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46 CoalCrusher PDF
46 CoalCrusher PDF
The preparation of ROM coal commences the moment it is received from the mine. The Rotary Coal Breaker crushes and breaks
the coal and removes the majority of the rock contamination.
The sized coal from the Rotary Breaker can then be fed into a Rolling Ring Crusher which produces a finer product.
For more specific and smaller sizing of the coal, the Double Roll Crusher is generally the preferred machine, particularly for
processing the sizes required by power stations and for the export market where tight specifications are required.
Serving the South African coal market for more than 80 years, Osborn’s Coal Crushers have proven to be extremely reliable and
have gained popularity as far afield as Australia, Turkey and neighbouring African countries, such as Zambia, Zimbabwe, Botswana
and Mozambique.
Uncrushable objects in the feed A segmented drive sprocket bolted to the machined end Special wide faced trunnion rollers support the breaker
are passed through an outlet disc. drum. Rollers are housed in self-aligning spherical roller
scoop into a collecting bin. bearings.
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Mineral Sizers/Roll Sizers for Primary/Secondary
and Tertiary Applications
Osborn’s range of Single Shaft and Twin Shaft Roll Sizers are of a heavy duty low profile design capable of handling high
tonnage throughputs using minimal installed primary power.
The Roll Sizer can be configured to operate in two ways depending on the material output size required. These being either through the centre
(Centre Sizers) or down the side (Side Sizers). All Osborn Sizers are designed to operate with a single drive or a twin drive.
Osborn’s Roll Sizers are ideally suited for static, semi mobile and mobile installations. The overall weight and compact design with all the crushing
forces kept within the actual body of the sizer allows for a more cost effective design without any major foundations.
Mineral Sizer
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Mineral Sizers – Range of Models
Osborn’s range of Mineral Sizers start at our 550 model through to a 1650 model. Model sizes are determined by the
centre distance in mm between the main rotors.
The working area length can vary between 1- 4 meters depending on capacity required (working throat). This is in 500 mm sections.
The success of the crushing action is very dependent upon the tooth configuration with the size and shape of the teeth specifically
selected for each Mineral Sizer application. The teeth are designed to be locked into machined recesses on the shaft that ensures easy
replacement of the teeth caps without the need to remove the entire rotor assembly.
Heavy duty clamps hold the teeth in place on the rotor and each row of teeth is torqued through tensioning bolts which are located
outside of the feed stream.
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Construction features of Osborn Mineral Sizers
Main frame
• Fabricated from carbon
steel. Shaft Assemblies
• End plates are machined
from solid plate and • Rotor shafts and drive
horizontally split along gears are machined
the rotor shaft centre line. from high carbon steel.
• Side frames are fully welded, of ribbed construction and • Shaft bearings are of the
machined to size, spigotted and bolted to form a highly spherical roller type.
robust assembly capable of containing any dynamic forces • Bearings and cartridges are retained on each end of the
created whilst the machines is in operation. shaft by large locking nuts so that all the thrust on the
teeth and shafts is contained inside the shaft and not
transferred onto the bearings.
Wear plates
• Osborn mineral sizers
are fitted with wear plates
completely covering the Modular Reduction Gear Box and Drive
inside of the body and Pinions and gears are machined, carburised and ground
sizing chamber. from high tensile steel. All bearings are spherical roller type.
• The wear plates are made from high wear steel and are Gearbox selection is sized to include a high safety factor.
bolted to the sizer to allow ease of replacement.
Sizing Teeth
Osborn provides a range
of sizing teeth suitable for
different applications. Type
and fitment thereof varies
accordingly.
Lubrication
• All gears in the Osborn sizer are lubricated through an oil bath.
• The reservoir is fitted with an oil level sight glass, magnetic drain plug and oil sampling point.
Drive Details
• A TEFC electric motor drives through a fluid coupling which is fitted with an inspection cover for maintenance of the coupling.
A reduction gearbox is bolted to the transfer box which is also fitted with inspection covers. The final drive is via a spur gear which
is housed in the transfer box.
• All rotor drive gears (in & output) in the transfer box are spline coupled onto their mating shafts for ease of maintenance,
replacement if necessary and timing adjustments. The reason for timing adjustment, is for rotor self-cleaning purposes.
• Also different rotorshaft ratios can be obtained by fitting different spur gears other than the 1:1 ratio.
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The Osborn Mineral Sizer has counter rotating rolls,
driven by the electric motor prime mover through
a fluid coupling and connected to a heavy duty
gearbox.
Breaker bar
support
Shaft Centres
Cleaning Combs
Non-Drive End
Wear Plate
Working Area
Fluid Coupling
Supported Area
Side Frame
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Rolling Ring Crushers
This Rolling Ring Crusher “hammermill” design has the capability to reduce a coal feed size of 500 mm to 25 mm in one
pass. Capacities are in excess of 2 000 tph dependent 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
3 6 1
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Pivoted arrangement for ease of access is an Breaker plate, screen plates and rotor assembly.
optional extra on all machines.
Hand wheel (and gearbox on
large machines) for drop cage
adjustment.
Access door for shredder ring change and Breaker plate adjustment screws
metal trap clean out. on both sides.
MODEL A B C D E
Heavy duty bearing and plummer WS 16 BG 667 508 1346 1525 965
WS 28 BG 667 787 1346 1805 965
blocks for rotor shaft.
WS 46 BG 667 1219 1346 2237 965
WS 70 BG 667 1829 1346 2846 965
AC 3B BG 667 1232 1632 2470 1168
AC 3D BG 667 1537 1632 2775 1168
AC 3F BG 667 1842 1632 3080 1168
AC 7C BG 864 1842 2038 3131 1473
AC 7D BG 864 1994 2038 3283 1473
AC 7F BG 864 2299 2038 3588 1473
AC 7J BG 864 2756 2038 4045 1473
AC 57G BG 1219 2959 2571 4394 2032
AC 72H BG 1372 2819 2931 4458 2337
AC 72J BG 1372 3105 2931 4743 2337
Access for inspection of drop cage and NOTE
screen plates. Dimensions shown are approximate only and should not be used for plant layout.
A
D
B
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Double Roll Crusher
Osborn Double Roll Crushers can be used for primary and secondary crushing. The Double Roll Crusher is generally regarded as a 4:1 feed to
product ratio crusher, however in some instances, dependent 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 and this
ensures a uniform product size distribution.
For strict coal product specifications the Osborn Double Roll Crusher is preferred. It is important to understand the material characteristics, as
the type of coal will often vary considerably. Hardness, rock content, friability and moisture content are the major factors that need to be identified,
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 increase the life of the crusher segments. When the correct crushing ratio is used and
the optimum roll diameters selected, the segments will grip the feed material more efficiently and it will also not allow pieces to roll on top of the
segments due to the incorrect nip angle, this assists in reducing wear.
The rolls are separately driven by two identical motors, through sets of vee belts which are connected between the gearbox pulley and the flywheels.
The drive arrangement is free standing with the electric motors mounted on adjustable base plates.
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Frame and Canopy
Fabricated channel beams serve as the main frame support. For ease of adjustment, machined low friction polymer pads are provided. Inspection
doors are provided at the roll ends on the non-drive side as well as on the crusher ends. Flanges are provided on the top for connecting a feed
chute.
Crusher Model
A B C D
Dia x Width mm
Release Mechanism
Uncrushable material entering the rolls will load the springs causing them to compress and allow the passing of the non crushable objects.
Compression springs are fitted at one end and act on the bearing housings of one roll. Spring adjustment bolts and shim plates are fitted for
adjusting the roll position. Hydraulic roll adjustment and force relief cylinders can be supplied instead of the springs as an optional extra.
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Head Office:
57 Jansen Road, Elandsfontein
PO Box 8182
Elandsfontein, 1406
Johannesburg
South Africa
E-mail: osborn@osborn.co.za
www.osborn.co.za
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any purpose other than personal use. Therefore, reproduction, modification, storage in a retrieval system or retransmission, in any form or by any means, electronic, CoalCrush/0412/Rev1
mechanical or otherwise, for reasons other than personal use, is strictly prohibited without prior written permission.