Gyratory Crushers

ThyssenKrupp Frdertechnik

ThyssenKrupp

Gyratory Crushers by ThyssenKrupp Frdertechnik: because its the perfected design that does the job

ThyssenKrupp Frdertechnik are 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 in the background Gyratory Crusher KB 160-290 on a semi-mobile crushing plant for copper ore. Capacity: 9,600 t/h

2 Gyratory Crusher KB 137-190 on a semi-mobile crushing plant in a copper ore mine. Capacity: 4,600 t/h

3 Gyratory Crusher KB 137-190 in a crushing plant for limestone. Capacity: 2,000 t/h 2 3

Fields of application and design characteristics

The design of the gyratory crushers and jaw type 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 state-of-the-art. They are designed for high performances at low operating and maintenance costs.

Fields of application

Natural stone industry Ore mines Lime and cement works Coal preparation plants
Design characteristics

low power requirement change of stroke possible through adjustment of

eccentricity

robust construction possibility of direct feed no idle strokes due continuous crushingto high throughput rates optimum crushing ratio low fines content in the crushed material (if required)
4 Gyratory crusher 5 Jaw type gyratory crusher

start under load possible different available drive systems hydraulic main adjustment andshaft overload
protection low operating and maintenance costs.

Gyratory Crusher

Working principle The main shaft (B) of the crusher is radially guided in the rolling contact bushing in the upper main shaft bearing (A) and in the inner eccentric bushing in the lower eccentric bearing (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 in the eccentric bearing (G). This rotating eccentric bushing is responsible for generating the wobbling motion of the main shaft (B) this wobbling motion is characteristic of cone crushers. Consequently, the crushing gap between the stationary concaves in the crusher housing and the wobbling crushing cone 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). v
A

B C

v v v v

C D

v v

E F G H I J

v v v v v
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The crushing gap is adjusted by hydraulically lifting or lowering the main shaft. This hydraulic main shaft adjustment is particularly used with abrasive feed material and frequent corrections of gap setting. It also serves as overload protection when uncrushable foreign matter finds its way into the crushing chamber. Easy restart under load due to hydraulic main shaft lifting and lowering. Main shaft jumping under adverse crushing conditions is avoided by a pressurized hydraulic system ensuring permanent contact of the individual thrust bearing discs.

Construction
A upper main shaft bearing assembly with two-armed spider ensures a spacious feed opening, automatic grease lubrication with electronic and visual level control B main shaft C crushing tools made of highly wear-resistant material D cast-steel shell sections, weight-optimised by means of FEA calculations E dust seal requiring minimum maintenance, highly efficient due to compressed air 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 unbalances H transmission gear with pivotally arranged bushing for setting the tooth clearance, safe lubrication due to hermetically sealed stationary lubrication, electrical and visual oil level and temperature control I bevel gear and -pinion with Zyklo-Paloid toothing ensures smooth running J lower thrust bearing of main shaft K hydraulic cylinder for convenient main shaft adjustment under load and overload protection in case of uncrushable foreign matter being fed to the crusher

6 Conversion of gyratory crushers with mechanical main shaft adjustment in the upper main shaft bearing (on the right) into crushers with hydraulic main shaft adjustment (on the left) 7 Semi-mobile crushing plant with gyratory crusher fed by an apron feeder

Technical Data

Gyratory crusher type [cm] KB KB KB KB KB KB 87-170 105-190 137-190 152-230 152-280 160-290 [inch] 35- 67 42- 75 54- 75 60- 89 60-110 63-114

Diam. Speed of of feed eccentric opening bushing [mm] [1/min] 2,710 3,150 3,640 4,080 4,800 4,650 145 134 134 125 125 127

Max. motor rating [kW] 315 400 600 600 900 1,100

Max. stroke [mm] 38 41 41 45 50 50

Weight
KB hydraulic KB mechanical Spider

(incl. crushing tools and wear parts)

Heaviest shell Bottom shell Main shaft assembly Eccentric bushing with bottom Hydraulic cylinder

[kg] 122,000 185,000 208,900 365,000 575,000 562,885

[kg] 118,000 173,900 194,000 351,000 552,400

[kg] 19,000 31,000 33,150 58,700 81,000 94,9001)

[kg]

[kg]

[kg]

[kg]

[kg] 5,200 9,500 9,500 18,000 30,500 26,470

26,000 28,000 26,600 37,500 26,500 41,500 42,000 34,330 40,000 74,000 57,800 77,000 102,000 112,000 121,000 79,3901) 122,5001) 122,000

5,100 8,400 8,400 12,000 18,800 15,700

Gyratory crusher type [cm] KB KB KB KB KB KB 87-170 105-190 137-190 152-230 152-280 160-290 [inch] 35- 67 42- 75 54- 75 60- 89 60-110 63-114

80 Min. Max. 660 1,424

100 Min. Max. 833 1,424

Capacity [t/h] at open side setting [mm] and bulk density 1.6 kg/m3 2) 175 200 225 150 125 Min. Max. Min. Max. Min. Max. 3,116 3,472 3,119 4,303 Min. Max. 1,857 1,684 2,301 3,112 3,224 Min. Max.

250 Min. Max.

300 Min. Max.

1,041 2,225 1,249 2,671 1,458 1,160 2,480 1,392 2,976 1,624 1,052 2,250 1,255 2,684 1,459 1,726 3,689 2,013

3,968 3,599 4,918 3,589 5,533 6,652 3,501 7,484 3,890 8,316 4,669 9,979 6,890 3,626 7,751 4,029 8,613 4,835 10,335
1) Divided construction 2) Min. values apply to hard tough feed material with a fines content of less than 20 %, max. values apply to hard feed material with a fines content of at least 70 %. 3) Minimum clearance for maintenance

The model designation is made up of the feed opening and the cone diameter indicated in centimetres. The maximum feed size should not exceed 80 % of the feed opening. The portion of crushed material smaller than the open side setting is 70-90 % at the most, dependent on the feed material.

Installation drawing with mating dimensions on request.

C O

L2 M

A D E

R
The stated values are only approximate. The guiding values depend on the crushing duty (characteristics of feed material, product requirements) und the crusher configuration. In case of need, throughput rates are determined for the specified crushing duty.

L1 M I

K J
H Construction with cylinder

To keep pace with technical progress, we reserve the right to make improvements without prior notice.

Gyratory crusher type [cm] KB KB KB KB KB KB 87-170 105-190 137-190 152-230 152-280 160-290 [inch] 35- 67 42- 75 54- 75 60- 89 60-110 63-114

A B C D E
3,660 3,930 4,475 5,600 6,020 6,240 3,850 4,410 4,600 5,530 6,030 6,450 1,250 1,630 1,572 1,840 2,260 2,273 2,045 2,475 2,385 2,700 3,190 3,225

3)

F G H I
2,800 3,400 3,400 4,000 4,600 5,000

3)

J K L1 L2 M O P R S
1,475 1,750 1,745 2,080 2,450 2,335 20 20 20 20 20 105 3,300 3,900 3,900 4,500 5,300 5,800 3,300 3,900 3,900 4,500 5,300 5,500 2,700 3,000 3,000 3,600 4,300 4,500 5,330 6,050 6,215 7,800 8,750 8,635 1,400 1,460 1,460 1,880 2,000 2,100 720 1,650 880 2,000 880 2,650 900 3,150 3,400 1,100 3,160 1,050

[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] 1,150 753 1,700 1,350 900 2,000 1,350 900 2,090 1,550 980 2,400 1,800 1,130 2,800 2,000 2,680 2,000 2,320 2,320 2,400 2,850

Jaw Type Gyratory Crusher

Working principle Special feature of the jaw type 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. Secondary 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 type gyratory crushers are designed to handle even bigger feed lumps than the comparable size of the gyratory crusher with the same cone diameter.

Feed opening Primary crushing zone

Crushing chamber

8 Jaw type gyratory crusher 9 Jaw typ gyratory crusher BK 160-210 in a dolomite quarry. Capacity: 1,200 t/h 10 Jaw typ gyratory crusher BK 160-190 on a semi-mobile crushing plant for crushing overburden in a lignite mine. Capacity: 500 t/h 10

Technical Data

Diam. Speed of Jaw type of feed eccentric gyratory crusher opening bushing type [cm] [inch] [mm] [1/min] BK BK BK BK BK BK 100-125 120-150 135-170 135-190 160-190 160-210 40-49 48-59 54-67 54-75 63-75 63-83 2,000 2,100 2,640 2,640 3,080 3,300 136 136 136 136 137 115

Max. motor rating [kW] 160 200 250 315 650 400

Max. stroke [mm] 23 25 27 29 42 34

Weight
BK hydraulic (without auxiliary drive) BK mechanical (with auxiliary drive)

(incl. crushing tools and wear parts)

Spider Heaviest shell Bottom shell Main shaft assembly Eccentric bushing with bottom Hydraulic cylinder

[kg]

[kg]

[kg] 13,500 18,600 25,000 25,000 46,090 13,400

[kg] 11,200 14,200 15,700 15,700 44,710 21,700

[kg] 9,000 16,000 21,500 24,600 39,756 41,400

[kg] 14,000 18,900 26,500 29,500 43,200 50,000

[kg]

[kg] 9,500

193,000

56,000 80,000 116,500 123,000 184,000

2,700 3,500 4,100 4,800 8,500 5,300

Jaw type gyratory crusher type [cm] [inch] BK BK BK BK BK BK 100-125 120-150 135-170 135-190 160-190 160-210 40-49 48-59 54-67 54-75 63-75 63-83

80 Min. Max. 287 363 595 775

100

Capacity [t/h] at open side setting [mm] and bulk density 1.6 kg/m3 1) 150 175 200 125 Min. Max. 435 567 694 833 1,215 913 929 1,212 1,483 1,780 2,597 1,951 Min. Max. 522 680 833 1,000 1,458 1,095 1,115 1,454 1,780 2,136 3,117 2,341 Min. Max. 608 794 971 1,166 1,701 1,278 1,301 1,696 2,076 2,493 3,636 2,731 Min. Max. 1,333 2,849 1,944 4,156 1,460 3,121

225 Min. Max. 1,643 3,511

Min. Max. 348 454 555 666 972 730 743 969 1,186 1,424 2,078 1,561

The model designation is made up of the feed opening and the cone diameter indicated in centimetres. The maximum feed size should not exceed 80 % of the feed opening. The portion of crushed material smaller than the open side setting is 70-90 % at the most, dependent on the feed material.

Installation drawing with mating dimensions on request.

1) Min. values apply to hard tough feed material with a fines content of less than 20 %, max. values apply to hard feed material with a fines content of at least 70 %. 2) Minimum clearance for maintenance

L M U R N O

A P F I K

E J
H
Construction with cylinder

The stated values are only approximate. The guiding values depend on the crushing duty (characteristics of feed material, product requirements) und the crusher configuration. In case of need, throughput rates are determined for the specified crushing duty. To keep pace with technical progress, we reserve the right to make improvements without prior notice.

V T

2) 2) Jaw type gyratory crusher type [cm] [inch] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]

A B C D E F G H I
2,500 2,800 3,400 3,400 4,400 4,200 1,810 1,780 1,982 1,982 2,400 2,205 1,739 1,985 2,100 2,192 2,592 2,765

J K L M P Q R S T U V W
780 780 900 900 880 980 1,620 1,880 2,150 2,150 2,640 2,350 2,620 2,920 3,460 3,460 4,100 4,000 1,000 1,200 1,350 1,350 1,675 1,600

BK BK BK BK BK BK

100-125 120-150 135-170 135-190 160-190 160-210

40-49 48-59 54-67 54-75 63-75 63-83

3,200 3,600 4,295 4,295 4,525 4,730

850 895 1,440 1,970 1,650 150 2,500 2,250 900 370 2,000 900 1,000 1,600 2,270 2,030 250 2,700 2,400 1,200 390 2,100 1,030 635 1,670 2,700 2,050 5 3,100 2,500 1,485 380 2,640 1,100 708 1,730 2,900 2,200 5 3,400 3,100 1,485 380 2,640 2,300 2,100 3,400 1,855 20 3,900 3,000 1,425 505 3,080 1,450 920 1,850 3,080 2,600 20 3,600 2,800 1,500 210 3,300

5,450 6,000 6,450 6,510 7,115 7,300

Crusher Drives

Nowadays, gyratory crushers are usually driven directly by a multiple-disk steel clutch with intermediate shaft and a safety coupling. The multiple-disk steel clutch compensates axial, angular and radial deviations between motor- and transmission gear shaft, while the 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. Compared with the V-belt drive, the direct drive reduces the loads of motor and transmission gear considerably.

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11 Gyratory crusher with multiple-disk steel clutch with intermediate shaft and safety coupling 12 Gyratory crusher with gear and hydraulic coupling 13 Auxiliary drive with squirrel cage motor and hydraulic coupling 12 13

Lubrication Systems of Gyratory Crushers

C A B

v vv

Circulating lubrication of the lower bearing of the main shaft (consisting of eccentric bearing and thrust bearing) and the bevel gear pair.

Lubrication of the upper main shaft bearing by separate motor pump unit.

Hermetically sealed stationary lubrication of the antifriction bearings of the transmission gear. v v
Circulating lubrication system, return flow

Circulating lubrication of A bushing

Circulating lubrication thrust bearing, eccentric bushing and slide ring of the eccentric bushing B

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Examples of Crushing Plants with Gyratory Crushers

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

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15

14 Primary crushing plant with gyratory crusher KB 137-190. The crusher is directly fed from two sides by means of 45-ton dump trucks. Capacity: 1,000 t/h 15 Gyratory crusher BK 135-170 in a limestone crushing plant. The crusher is fed via reciprocating plate feeder and scalping screen. Capacity: 600 t/h 16 Two semi-mobile crushing plants equipped with gyratory crushers KB 137-190 being fed by 85-ton dump trucks via apron feeder. Capacity: 2,000 t/h each 16

Research, Development and Services

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ThyssenKrupp Frdertechnik are attaching great importance to research and development. Committed employees, experience and the ability to tread new paths together with the innovative power, flexibility and know-how are the foundation on which the successful cooperation with our customers is built. 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 thereon 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 onsite 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 Inspectionemergency Stand-by services Repair services on site

17 Crushing tools of gyratory crushers usually have smooth surfaces (mantle and concave).Toothed crushing tools are the alternative where the cubical portion in the product and/or the crushing effect have to be increased. 18 Equipment for material analysis 19 Weight-optimised housing by means of finite element analysis 20 A trained maintenance staff assembling a main shaft with mantle

in the workshop of the service centre Diagnostic systems Maintenance contracts Spare parts services.

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ThyssenKrupp Frdertechnik Partners of the mineral processing industry

Delivery program
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

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

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 Systems Systems for power plants Coal preparation systems Engineering Modernization, Refurbishment After-sales service Training

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

ThyssenKrupp Frdertechnik GmbH Processing Schleebergstrae 12 D-59320 Ennigerloh (Germany) Tel.: +49 (25 24) 30 - 0 Fax: +49 (25 24) 22 52 E-mail: info.tkfen@thyssenkrupp.com http: //www.tk-processing.com

Technical details subject to changed. Printed in Germany. Kreiselbrecher 03 D 10.09