber from the top is continuously crushed between the crushing tools (C) as it falls by gravitation until it exits the crushing chamber at the bottom (F).

B C C D

E F

I J H K

Design
A Upper main shaft bearing assembly with two-armed spider ensures a spacious feed opening, equipped with automatic grease lubrication with electronic and visual level control B Main shaft C Crushing tools made of high wear-resistant material D Cast-steel shell sections, weight-optimized by means of FEA calculations E Highly efficient dust seal F Large discharge openings owing to three-armed bottom shell G Eccentric bearing assembly with replaceable inner eccentric bushing for stroke adjustment, integrated counterweight to minimize unbalanced forces H Transmission gear including device for setting the tooth clearance, safe lubrication due to hermetically sealed splash lubrication, electronic and visual oil level and temperature control, optionally vibration control I Bevel gear and -pinion with cyclo-palloid toothing ensures smooth transmission of high torque J Thrust bearing of the main shaft K Hydraulic cylinder for main shaft adjustment under load

Gap increase caused by wear is compensated by hydraulic lifting of the main shaft. It also serves as overload protection when tramp iron finds its way into the crushing chamber. Restart under load in an emergency is supported by a heavy duty drive train using a bevel gear set with cyclo-palloid toothing. The spiral bevel gear allows the installation of drive motors with high ratings. Main shaft jumping under adverse crushing conditions is avoided by a pressurized hydraulic system ensuring permanent contact of the individual thrust bearing discs.

6 Bevel gear for KB 63-89 with cyclo-palloid toothing

Technical Data

Gyratory Crusher type Feed Opening [mm] / [inch] KB KB KB KB KB 54 - 67 54 - 75 63 - 75 63 - 89 63 - 114 1,370 / 54 1,370 / 54 1,600 / 63 1,600 / 63 1,600 / 63 Mantle Diameter (oversized) [mm] / [inch] 1,700 / 67 (1,750 / 69) 1,900 / 75 (1,965 / 77) 2,030 / 80 (2,100 / 83) 2,260 / 89 (2,370 / 93) 2,900 / 114 (2,985 / 118)
Speed of Eccentric

1) Weights Max. Motor power [kW] 450 650 650 1,000 1,200 Total weight of Crusher [kg] 180,000 215,000 270,000 332,000 530,000 Spider 2) Heaviest Shell 4) [kg] 30,500 33,000 66,000 71,000 73,000 5) 215 Min. Max. Min. 240 Max. Bottom Shell 3) [kg] 37,100 43,500 43,500 53,000 124,000 Main Shaft Assembly 4) [kg] 32,500 43,000 50,000 69,500 124,000 Eccentric Bushing with Bottom [kg] 7,100 8,500 9,500 13,000 16,000 Hydraulic Cylinder [kg] 8,100 9,500 9,500 14,000 19,000

Bushing [rpm] 137 137 137 130 127

[kg] 29,000 32,000 37,800 46,500 65,500

Gyratory Crusher type 130 Min. 1,226 1,292 Max. 2,284 2,408 Min. 1,479 1,480 1,790 2,501 150 Max. 2,853 3,239 3,304 4,518

Throughput [t/h] at open side setting OSS [mm] 170 Min. 1,762 1,851 2,092 2,784 2,964 Max. 3,674 4,177 4,483 5,116 5,514 Min. 2,017 2,066 2,219 3,024 3,362 185 Max. 4,317 4,787 5,058 5,888 6,368 2,216 2,868 3,407 3,829 Min. 200

KB KB KB KB KB

[inch] 54 - 67 54 - 75 63 - 75 63 - 89 63 - 114

Max.

5,277 5,613 6,700 7,317 2,925 3,638 3,959 6,014 7,489 8,036 3,829 4,722 8,503 10,274 1) Average component weight incl. internal fittings; safety factors for dimensioning of lifting equipment have not been considered 2) including wear cap 3) excluding hydraulic cylinder 4) with oversized mantle incl. crushing tools 5) Min: typical throughput at minimum eccentricity and F80=680mm Max: typical throughput at maximum eccentricity and F80=230mm Bulk density: 1,600kg/m Clearance for mainshaft removal The stated values are for information only and not warrantied. They depend on material characteristics and crusher configuration.

The maximum feed size should not exceed 80 % of the feed opening width. Installation drawing with mating dimensions and loads on request.

Supporting surfaces Discharge opening

Drawn displaced by 120 End of motor shaft Gyratory Crusher type KB KB KB KB KB [inch] 54 54 63 63 67 75 75 89

A
[mm] 4,475 4,475 4,950 4,950 6,250

B
[mm] 4,430 4,600 5,750 6,020 6,450

C
[mm] 1,535 1,630 1,955 2,120 2,273

D
[mm] 1,642 1,745 1,745 1,808 2,270

E
[mm] 4,352 4,484 4,497 4,900 5,800

F
[mm] 6,026 6,295 6,930 7,024 8,725

G
[mm] 200 200 200 200 200

H
[mm] 3,200 3,400 3,400 3,720 5,000

I
[mm] 2,800 3,000 3,000 3,300 4,500

J1
[mm] 3,660 3,900 3,900 4,290 5,500

J2
[mm] 3,660 3,900 3,900 4,290 5,500

63 - 114

Jaw Gyratory Crusher

Working principle Special feature of the jaw gyratory crusher is the specific shape of the feed opening, which is extended to one side. The feed opening is normally toothed, and together with the upper mantle it forms the primary crushing zone. Further crushing of the roughly pre-crushed material takes place in the lower part of the crushing chamber, where the specified final grain size is produced. Jaw gyratory crushers are designed to handle substantially bigger feed lumps than the comparable size of the gyratory crusher with the same mantle diameter. Jaw gyratory crushers have higher crushing ratios and a low tendency to get clogged in the feed area as a result of bridging.
Large Feed opening 3080 x1675mm

Fields of Application:

feed material Coarse Block cave mining Underground mines

7 Jaw gyratory crusher with specially designed feed opening 8 Jaw gyratory crusher for iron ore in an underground application 9 Feed opening of BK 63-75 in a stationary copper ore plant 8 9

Technical Data

Jaw Gyratory Crusher type Feed Opening [mm] / [inch] BK BK 54 - 67 63 - 75 2,640 x 1,350 / 104 x 54 3,080 x 1,680 / 121 x 66 Mantle Diameter (oversized) [mm] / [inch] 1,700 / 67 (1,750 / 69) 1,900 / 75 (1,955 / 77)
Speed of Eccentric

1) Weights Max. Motor power [kW] 450 650 Total Crusher weight [kg] 175,000 209,000 Spider 2) Heaviest Shell 4) [kg] 42,000 45,500 Bottom Shell 3) [kg] 36,800 43,500 Main Shaft Assembly 4) [kg] 34,000 45,000 Eccentric Bushing with Bottom [kg] 7,100 8,500 Hydraulic Cylinder [kg] 8,100 9,500

Bushing [rpm] 137 137

[kg] 46,000 50,400

Jaw Gyratory Crusher type 130 Min. 944 1,057 Max. 2,133 2,398

Throughput [t/h] at open side setting OSS [mm] 150 Min. 1,186 1,328 Max. 2,542 3,036 Min. 1,570 1,757 170 Max. 3,376 3,973 Min. 1,738 1,946

5) 200 Min. 1,833 2,052 Max. 4,017 4,871

185 Max. 3,872 4,555

BK BK

[inch] 54 - 67 63 - 75

The maximum feed size should not exceed 80 % of the feed opening width. Installation drawing with mating dimensions and loads on request.

Discharge opening Supporting surfaces

1) Average component weight incl. internal fittings; safety factors for dimensioning of lifting equipment have not been considered 2) including wear cap 3) excluding hydraulic cylinder 4) with oversized mantle incl. crushing tools 5) Min: typical throughput at minimum eccentricity and F80=680mm Max: typical throughput at maximum eccentricity and F80=230mm Bulk density: 1,600kg/m The stated values are for information only and not warrantied. They depend on material characteristics and crusher configuration.

Clearance for mainshaft removal

Drawn displaced by 120 End of motor shaft

Jaw Gyratory Crusher type [inch]

A
[mm]

B
[mm]

C
[mm]

D
[mm]

E
[mm]

F
[mm]

G
[mm]

H
[mm]

I
[mm]

J1
[mm]

J2
[mm]

K
[mm]

L
[mm]

M
[mm]

BK BK

54 - 67 63 - 75

4,252 4,252

3,400 4,400

2,010 2,400

1,642 1,745

4,352 4,484

6,500 7,200

200 200

3,200 3,400

2,800 3,000

3,660 3,900

3.660 3,900

2.150 2,640

1.350 1,675

2.640 3,080

Crusher Drives

ThyssenKrupp gyratory crushers are driven directly by a multipledisc steel clutch with intermediate shaft and a safety coupling. The multiple-disc steel clutch compensates geometric deviations between motor- and transmission gear shaft, while the hydraulic safety coupling protects the crusher motor against overload when uncrushable foreign matter is fed to the crusher. The intermediate shaft allows the disassembly of the transmission gear without dismantling the motor.

10 Gyratory crusher with multiple-disc steel clutch with intermediate shaft and safety coupling 11 Direct drive of the gyratory crusher A Crusher side B Fully enclosed cartridge C Multiple-disc steel clutch D Safety coupling E Intermediate shaft F Motor side 10 A B C D E C F

The monitoring and control system Gyramatic of ThyssenKrupp Frdertechnik gyratory crushers ensures an easy and safe operation of these crushers in different applications. This compact and solid unit consists of a control cabinet with a touch screen terminal and will be integrated into the local electrical equipment. The input values are important operation parameters being measured on the crusher, on relating units and the environment. The touch screen terminal will accept interactive input to set parameters and display the operating data.

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12 Monitoring and control system of the gyratory crusher Gyramatic 12

Customized Crusher Solutions

1: Ring spider

2: Split ring spider

Wear parts in Rock-Box design

Hydraulic spider lock (Patent pending)

3: Bone type spider

4: Jaw type spider

Scissor lift for dismantling of eccentric

For individual applications individual designed spiders are available 1: Standard ring spider 2: Split ring spider for applications with dimension and/or weight restrictions 3: Bone type spider for quick release and larger feed opening 4: Jaw type spider for extreme large feed opening ThyssenKrupp Frdertechnik pays large attention to provide crusher solutions adapted to clients needs. For varying crusher demands dependent on feed material properties and product requirements ThyssenKrupp provides individual solutions. There are different spider designs, wear part shapes and crushing tools available or even tailor-made solutions for specific needs.

Chamber covers and Concave racks for safe & quick maintenance

Split shell

Hydraulic nut for quick shell release

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Examples of Crushing Plants with Gyratory Crushers

Dependent on the crushing duty, the performance and availability of gyratory crushers are optimised due to specific design and arrangement of feeding and discharging devices.

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13 Primary crushing plant with gyratory crusher KB 63-75 for iron ore / overburden. The crusher is directly fed from two sides by means of dump trucks. Capacity: Ore 3,650 t/h Overburden 4,500 t/h Ore 280 mm Product P99: Overburden 350 mm Feed size: max. 1,400 mm 14 Jaw gyratory crusher BK 63-75 installed underground in a crushing plant for copper ore. Capacity: 2,000 t/h Product: P80 150 mm Feed size in block caving: max. 2,000 x 1,500 x 1,000 mm 15 Relocation of semi-mobile crushing plant equipped with KB 63-114 for copper ore. Proven capacity >10,000t/h

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Research, Development and Services

ThyssenKrupp Frdertechnik is dedicated to continuous, innovative research and development. For us, innovations and technical progress are key factors in managing global growth and using finite resources in a sustainable way. With our engineering expertise we enable our customers to meet the rising demand for more in a better way, gain an edge in the global market and manufacture innovative products in a cost- and resource-efficient way. This ranges from basic analyses to measurements on new and old crushers. At first analyses of the deposits or the feed material are carried out by means of up-to-date methods allowing a material characterization and based hereon the right choice of a suitable crusher. Furthermore, by these basic analyses the best possible adaptation of the crusher can be ascertained, like e.g. the correct sizing of individual components by means of the finite element analysis. The computed values will then be field-tested using a newly developed control- and diagnosis system which allows the control of the most important operating data.

Our services include project research, damage analyses, planning and modification aimed at a modernization and an increase of the output of machines and plants in conjunction with a worldwide after-sales service which also covers the equipment of other manufacturers. Maintenance and repair services offered by ThyssenKrupp Frdertechnik include expert on-site consultancy. Repairs are carried out by highly qualified staff using high-quality and tested spare parts. Increase the productivity of your machinery and equipment.

Get in touch with ThyssenKrupp Frdertechnik wherever you are. services Inspection Stand-by emergency services services Repair on site

in the workshop of the service centre Diagnosis systems Maintenance contracts Spare parts services ImProMa - Program (Improvement of Process and Machines)

16 Teleservice - Collecting, archiving and evaluating machine / process data - Worldwide access via GSM 17 Spare Parts Service Easy access of crusher components via electronic spare parts catalogue 18 Scan service - Crushing Tools evaluation by on-site 3D scanning - Wear analyses and optimization of crushing tools

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ThyssenKrupp Frdertechnik Partners of the mineral processing industry

Product range
Crushing technology Stationary, semi-mobile and mobile crushing plants Gyratory crushers KUBRIA cone crushers Double-toggle jaw crushers Single-toggle jaw crushers Impact jaw crushers MAMMUT single-shaft hammer crushers TITAN double-shaft hammer crushers Impact crushers Roller crushers RollSizers SIEBRA swivel-arm crushers

Feeding and conveying systems Apron feeders Chain conveyors Reciprocating plate feeders Vibrating screens Wobbler feeders Filtering- and drying technology Magnetic separators Dryers Vacuum belt filters CHF vacuum belt filters Separating cyclones Hydro-cyclones Cyclone clusters Disc filters

Grinding technology Ball mills Rod tube mills Hammer mills Roll mills Separating systems Water injection systems

Screening technology Linear vibrating screens Circular vibrating screens Elliptical vibrating screens Eccentric vibrating screens Screener Fines screening machine Grizzly primary screens Vibrating screen feeders Unbalance drive units Aqua vibrating separators

Systems Systems for power plants Coal preparation systems Detection systems Engineering Modernization, Refurbishment After-sales service Training
Technical details subject to changed. Printed in Germany. Gyratory Crushers 02 GB 08.12

More info?

ThyssenKrupp Frdertechnik GmbH Processing Schleebergstrae 12, D-59320 Ennigerloh (Germany), Tel.: +49(2524)30-0, Fax: +49(2524)2252 E-mail: info.tkfen@thyssenkrupp.com, http://www.tk-processing.com