Chapter 5, Gyratory and Cone Crusher 5, INTRODUCTION Gyratory crushers were invented by Charles Brown in 1877 and developed by Gates around 1881 and was referred fo as a Gates Crusher [1]. The smaller form is described as a cone crusher, The larger crushers are normally known as primary crushers as they are designed to receive run-on-mine (ROM) rocks directly ftom the mines. The gyratory crushers crush to reduce the size by a maximum of about one-tenth its size. Usually metallurgical operations require greater size reduction, hence the prodhcts Srom the primary crushers are conveyed to secondary or cone crushers where further reduetion in size takes place, Here the maximum, duction ratio is shout 8:1. Ih some eases installation of a tertiary crusher is required were the maximum reduction is shout 10:1, The secondary crushers are ulso designed on the principle of gyratory crushing but the construction details vary Similar 10 jaw crushers, the mechanism of size reduction in gyratory erashers is primarily by the compressive action of two pieces of sleel against the rock. As the distance etween the ‘wo plates decrease continuous size reduction take place. Gyratory crushers tolerate a variety ff shapes of feed particles, including slabby rock, whick are not readily accepted in jaws crushers because ofthe shape of the feed opening. SAT Primary erusher Primary crushers aze solidly built to receive large lumps of rock dire ly from the mines and designed for large tonnage throughputs. Basically eyratory crushers consists of a fixed solid conical shell or bow! {also called concaves) and a solid cone within the bow! called a breaking head (Fig. 5.1). The breaking head is fixed to a central spindle, which is hydraulically suspended or mechanically held from a spider. The bottom end of the spindle usually rests on ‘hydraulically supported piston. The bottom end of the spindle is connected 10 a bevel and pinion arrangement with straight or spiral teeth which on rotating by a joursal moves she bottom of the shaft eccentrically. In some models, the spindle is fixed at the top and bottom, and is made to move side-ways to impart the crushing action. The entire assembly ean be visualised as scireular jaw crusher. Fig.5.1 is a typical sketch of a large gyratory cnusher used as a primary crusher to reduce the size of large pieces of rocks produced during blasting in mines, Variations in the design of the breaking head and the mantic bave been adopted by different manufacturers, Such variations are adopted from studies on stress distriputions of component parts endured during the crushing operation. Effort is also made to improve the efficiency of the mechanical movements of the eveentric shaft, Such details are best described in manufacturer's bert ‘The rule of thumb for deseribing the dimensions of primary gyratory erushers may he9 1. For sizes « 66 em, the circumference along the opening = 8 along the outer perimeter), 10 x gape (measured 2. For sizes » 66 em, the circumference along the opening ~ 63 7.5 x gape (measured long the outer perimeter) 3. The ratio of mantle diameter to prape = 1.3 —1.7:10 4. The feed size ~ 0.9 x gape (up to 2m in diameter} 5. The reduction ratio ranges from 3:1 to 101 ‘The angle of nip for large erushers varies between 21° and 24” (average about 22°) but for ceurved surfaees itis about 27” to 30° [2]. The distance of openings between the concave and the breaking head at the top and the bottom ends are usually used to describe the size of the ytatory crusher. The other modes frequently adopted are 1, Bow! diameter atthe discharge end x gape 2, Bowl diameter atthe feed end. x gape 3. Bowl circumference atthe feed end x pape 4. Maximum diameter at the head x. gape The designs of the breaking faces differ with different manufseturers.. In so doing the crusher products have different size distributions. The movement of the mantle or conical lhead that performs the erushing aetion ean be visualised in Fig. 5.2 where it can bee soem that as the feed drops down, the mantle squee7es it agains! the concave and fractures the rock. ante damater ive hydrate support Fig. 5. Sketch of « Gyratory Crusher (Crasher size is designated hy the gape and mantle diameter130 Fig. £2. Scotion of Gyratory Crusher When the mantle moves away during its eyele of gyration, the erushed rock slips down to be ‘again between the mantle and the concave on the next eyele, resulting in further size reduction. The process is repeated until the sizes of the broken rock are less than the open set tl the botiom of the crusher. ‘The sizes of commercially available gytatory crushers vary considerably, The sizes are usually designated as gape x diameter of mantle (breaking hs For a particular guide Tables 5.1-5.2 summarises the designs and other general characteristics of gyratory Crushers manufactured by difieremt manufacturers and distinguished by the lengths of their The tixed spindle gyratory crusher characterisies are inelu 1d) of referred to by gape only airement it is advisable to consult mantfaeturer's literature, AS a rough in Table 5.3, able 5.1. Design Characteristics of Long Shatl primary Gyeatory Crushers (3) Characteristics Usefil height Set range Rev minute 228 = 305 mm 173 Set range Rev.'minute 425 25 Motor rating 9 750