1-402-11144-0 - Bahia Mineracao-Appendix 3

Appendix3:TechnicalSpecification
Project:1-402-11144-1BahiaMineracao Ltda,Brazil
SectionT01: TechnicalSpecification(ShortVersion)
ThyssenKrupp SemiMobileCrushing
PlantwithPrimaryGyratoryCrusher
KB54x75
1-402-11144-0– SemiMobileCrushingPlantSMCP54x75
SectionT02: ReferenceDrawings
SectionT03: Brochures
ThyssenKruppFoerdertechnik
SectionT01: TechnicalSpecification(Short
Version)ThyssenKruppSemiMobile
CrushingPlantwithPrimaryGyratory
CrusherKB54x75

ThyssenKruppFördertechnik
BUDGET PROPOSAL FOR SEMI MOBILE PRIMARY CRUSHING PLANT SMCP 54x75
Client : BAHIA MINERACAO LTDA, Brazil
Project No. : 1-402-11144-0 Rev.: 00 Date: 25.07.2011 Page: 1
Pos Qty Description
BAHIA MINERACAO LTDA, BRAZIL
SMCP PROJECT, BRAZIL

-
APPENDIX 3
SECTION T01: TECHNICAL SPECIFICATION (SHORT
VERSION)
One (1) Semi Mobile Primary Crushing Plant with Gyratory Crusher
ThyssenKrupp model KB 54 x 75
Content
1. Process and Equipment Data

Pos Qty Description
1 Process and Equipment Data
1.1 Material and Process Data
Operating mode : Direct dump into feed hopper by trucks with

220 mt payload (payload to be confirmed!)
Feed material : ROM Iron Ore
Feed size ROM : 0 – 1,000 mm
ROM size distribution:
Feed size ROM F100 : 1,000 mm

Feed size ROM F94 : 500 mm
Nominal Capacity : 5,400 mtph
Product : 0 - 250/X mm measured on square mesh

according to ISO 2591 and ISO 3310
Specific density : 3.0 t/m³
Bulk density : 2.0 t/m³
Moisture content : T.b.a., max. 3 % assumed
Crusher work index : T.b.a., 13 kWh/t assumed
Compressive strength : max. 150 MPa
Note*): The throughput, recommended gap setting and product size is depending on
material characteristics, higher capacities are possible with higher portions of
fines in the ROM. Higher moisture may reduce the throughput.
We would welcome the receipt of more detailed basic data to revise the
performance data and to prove the equipment selection.

Pos Qty Description
1.2 Equipment Data

Semi Mobile Primary Crushing Plant with Gyratory Crusher model ThyssenKrupp
KB 54 x 75 “Direct Feed” – Data per each Plant
Crusher: Type: Gyratory
Size: KB 54 x 75
Installed Power: Max. 650 kW
Weight: 217 t (with Accessories)
Discharge Conveyor: Width: 2,4 m
Length: 47 m
Capacity: max. 6,500 t/h design
Installed Power: 350 kW
3
Feed Hopper: Life Volume: Approx. 260 m
3
Discharge Hopper: Life Volume: Approx. 260 m
Acessories: Standard Maintenance Car
Truck Ramps: Trucks: 220 mt payload (to be

confirmed!)
Optional Items: Hydraulic Crane 55t/ 7t
Hydraulic Rockbreaker, Boom 4.8 m, Arm 3.9 m
Plant Weight: Total including optional items: Approx. 1430 t
End of document
SectionT02: ReferenceDrawings
• 3315899– ExemplaryPlantLayoutSMCP
54x75
• 4470460- InstallationPlantKB54x75,
Sheet1-5
• 4415960– P&IKB54x75
• 4473148– HydraulicDiagramKB54x75
• 4415444– HydraulicUnit
Electro-Hydraulic
Jib Crane 55t/ 7t
(Optional Item)
Truck Ramp Truck Ramp

for Trucks 220 for Trucks 220
mt Capacity. mt Capacity.
Rock Breaker
(Optional Item)
Feed Hopper
approx. 260 m³
Life Capacity.
ThyssenKrupp
Primary
Gyratory
Crusher Model
KB 54 x 75,
max. 650 kW.
Height from Plant

Feed Hopper Tramp Metal Crusher Discharge Foundation Level to
approx. 260 m³ Magnet. Conveyor 2,0 m x Truck Ramp Level 21 -
Life Capacity. 47.0 m, 315 kW. 23 m depending on
Capacity of Feed
Hopper and Surge Bin.
Plant
Electric.
SectionT03:
Brochures
Mineral Processing
ThyssenKrupp
A company of
ThyssenKrupp ThyssenKrupp Fördertechnik
2 Processing technology
from ThyssenKrupp Fördertechnik:
The complete range of systems and components
for the processing industry
Processing technology from They are the core components of

ThyssenKrupp Fördertechnik - state-of-the-art installations and
for a complete range of form, along with other compo-
systems based on exemplary nents, tailored and efficient pro-
technology and state-of-the- cessing systems in stationary or
art process development. mobile units.
Whether direct at source or at High-capacity components for

the point of further handling, thermal drying of bulk materials
mineral processing is always an – from impact dryers to rotary
essential part of extraction, dryers, mills, air separators and
industrial preparation and vacuum belt filters for dewatering
refining of bulk materials. all types of suspensions –
All kinds and sizes of crushers round off the product line.
are constantly proving their
value crushing hard rock, ThyssenKrupp Fördertechnik –
limestone, ore and overburden the international name for
in open-pit mines, quarries and comprehensive know-how built
many other places. up in many years of close
For each of the manifold appli- cooperation with the customer.
cations special crusher types are
available which our engineers
have improved and adapted
step by step to their respective
duty.
Relocation of two semi-mobile crushing

plants equipped with
ThyssenKrupp Fördertechnik
gyratory crushers type 63/114,
Capacity: 7 500 t/h each
Freeport Mining / Indonesia.
Contents 3
Crusher plants _______________________________________________________________________

_ 4
Mobile crushing plants _________________________________________________________________ 5

Semi-mobile crushing plants _____________________________________________________________ 6
Stationary processing plants ________________
_______________________________________________ 7
Crushers ______________________________________________________________________________ 8
Gyratory and KUBRIA® cone crushers ______________________________________________________ 9
Single- and double-toggle jaw crushers, impact jaw crushers __________________________________ 10
Hammer crushers, hammer mills ___________________________________________________________ 11
Impact crushers ___________________________________________________________________________ 12
RollSizers, roll crushers, roll mills ____________________________________________________________ 13
Feeding, classifying and separating ______________________________________________________ 14

Screens, aqua vibrating separators, screeners _______________________________________________ 15
Wobbler feeders, reciprocating plate feeders ___________________________________________________ 16
Apron feeders, chain conveyors, vibrating feeders __________________________________________ 17
Magnetic separators ____________________________________________________________________ 18
Process technology ______________________________________________________________________ 19

Grinding plants ___________________________________________________________________________ 19
Separators, powder coolers _______________________________________________________________ 21
Dryers __________________________________________________________________________________ 22
Cyclones ______________________________________________________________________________ 23
Filter technology _______________________________________________________________________ 24

Vacuum belt filters _______________________________________________________________________ 25
Planning, consultation, engineering, modernisation, refurbishment ______________________ 26
Service, erection, spare parts _____________________________________________________________ 27
Product range _________________________________________________________________________ 28

4 Crusher plants
Mobile, semi-mobile and Up-to-date manufacturing tech-

stationary crushing plants are in niques and high-quality work-
operation all around the world. manship down to the last detail
ensure optimum operating costs
Our product range comprises due to:
both mobile crushing plants
ready-mounted on their own
• high availability,
travel gear and semi-mobile
• optimum reliability,
plants that can be moved as
• low maintenance
requirement and
piggyback load on separate
haul units.
• high wear resistance.
1
Independent of the kind of That’s the reason why the Mobile crushing plant on transverse
installation, capacities range majority of the world’s crusher crawler tracks at Saudi Cement Company,
between 200 and 10,000 t/h. Ain Dar Works, equipped with a 4
users have made the choice of A complete gravel processing and loading
TITAN double-shaft hammer crusher for
ThyssenKrupp Fördertechnik. 1 000 t/h of limestone and a final grain plant with a maximum processing and
size of 0 - 25 mm. loading capacity of 900 t/h installed at
Hülskens Liebersee GmbH & Co. KG in
2 Saxony/Germany.
Semi-mobile crushing plant on pneumatic The largest screens with double
tyres at White Industries – Piparwar in out-of-balance drive (screening area
India. Capacity: 2800 t/h of hard coal. 3 300 x 6 000 mm) are used for gravel and
sand classification. The plant comprises a
3 double-toggle jaw crusher as primary
Semi-mobile crushing plant at crusher and two Kubria® cone crushers in
HeidelbergCement AG in Germany the gravel sector. The whole plant is
equipped with a TITAN double-shaft electronically controlled right down to the
hammer crusher. print-out of individual weighbridge tickets
Capacity: 1 600 t/h of limestone. for the trucks.
1 2
3 4
Mobile crushing plants 5
It was ThyssenKrupp
Fördertechnik that pioneered
mobile crushing plants making
it possible to crush minerals
directly at the site of extraction
and synchronize to the rate of
mining advance into sizes ready
for conveyor transport.
Thanks to this development
continuous transport of the
crushed material from the
mining face to the processing
plant – and thus most economic 1
operation – can nowadays be
ensured.
1
Mobile crushing plant on pneumatic tyres
at Ulan Coal Mines Ltd. in Australia with a
double-roll crusher. 2
Capacity: 2 300 t/h of hard coal.
2
Mobile crushing plant on hydraulic 4
walking pads equipped with a gyratory Mobile crushing plant on transverse
crusher at Foster Yeoman Ltd. crawler tracks with a TITAN double-shaft
in Great Britain. hammer crusher at Saudi Cement
Capacity: 3 900 t/h of limestone. Company, Dammam – Hofuf Works in
Saudi Arabia.
3 Capacity: 500 t/h of limestone.
Mobile crushing plant on hydraulic
walking pads with a TITAN double-shaft
hammer crusher at Deuna Zement GmbH 5
belonging to Dyckerhoff Zementwerke AG, Mobile crushing plant on hydraulic
Germany. walking pads at Martin Marietta in the USA.
Capacity: 2 000 t/h of limestone. Capacity: 4 500 t/h of limestone.
3
4 5
6 Semi-mobile crushing plants
While mobile crushing plants are

built ready-mounted on their
own travel gear, semi-mobile
plants are moved from one loca-
tion to the next as piggyback
load on separate haul units.
Each crushing plant comes
ready to operate with its own
feed hopper, feed conveyor,
discharge conveyor and material
transfer belt. The size and
design of the crusher naturally
depend on the work that it is 1
intended for. Even plants with
the largest gyratory or jaw
crushers can reach availabilities
in excess of 90 % and that in
the hardest of rocks, while at
the same time cutting back the
2
inner-pit transport costs by
50 % and more.
Semi-mobile crushing plants are

always to be recommended
when they are relocated at long
intervals only. This is especially
the case in large and deep
1
open-pit mines where Semi-mobile crushing plant with single-
overburden and minerals are shaft impact crusher at Loma Negra S.A.
being extracted at several points in Argentina.
Capacity: 2 200 t/h.
simultaneously.
2
To keep piggyback loads as low Semi-mobile crushing plant equipped with
as possible, the largest semi- a gyratory crusher at Freeport Mining,
Irian Yaja in Indonesia.
mobile plants are designed in Capacity: 6 500 t/h of copper ore.
individual modules for fast and
easy movement. 3
Semi-mobile crushing plant at
Cape Portland Cement in South Africa on
3 its way to a new location. This gyratory
crusher crushes up to 1 600 t/h of
limestone to 0-200 mm.
4
Semi-mobile crushing plant equipped
with a roll crusher at Alcoa Suriname
Aluminium Co., Paranam Mine, Suriname.
Capacity: 600 t/h of bauxite.
5
with a gyratory crusher and relocatable
by crawler transporters at Kennecott
Company, Bingham Canyon Mine,
Utah, USA.
Capacity: 9 000 t/h of copper ore.
4 5
Stationary processing plants 7
ThyssenKrupp Fördertechnik That’s the reason why

builds and installs turnkey stationary plants from
processing plants from ThyssenKrupp Fördertechnik
stationary primary crusher bring a maximum of perfor-
plants via complete gravel mance and return with a
processing plants right up to minimum of maintenance and
hard rock processing plants operating costs.
with all components.
In addition to that
The planning of a completely ThyssenKrupp Fördertechnik
new plant for the aggregate, offers one of the widest ranges
cement, lime and gypsum of strong, robust and proven
industries is taken care of by machines and components, 1
long-serving specialists. such as gyratory crushers,
They lay down the required Kubria® cone crushers,
process techniques, design and hammer crushers, impact
manufacture the machinery and crushers, single- and double-
components and then install, toggle jaw crushers,
erect and commission the roll crushers, scalpers, screens,
complete plant. vibrating feeders etc.
1 5
Greenstone processing plant equipped A limestone processing plant at
with a hydraulic reciprocating plate feeder, Alfred Moeck KG in Lenningen, Germany
Turbo screens and two Kubria® cone with a capacity of 1 000 t/h.
crushers at Burgk in Germany. The plant produces mineral product sizes
of 0-56 mm using a jaw-type gyratory
2 crusher, a reciprocating plate feeder,
Gravel processing and loading plant with a screens with double out-of-balance drive,
maximum processing and loading capaci- fines screens and Kubria® cone crushers.
ty of 900 t/h installed at Hülskens
Liebersee GmbH & Co. KG in Germany.
View of a part of the processing plant with 3
screens, fluidized bed separator and
bucket wheel.
3
Stationary secondary crushing plant
equipped with an impact crusher at
Loma Negra S.A., Olavarria, Argentina.
Capacity: 900 t/h of limestone producing
a final grain size of 0-19 mm.
4
Stationary two-stage plant with double-roll
crushers at the Märker Cement Works in
Germany.
Capacity: 1 000 t/h of limestone producing
a final grain size of 0-80 mm.
4 5
8 Crushers
Each raw material to be crushed

has its own specific features.
Its nature and the desired final
shape, the size of the final
product, the expected capacity
and the cost effectiveness of the
plant all have to be borne in
mind in the selection of a
suitable crusher.
The wide range of

crushers shown on the following
pages always offers the best
possible solution for a specific
duty.
1
Single-toggle jaw crusher of the latest
construction series.
1
Gyratory and Kubria® cone crushers 9
Gyratory crushers are real 1

Jaw-type gyratory crusher type BK 160-190
state-of-the-art technology and (63”-75”) installed in a semi-mobile
have been designed for high crushing plant for the comminution of
throughputs and economical overburden in an open-pit lignite mine.
operation. They are used mainly Capacity: 500 t/h.
as primary crushers in ore 2

mines, quarries, lime and Gyratory crusher type KB 137-190 (54”-75”)
cement works. Kubria® cone installed in a semi-mobile crushing plant
working in a copper ore mine.
crushers are high-class
Capacity: 4 600 t/h.
technology for medium and fine
crushing of hard rock. 3
They achieve a high capacity, Two Kubria® cone crushers installed
in a gravel works.
reduction ratio and a cubical Capacity: approx. 60 t/h each.
final product at low operating
costs, with minimum mainte- 4
Kubria® cone crusher
nance and simple operation.
(mantle diameter 1 100 mm)
These safe and reliable crushers installed in a quartz-porphyry works.
are available with mantle Feed size: 5-32/44 mm
diameters ranging from Final grain size: 0-22 mm
Capacity: approx. 150 t/h.
700 to 2100 mm.
5
Jaw-type gyratory crusher type BK 135-170
(53”-67”) with one-side feed opening
extension for the crushing of medium-hard
material. It is designed to handle much
bigger feed lumps than comparable gyratory
crushers with the same mantle diameter.
1
2 3
4 5
10 Single- and double-toggle jaw crushers
Impact jaw crushers
Whatever the material to be 1

Single-toggle jaw crusher type EB 14-11/H
crushed – granite, basalt, Feed opening: 1 400 x 1 100 mm for the
porphyry, greenstone, gabbro, crushing of basalt.
limestone, ore, slag, carbide or Capacity: 300 -350 t/h
hard chemicals – single- and Final grain size: 0 -300 mm.
double-toggle jaw crushers from 2

ThyssenKrupp Fördertechnik Single-toggle jaw crusher type EB 20-15/H
have everything needed for high Feed opening: 2 000 x 1 500 mm for the
crushing of copper ore in Chile.
availability, reliability and
Capacity: 850 t/h
economy in operation. Final grain size: 0-300 mm.
And that with a minimum
maintenance requirement. 3
1 2 with a jaw crusher type EB 16-12
Double-toggle jaw crushers are for the crushing of 1200 t/h limestone
the specialists for highly at Wopfinger in Austria.
abrasive, extremely hard and
4
tough materials. Double-toggle jaw crusher type DB 21-16
Feed opening: 2 100 x 1 600 mm used for
Single-toggle jaw crushers are the crushing of overburden in Zaire
and iron ore in Australia.
ideally suited to hard and Capacity: 1 200 t/h
tough, but less abrasive Final grain size: 0-300 mm.
materials.
5
Double-toggle jaw crusher type DB 15-12
Impact jaw crushers only built Feed opening: 1 500 x 1 200 mm
by ThyssenKrupp Fördertechnik for the crushing of gabbro.
were particularly developed for 3
Capacity: 550 t/h
Final grain size: 0-300 mm.
the toughest applications such
as the crushing of ferrous alloys 6
and carbon anodes with casting Double-toggle jaw crusher type DB 15-12
nodules still in them. Feed opening: 1 500 x 1 200 mm
for the crushing of gangue rock.
Capacity: 400 t/h
7
Impact jaw crusher type “5 goh”
Feed opening: 800 x 630 mm
for the crushing of iron slag.
This model has an especially effective
overload protection.
Capacity: 150 t/h
4 5 Final grain size: 0-120 mm.
6 7
Hammer crushers, hammer mills 11
Crushers of Other applications are in the

ThyssenKrupp Fördertechnik selective reduction of
were developed for the crushing ore-bearing materials and in
of coarse, medium-hard raw the chemical industry for the
materials for the cement-, reduction of sulphur gravel,
gypsum- and limestone baryte, bauxite etc.
industries. They are available as
impact crushers, single-shaft Double-shaft impact crushers
hammer crushers and TITAN achieve the very high reduction
double-shaft hammer crushers. ratio of 1:100, reduce large feed
These state-of-the-art machines lumps in one process to a final
are extremely compact, robust, grain size of approx. 25 mm
efficient and easily serviced. reaching throughput rates of
They can be fed with large, up to 2000 t/h.
bulky material and produce a They are mainly used in the
clearly defined final grain size. cement-, lime- and gypsum
industries.
Impact crushers, single-shaft
hammer crushers and
TITAN double-shaft hammer
crushers achieve throughputs
of more than 2000 t/h.
The latter are particularly suited
to the comminution of wet and
sticky materials.
Hammer mills
of ThyssenKrupp Fördertechnik
were especially conceived for
the fine reduction, grinding,
homogenization, fiberizing and 1
selective crushing of natural
and industrial products.
The process can be combined
with drying.
impact crushers have been
designed to cover the whole
range from coarse to fine
reduction. They handle hard
and medium-hard material, 2
and are used especially in
those applications where a
high reduction ratio and a cubic,
stress-free final product are 1
called for. They are used to Impact crusher at work.
crush coal, potash, limestone, 2

gypsum, slag, overburden, TITAN double-shaft hammer crusher
rubble and asphalt material. at work.
3
MAMMUT single-shaft hammer crusher.
3
12 Impact crushers
MULTIROK vertical shaft impact production of high-grade

crushers are built in cooperation chippings or crushed sand
with CEMCO, USA. from hard rock such as basalt,
The vertical arrangement of the granite, diorite, andesite,
rotor makes for a compact, gravel, dolomite, clinker
low-weight unit that is ideal for and slag.
mobile operations.
MULTIROK is a low-cost
secondary crusher for the
1 2
1
MULTIROK vertical shaft impact crusher.
2
Impact crusher at work.
3
TITAN double-shaft hammer crusher.
4
BIROTOR hammer mill.
3
RollSizers, roll crushers, roll mills 13
1
Double-roll crusher
Roll diameter: 2 000 mm
Roll width: 2 000 mm
Capacity: 2 000 t/h of limestone
2
RollSizer type DRS 660 x 2000
executed as CenterSizer
for primary crushing.
3
View inside the crushing chamber
of a double-roll crusher.
Roll width: 2 000 mm.
4
Hydraulic gap adjustment and overload
protection of a double-roll crusher
for coal and overburden on a semi-mobile
crushing plant.
Roll width: 2 200 mm.
1
RollSizers and roll crushers of ThyssenKrupp Fördertechnik roll

ThyssenKrupp Fördertechnik are mills are used for the fine
specialized machines for reduction of all kinds of material
medium-strength, highly sticky – even up to corundum,
materials such as limestone, when a low content of ultra-fine
marl and contaminated clay, particles in the finished product
but also for coal, oil sands and is required.
overburden.
3 4
14 Feeding, classifying and separating
Crushing plants can only

achieve high throughput rates,
if they are combined with
reliable feeders and discharge
systems such as apron feeders,
chain conveyors, vibrating
feeders, reciprocating plate
feeders and grizzly feeders.
For the production of

high-quality products from the
crushed raw materials
offers a variety of screens.
1
1
Bulk material screen type DU-Stk 2.6x5.75
Handling capacity: 3 000 t/h
Copper ore: 0 -1 000 mm
Cutting size: 150 mm.
2
Apron feeder type RKF 2 400 x 22 600-D8.
3
Linear vibrating screen type DU 64
4.0 x 9.6 (10.5) ED
installed in a Canadian oilsand plant.
Feed material: oilsand
Feed capacity: 10 000 t/h
2 3
Screens, aqua vibrating separators, 15
screeners
Whatever the material and wher-

ever the location the specialists
of ThyssenKrupp Fördertechnik
know exactly which screen is the
most effective and most econo-
mical one for the respective
duty. Depending on the applica-
tion, the screen can have linear
or circular oscillation or can be
the eccentric-shaft type.
For the screening of fines
machines with directly excited
screen covers are offered. 1 2
1
Circular oscillating screen
type Turbo 2.0 x 6.0 (6.9) 3.5D
with 31/2 screen decks.
Feed material: greywacke
Feed capacity: 360 t/h
Cutting size: 5, 16, 40 and 65 mm.
2
Banana screen type DU 23-3.6 x 8.0 (8.9)1D
Screening capacity: 1 900 t/h
Limestone / shale: 0 -100 mm
3
Linear vibrating screen with double out-of-
balance drive in a German steelworks.
Screening surface: 3 300 x 8 000 mm
Feed material: lump ore or pellets, 0-25 mm 3 4
Feed capacity: 800 t/h.
4
Aqua vibrating separator for gravel.
5
Aqua vibrating separator type ASK 18/48
in a German gravel works.
Feed material: gravel
6
Heavy linear grizzly feeder with
double out-of-balance drive,
2 500 mm wide and 6 500 mm long
with a 2 500 mm long grizzly screen.
Loacted in Iran and Hong Kong.
Feed capacity: 2 000 t/h 5 6
7
Circular oscillating screen type
Turbo 1.3 x 3.0 (3.3) ED in a German
limestone works.
Feed material: limestone
8
Fines screening machine type Screener for
the separation of fillers from crushed sands
and also for the very difficult screening of
coke fines. Located in Germany.
Feed material: basalt
Cutting size: 0.09 mm.
7 8
16 Wobbler feeders, reciprocating plate feeders
Wobbler feeders are used to

classify difficult-to-screen
materials and achieve very high
throughputs depending on the
cutting size. Advantage:
no vibrating mass.
Reciprocating plate feeders are

used for a uniform material
draw-off from large feed
hoppers and for the feeding of
crushers.
1
Reliable state-of-the-art
components from
ThyssenKrupp Fördertechnik.
2 3
1
Reciprocating plate feeder
type 1700 x 6500 for drawing-off of 800 t/h
limestone 0-300 mm from an outside
stockpile.
2
An enclosed wobbler feeder in a German
power station for the separation of lignite at
15 mm. Each shaft is individually driven.
4
3
Wobbler feeder type SRK 450/15-2800
for the separation of limestone.
4
A hydraulically driven reciprocating plate
feeder with infinitely variable speed and
stroke adjustment.
5
Wobbler feeder for the separation
of limestone.
5
Apron feeders, chain conveyors, 17
vibrating feeders
builds heavy-duty apron feeders
being equipped with chains,
track rollers and sprockets.
They are used as feed and
discharge conveyors in crushing
plants for limestone, hard rock,
coal, ore and overburden, even
for extremely abrasive materials.
Apron feeders with conveying
distances of up to 30 m and
widths of up to 3000 mm have
been realized so far achieving
handling capacities of up to
12000 t/h.
Special designs allow inclines to
be varied from 20-25° and
allow shifting up to 3000 mm.
Bevel spur gearboxes, planetary
gears and hydraulic motors
can be installed for either
fixed-speed or infinitely variable
drives. Double drives are
installed to achieve higher
driving powers.
1
Chain conveyors in light-duty
design with capacities of up to
4000 t/h are the choice for less
abrasive materials.
Our extensive vibrating feeder

program caters for capacities
ranging between 50 and 1
For logistical reasons the semi-mobile
70000 t/h. For bin draw-off and crushing plant with a capacity of 10 000 t/h
transport of all kinds of bulk is equipped with two feed hoppers and two
material. apron feeders (2 440 x 32 630 mm each).
The plant is fed by 240 t dumpers.
2 2
Apron feeder
type RKF 2 200 x 14 800 mm - D8.
Capacity: 850 t/h
Limestone: 0-1 700 mm.
3
Variable speed vibrating feeder
800 x 3 000 mm.
Capacity: 100 t/h
Rubble: 0-800 mm.
4
Chain conveyor
type OTK 2400 x 12050 mm.
Capacity: 1 000 t/h
Limestone: 0-150 mm.
3 4
18 Magnetic separators
Magnetic separators create

strong magnetic fields to
remove ferrous metals from
bulk materials while the material
is passing over a feed or
discharge conveyor.
Fields of application range from

lignite and hard coal, ores and
minerals, foodstuffs, wood
chippings and saw dust,
mineral building material and
glass sands as well as
chemicals to recycled materials
of the building-, metallurgical-
and allied industries.
State-of-the-art drum/roller
separators and other types of
permanent magnets round off
the program.
2 3
1
One of the world’s largest overbelt magnetic
separators in a Chilean copper mine
2
Two-stage permanent magnetic roller
separator to remove contaminants from
corundum
3
Tandem magnetic drum separator for the
magnetic processing of sponge iron in an
Indian steel plant.
Process technology 19
Grinding plants
Drying – grinding – separating – They are used for the fine One main area of the use
for a variety of applications grinding of mineral raw of wet grinding systems is the
and uses. materials with an already high production of limestone
feed moisture or such mineral suspension by grinding for flue
Dry grinding systems are used raw materials which contain gas desulphurization plants
as open-circuit mills or in moist, sticky contaminations. (FGD-plants).
connection with high-efficiency Furthermore, they are used if,
separators in a closed circuit in the following process step,
and serve for the fine grinding the ground material is
of hard, brittle materials. In the processed in the form of a
case of circuit grinding, the water/solids suspension.
moisture of the material to be
ground is restricted to about Rod mills are ideal for producing
1.5 % H2O. Moistures exceeding sands by grinding gravel and for
this value cannot be dried by the preparation of ores.
the grinding heat alone.
Therefore, in these cases,
additional heat must be intro-
duced into the grinding system.
1 2
1
Two-chamber tube mill.
2
Wet grinding plant for the production of
limestone suspension for a flue gas
desulphurization plant.
3
Tube mill for wet grinding.
3
20
The core components of

grinding plants from
ThyssenKrupp Fördertechnik are
tube mills (autogenous or ball
mills), hammer mills, impact
mills and roll mills.
They can be used for either fine
or ultra-fine grinding of mineral
raw materials.
Further components of grinding

plants are air separators, bucket
elevators, belt conveyors, 1 2
air slides and pipelines as well
as the electrical equipment and
control. Cross-stream separa-
tors developed by
high-performance air separators
for classifying all types of
free-flowing and fine materials.
1
Autogenous cryolite mill in an
aluminium works.
2
Tube mill for wet grinding.
4 5
3
Combined drying and grinding plant with
heated mill.
4
UNIROTOR hammer mill.
5
BIROTOR hammer mill for combined drying
and grinding of limestone.
6
Cryolite grinding plant with impact crusher.
7
Roll mill for calcined anthracite.
6 7
Separators, powder coolers 21
plan, build and supply:
• Air separators
• Cyclone air separators
• Cage-type separators
• Static separators.
High-efficiency separators from

reach feed rates of up
to 1 200 t/h and can also be
realized in connection with
drying or cooling of the
separated material as well as in
explosion-proof versions.
Beyond the high separation Powder coolers from

efficiency, the series “QS” is ThyssenKrupp Fördertechnik are
characterized by its particular used for cooling dustlike,
economy and reliability. free-flowing materials.
As both bearings are arranged
outside the separator, they can The reasons for cooling dustlike
be replaced without dismantling materials during processing are
the rotor. multifarious. They reach from
To suit the different application chemical and mineralogical
conditions, the separators of all 1 changes to the material to be
our series are equipped with a ground at excessively high
metallic, chemical-ceramic or temperatures up to safety
ceramic (Al2O3-ceramics) wear aspects related to manual
protection. processing of hot products.
Upon request, the series “QS”

can also be supplied as modular
system.
This permits the subsequent
installation of an additional
separating air supply coil, an
additional cyclone and fan to
double the capacity of the sepa- 2
rator.
1
Cross-stream separator series “QS”.
2
Cross-stream separator.
3
Plant with two powder coolers.
3
22 Dryers
Thermal drying of bulk materials

whether fine, coarse, plastic or
sludgy calls for a special drying
system that has to be suited to
the material properties,
i.e. the consistency, moisture,
grain size, structure and
abrasiveness.
Whatever the drying task,
have a system to cope with it.
All dryers are convection 2

dryers that run in continuous
operation. They can be
complemented with ancillary
components such as hot gas
generators (gas- or oil-fired),
dedusting-, dosing- and
conveying systems.
1 3
4 5
1
Internals of a rotary dryer.
2
Rapid dryer with dedusting plant.
3
Impact dryer.
4
Double-stream rotary dryer.
5
Rapid dryer.
6
Impact dryer.
6
Cyclones 23
Here, aero- and hydro-cyclones

are distinguished.
Aero-cyclones serve for separa-
ting dustlike materials from
air-/gas-carrying media.
They offer high separation
efficiencies at low pressure loss
and are executed with a wear
protection suiting the respective
application conditions.
Hydro-cyclones are used for the

continuous classification and
concentration of suspended
particles from liquids.
Throughput rate and separating
behaviour can be varied by
changing the diameter of the
over- and underflow nozzles as
well as by changing the preset
pressure.
By the combination of individual

hydro-cyclones to cyclone
clusters, highest throughput
rates are achieved at a low 1
space requirement.
1
Pre-assembled hydro-cyclone station.
2
Hydro-cyclone connection at
feed distributor vessel.
3
Multi-cyclone station with 26 individual
cyclones each for a
vacuum belt filter plant.
4
Separating cyclone cluster of a wet
grinding plant with 3-way distributor box.
3 4
24 Filter Technology
Continuous filtration at high

throughput; maximum levels of
efficiency in filter cake washing;
low residual moisture contents –
all ensured results with
vacuum belt filters.
Our belt filters combine the

advantages of conventional
horizontal belt filters with
state-of-the-art components,
materials and control systems
to achieve efficient, reliable and
easily serviced filtering systems
at low capital outlay.
1
Vacuum belt filter with a filter area
of 2 x 51 m2.
1
Vacuum belt filters 25
Absolutely reliable vacuum

sealing permits continuous
operation at differential
pressures of up to 900 mbar.
Optimum installation flexibility to
correspond to prevailing
requirements ensures economic
operation - whether in wash
filtration or in the dewatering
of slurries.
1
Indexing filter CH (vacuum belt filter)
for solid-liquid separation of suspensions
in the chemical, food-stuffs and
environmental industries.
2
Vacuum pump with downstream process 3
water tank.
3
Vacuum pump with fitted water trap.
4
Filter tank with filtrate pump.
4
26 Planning, consultation, engineering,
modernisation, refurbishment
Research and development

are highly rating for
In the field of plant moderni-
sation and conversion
• availability
Increase of machine
by optimizing the
ThyssenKrupp Fördertechnik. ThyssenKrupp Fördertechnik operating conditions
Experienced and committed
employees, innovative power,
offers qualified planning,
consultation and execution of
• Retrofit of technical
improvements and further
flexibility and know-how are the the following measures: developments
basis of the successful
partnership with our customers.
• Upgrading and optimization
(incl. machines of other
• Adaptation of older plants
to current safety standards
manufacturers) • Automation of existing plants
Our experience results from • Refurbishment of old plants • Emission protection measures.
the permanent critical
comparison of the design- and
• Relocation of machines
and plants
dimensioning criteria with the 1
results from practical operation.
The basis
institutes and laboratories
undertake scientific and techni-
cal research, as well as practical
trials to provide the basis of the
most practical processing tech-
nique to be envisaged for the
engineering of complete plants. 2 3
Crushing, screening, Services offered by

grinding, washing, blending, ThyssenKrupp Fördertechnik
drying, filtering – from one also comprise:
single source. • Raw material analyses
ThyssenKrupp Fördertechnik. • Comminution tests
• Wear tests
The combination of theory and • Process evaluation
practice, research, development, • Planning and engineering
planning, design, manufacture, • Overall design
erection and service qualify • Component production
ThyssenKrupp Fördertechnik for • On-site planning
being your single-source • Electrical engineering 4 5
supplier of tailor-made • Erection and installation
processing plants with efficient • Commissioning
individual machines meeting
customers’ requirements and
• After-sales and spare-parts
service.
3
Upgrading from 1400 to 1 800 t/h using
a new reinforced bridge-type scraper.
ensuring highest economy.
4
1 Assembly of a new forged gear rim with
Research, engineering and material case-hardened pinions to a cement mill.
testing – from one single source.
5
2 Replacement of a shell section.
Refurbishment of a limestone crushing
plant equipped with a hammer crusher 6
from a mobile to a semi-mobile plant, with Relocation of a crushing plant with
new feed hopper and apron feeder a transport crawler.
6
Service, erection, spare parts 27
Whether they are manufactured

in own workshops or in the
factories of our many partners
worldwide tailor-made
installations can only achieve
their high quality standard,
which is typical of
ThyssenKrupp Fördertechnik, by
an adequate quality assurance.
ThyssenKrupp Fördertechnik’s
highly qualified production and
quality assurance staff make
sure of this all around the world. 1 2 3
Both complete plants and indivi-

dual machines as well as other
products are installed and
commissioned by our experts. Wear and spare parts meeting
Same applies to state-of-the-art the ThyssenKrupp Fördertechnik
hydraulic and control systems. quality standards and regular
inspections by our specialists
ThyssenKrupp Fördertechnik ensure optimum availability of
provides fully qualified staff for your machines and components
the supervision and coordination at any time.
of erection, commissioning and 4 5
repair work carried out by the
customer’s staff or external
personnel.
6 7 8
4
Assembly of a stationary crushing plant
equipped with a TITAN double-shaft
hammer crusher and an apron feeder.
1
A phone call is all it takes to get immedia- 5 8
te assistance. Assembly of an intermediate gear of Simultaneous assembly
a gyratory crusher. of 4 vacuum belt filters.
2
Assembly of a grinding plant. 6 9
Wear parts store. Whether direct personal collection or
3 worldwide airfreight – we give our
Assembly of a semi-mobile crushing plant 7 customers the fastest possible and most
before sea transport. Spare parts store. economical method of delivery.
9
Partners of the
mineral processing industry
Product range
Crushing technology Grinding technology
• Stationary, semi-mobile and • Ball mills
mobile crushing plants • Rod tube mills
• Gyratory crushers • Hammer mills
• KUBRIA® cone crushers • Roll mills
• Double-toggle jaw crushers • Separating systems
• Single-toggle jaw crushers • Water injection systems
• MAMMUT® single-shaft hammer crushers
Feeding and conveying systems
• TITAN® double-shaft hammer crushers
• Apron feeders
• Impact crushers
• Chain conveyors
•RollSizers
Roll crushers
• Reciprocating plate feeders
• • Vibrating screens
•SIEBRA swivel-arm crushers
®
• Wobbler feeders
Screening technology
Filtering- and drying technology
• Linear vibrating screens
• Magnetic separators
• Circular vibrating screens
• Dryers
• Elliptical vibrating screens
• Vacuum belt filters
• Eccentric vibrating screens
• Separating cyclones
• FineScreeners
• Hydro-cyclones
• Grizzly screens
• Cyclone clusters
• Screen troughs
• Disc filters
• Unbalance-type gears
Systems
• Systems for power plants
• Coal preparation systems
Engineering
Modernization, Refurbishment
After-sales service
Training
Technical details subject to changed. Printed in Germany.
ThyssenKrupp Fördertechnik GmbH

Mineral Processing 01 GB 11.04
Processing
Schleebergstraße 12
D-59320 Ennigerloh (Germany)
Tel.: +49 (25 24) 30 - 0
Fax: +49 (25 24) 22 52
E-mail: info@tkt-tkf.ThyssenKrupp.com
http: //www.eprocessingplants.com
Gyratory Crushers
ThyssenKrupp
A company of
ThyssenKrupp
Technologies
2 Gyratory Crushers by ThyssenKrupp Fördertechnik:
because it’s the perfected design that does the job

one of the world’s 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 –
always offer complete solutions
often found in cooperation with
the customer.
Reliable, safe, profitable,

innovative…
ThyssenKrupp Fördertechnik.
1
Gyratory Crusher KB 54-75 in a semi-
mobile crushing plant in a copper ore
mine.
Capacity: 4,600 t/h
2
Gyratory Crusher KB 54-75 in a limestone
crushing plant.
Capacity: 2,000 t/h
1 2
Fields of application 3
and design characteristics
The design of the gyratory crus-

hers and jaw gyratory crushers is
based on more than one hundred
years of experience of
ThyssenKrupp Fördertechnik in
the manufacture of these machi-
nes.
Changing mining and processing

methods demand (besides new
materials and design methods) a
continual development of the
products. ThyssenKrupp gyratory
crushers represent today’s state-
of-the-art. They are designed for
high performances at low opera-
ting and maintenance costs.
Fields of application
• Natural stone industry

• Ore mines
• Lime and cement works
• Coal preparation plants
Design characteristics
•Bevel gear with cyclo-palloid •Low fines content in the

toothing crushed material (if required)
•Drive motors with higher •Low power requirement
ratings upon request
•Change of stroke through
•Robust construction adjustment of eccentricity
•Possibility of direct feed •Start under load possible
(in an emergency)
•continuous
No idle strokes due to
•available
Different drive systems
crushing
•High throughput rates •adjustment
Hydraulic main shaft
•Optimum crushing ratio and overload
protection
3 • Low operating and
Gyratory crusher, basic scheme maintenance costs.
4
Jaw gyratory crusher, basic scheme
3 4
4 Gyratory Crusher
Working principle
The main shaft (B) of the

crusher is radially guided in the A
▲
rolling contact bushing in the
upper main shaft bearing (A)
and in the inner eccentric B
▲
bushing in the lower eccentric C
▲
bearing (G). The thrust bearing
C
▲
assembly (J) arranged on the
D
▲
piston of the hydraulic cylinder
(K) ensures the axial support of
the main shaft.
The rotation of the drive motor is E
▲
transmitted via the transmission F
▲
gear (H) to the eccentric bushing
in the eccentric bearing (G). The crushing gap is adjusted by H
▲
I
▲
▲
This rotating eccentric bushing hydraulically lifting or lowering G
J
▲
is responsible for generating the the main shaft.
wobbling motion of the main K
▲
shaft (B) – this wobbling motion This hydraulic main shaft 5
is characteristic of cone adjustment is particularly used
crushers. with abrasive feed material and Design
frequent corrections of gap
A upper main shaft bearing assembly with two-armed spider ensures a spacious feed
Consequently, the crushing gap setting.
opening, automatic grease lubrication with electronic and visual level control
between the stationary concaves B main shaft
in the crusher housing and the It also serves as overload
C crushing tools made of highly wear-resistant material
wobbling crushing cone changes protection when uncrushable
D cast-steel shell sections, weight-optimized by means of FEA calculations
continuously. foreign matter finds its way into
E low-maintenance dust seal, highly efficient due to compressed air
the crushing chamber.
F large discharge openings owing to three-armed bottom shell
The feed material that enters the
G eccentric bearing assembly with replaceable inner eccentric bushing for stroke
crushing chamber from the top Easy restart under load in an adjustment, integrated counterweight to minimize unbalances
is continuously crushed between emergency due to hydraulic main
H transmission gear including a device for setting the tooth clearance, safe lubrication
the crushing tools (C) as it shaft lifting and lowering. due to hermetically sealed stationary lubrication, electronic and visual oil level and
falls by gravitation until it exits temperature control
Main shaft “jumping” under optionally: vibration control
the crushing chamber at the
bottom (F). adverse crushing conditions is I bevel gear and -pinion with cyclo-palloid toothing ensures smooth running
avoided by a pressurized J lower thrust bearing of the main shaft

hydraulic system ensuring K hydraulic cylinder for convenient main shaft adjustment under load and overload
permanent contact of the protection in case of uncrushable foreign matter being fed to the crusher
individual thrust bearing discs.
The use of a bevel gear set with

cyclo-palloid toothing allows the
installation of drive motors with
higher ratings, if required.
6
Gyratory crusher KB 63-114
Schematic representation.
Installed in a copper ore mine in Indonesia
6
Technical Data 5
Gyratory crusher Speed of Max. motor Weight (crusher weight excluding the crusher environment)1)
type eccentric rating Total weight Spider Heaviest Bottom shell Main shaft Eccentric bush- Hydraulic
bushing of crusher shell assembly ing with bottom cylinder
[Inch] [1/min] [kW] [kg] [kg] [kg] [kg] [kg] [kg] [kg]
KB 36- 67 145 315 118,000 19,000 33,000 27,000 27,000 5,500 5,500
KB 54- 75 137 650 204,500 30,500 31,500 43,500 42,000 9,000 8,000
KB 63- 75 137 650 263,000 38,000 65,500 43,500 50,000 9,500 8,000
KB 63- 89 130 800 355,000 67,000 69,000 75,000 71,000 12,000 14,000
KB 63-114 127 1,100 553,055 94,9004) 80,0004) 126,0004) 123,900 15,700 24,000
Gyratory crusher Capacity [t/h] at open side setting [mm] 3) and bulk density 1,600 kg/m3
type 80 100 125 150 175 200 225 250 300
[Zoll] Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.2)
KB 36- 67 – – 694 1,472 882 1,865 1,074 2,468 – – – – – – – – – –
KB 54- 75 – – – – 963 2,043 1,173 2,684 1,386 3,119 1,606 3,590 – – – – – –
KB 63- 75 – – – – – – 1,227 3,016 1,451 3,537 1,680 4,064 1,913 4,605 – – – –
KB 63- 89 – – – – – – 1,480 3,850 1,650 4,375 1,850 5,043 2,107 5,496 – – – –
KB 63-114 – – – – – – – – 1,950 5,576 2,245 6,269 2,547 6,983 2,853 7,703 – –
1) Average component weights

incl. internal fittings; safety factors for
The model designation is made up of the feed opening width and the cone diameter indicated in inch.
dimensioning of lifting equipment have
The maximum feed size should not exceed 80 % of the feed opening width.
not been considered.
Installation drawing with mating dimensions and loads on request.
2) Min. values apply to hard, tough feed
ØB material with a low fines content and
a small stroke.
Max. values apply to hard feed material
C F with a high fines content and a great
stroke.
3) Usual gap widths,
depending on feed material properties
and machine configuration.
4) Divided construction.
Discharge opening Supporting surfaces
A G
The stated values are only approximate.

They depend on the crushing duty
ØH I J1 (characteristics of feed material,
product requirements) and the crusher
configuration.
D In case of need, throughput rates are
Drawn displaced by 120° determined for the specified crushing
duty.
I
End of motor shaft To keep pace with technical progress,
J2 E we reserve the right to make improvements
to the individual machines without prior
notice.
Gyratory crusher
type A B C D E F G H I J1 J2
[Zoll] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
KB 35- 67 3,755 3,400 1,382 1,600 4,355 5,700 3,500 2,670 2,500 3,100 3,100
KB 54- 75 4,500 4,600 1,605 1,855 4,484 6,295 4,300 3,338 3,000 3,900 3,900
KB 63- 75 4,985 5,750 1,835 1,855 4,484 6,930 5,235 3,338 3,000 3,900 3,900
KB 63- 89 4,985 6,020 2,035 2,100 5,140 6,930 5,235 3,608 3,270 4,170 4,170
KB 63-114 6,240 6,450 2,273 2,485 6,018 8,725 6,040 4,880 4,500 5,500 5,800
6 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. Feed opening
▲
Further crushing of the roughly

Primary crushing zone
▲
pre-crushed material takes place

Ring-shaped crushing chamber
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 cone

diameter.
Jaw gyratory crushers have
higher crushing ratios and a low
tendency of getting clogged in
the feed area as a result of
bridging. 7
7
Jaw gyratory crusher
8
Jaw gyratory crusher BK 63-75
in a dolomite quarry
Capacity: 1,200 t/h
9
on a semi-mobile crushing plant for
crushing overburden in a lignite mine
Capacity: 500 t/h
9
Technical Data 7
Jaw gyratory crusher Speed of Max. Weight (crusher weight excluding the crusher environment)1)
Type eccentric motor Total weight of jaw Spider Heaviest Bottom Main shaft Eccentric bush- Hydraulic
bushing rating gyratory crusher shell shell assembly ing with bottom cylinder
[inch] [1/min] [kW] [kg] [kg] [kg] [kg] [kg] [kg] [kg]
BK 54-67 137 250 122,000 27,000 19,000 27,000 28,000 5,500 5,500
BK 63-75 137 650 205,000 47,000 45,500 43,500 45,000 9,000 8,000
Jaw gyratory crusher Capacity [t/h] at open side setting [mm] 3) and bulk density 1,600 kg/m3
Type 80 100 125 150 175 200 225 250 300
[inch] Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.2)
BK 54-67 – – 551 1,169 700 1,482 852 1 961 1 008 2 321 – – – – – – – –
BK 63-75 – – – – 820 1 735 997 2 292 1 178 2 711 1 365 3 142 – – – – – –
1) Average component weights incl.

internal fittings; safety factors for
The model designation is made up of the feed opening width and the cone diameter indicated in inch. dimensioning of lifting equipment have
The maximum feed size should not exceed 80 % of the feed opening width. not been considered.
Installation drawing with mating dimensions and loads on request. 2) Min. values apply to hard, tough feed
material with a low fines content and
a small stroke.
Max. values apply to hard feed material
with a high fines content and a great
Discharge opening Supporting surfaces
stroke.
3) Usual gap widths, depending on feed
material properties and machine
configuration.
ØB
ØH I J1
C F
I
J2
A G
K
L
The stated values are only approximate.
They depend on the crushing duty
(characteristics of feed material,
M D
product requirements) and the crusher
Drawn displaced by 120° configuration.
In case of need, throughput rates are
determined for the specified crushing
E End of motor shaft
duty.
To keep pace with technical progress,
we reserve the right to make improvements
to the individual machines without prior
notice.
Jaw gyratory crusher

Type A B C D E F G H I J1 J2 K L M
[Inch] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
BK 54-67 4,295 3,400 1,982 1,600 4,355 6,780 3,335 2,670 2,500 3,100 3,100 2,150 1,350 2,640
BK 63-75 4,525 4,400 2,585 1,855 4,484 7,195 3,475 3,338 3,000 3,900 3,900 2,640 1,675 3,080
8 Crusher Drives
Nowadays, gyratory crushers

are usually driven directly by a
multiple-disc steel clutch with
intermediate shaft and a safety
coupling. The multiple-disc steel
clutch compensates geometric 10
deviations between motor- and Gyratory crusher with multiple-disc steel
clutch with intermediate shaft and safety
transmission gear shaft, while
coupling
the safety coupling protects the
crusher motor against overload 11
when uncrushable foreign Direct drive of the gyratory crusher
A crusher side
matter is fed to the crusher. B transmission gear
The intermediate shaft allows C multiple-disc steel clutch
the disassembly of the D safety coupling
E intermediate shaft
transmission gear without F motor side
dismantling the motor.
12
Monitoring and control system of the
gyratory crusher
10
A B C D E C F
▲ ▲ ▲
▲
▲ ▲ ▲
11
The monitoring and control
system of ThyssenKrupp
Fördertechnik gyratory crushers
ensures an easy and safe
operation of these crushers in
different applications. This com-
pact 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 environ-
ment. The touch screen terminal
will accept interactive input to set
parameters and display the
operating data.
12
Lubrication Systems of Gyratory Crushers 9
▲
Oil supply unit for the Lubrication of the upper
circulating lubrication, main shaft bearing
oil cleaning and cooling by electric/visual
as well as the main shaft level control
hydraulics. Two pumps
each (one of which on
stand-by) are provided for
the lubrication system as
well as for the cleaning
and cooling system to
achieve a high availability.
Hermetically sealed
stationary lubrication of
the antifriction bearings
▲
of the transmission gear

Circulating lubrication
of bushing and bevel Circulating lubrication
▲
gear pair system, return flow
▲
▲
Circulating lubrication thrust

bearing, eccentric bushing and
slide ring of the eccentric
bushing and bevel gear pair
10 Examples of Crushing Plants
with Gyratory Crushers
Dependent on the crushing duty,

the performance and availability
of gyratory crushers are optimi-
sed due to specific design and
arrangement of feeding and
discharging devices.
13 14
13
Shougang
Two primary crushing plants with gyratory
crushers KB 63-75 for iron ore and over-
burden. The crushers are directly fed from
two sides by means of dump trucks.
Capacity: Ore Ø 3,650 t/h
Overburden Ø 4,500 t/h
Produkt: Ore <_ 280 mm
Overburden <_ 350 mm
Feed size: max. 1,400 mm
14
Northparkes
installed underground in a crushing plant
for copper ore.
Capacity: 900 t/h
Product: P80 <_ 150 mm
Feed size in block
caving: max. 2,000 x1,500 x1,000 mm
15
Freeport, Indonesia
Relocation of the semi-mobile crushing
plants equipped with gyratory crushers
KB 63-114 for overburden and copper ore.
15
Research, Development and Services 11
ThyssenKrupp Fördertechnik are Our services include project Get in touch with
attaching great importance to research, damage analyses, ThyssenKrupp Fördertechnik –
research and development. planning and modification wherever you are.
Committed employees, aimed at a modernization and
experience and the ability to an increase of the output of • Inspection services
tread new paths together with machines and plants in • services
Stand-by emergency
the innovative power, flexibility conjunction with a worldwide
and know-how are the after-sales service which also • Repair services
– on site
foundation on which the covers the equipment of other
successful co-operation with our manufacturers. – in the workshop
customers is built. of the service centre
Maintenance and repair services • Diagnosis systems 16
This ranges from basic analyses offered by ThyssenKrupp • Maintenance contracts Crushing tools of gyratory crushers usually
have smooth surfaces (mantle and
to measurements on new and Fördertechnik include expert • Spare parts services. concave). Toothed crushing tools are the
alternative where the cubical portion in the
old crushers. on-site consultancy. Repairs are product and/or the crushing effect have to
carried out by highly qualified be increased.
At first analyses of the deposits staff using high-quality and
17
or the feed material are carried tested spare parts. Increase the Equipment for material analysis.
out by means of up-to-date productivity of your machinery
methods allowing a material and equipment. 18
Housing weight-optimised by means of
characterization and based the finite element analysis.
thereon the right choice of a
suitable crusher. 19
Trained maintenance staff assembling a
main shaft with mantle.
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 diagno-
sis system which allows the
control of the most important
operating data.
18
16 17 19
Partners of the
mineral processing industry
Delivery program
Crushing technology Grinding technology
• Stationary, semi-mobile and • Ball mills
mobile crushing plants • Rod tube mills
• Gyratory crushers • Hammer mills
• KUBRIA® cone crushers • Roll mills
• Double-toggle jaw crushers • Separating systems
• Single-toggle jaw crushers • Water injection systems
• Impact jaw crushers
Feeding and conveying systems
• MAMMUT® single-shaft hammer crushers
• Apron feeders
• TITAN® double-shaft hammer crushers
• Chain conveyors
• Impact crushers
• Reciprocating plate feeders
•RollSizers
Roller crushers
• Vibrating screens
•SIEBRA swivel-arm crushers • Wobbler feeders
• ®
Filtering- and drying technology

Screening technology
• Linear vibrating screens • Magnetic separators
• Circular vibrating screens • Dryers
• Elliptical vibrating screens • Vacuum belt filters
• Eccentric vibrating screens • Separating cyclones
• Screener Fines screening machine • Hydro-cyclones
• Grizzly primary screens • Cyclone clusters
• Vibrating screen feeders • Disc filters
• Unbalance drive units Systems

• Aqua vibrating separators • Systems for power plants
• Coal preparation systems
Engineering
Modernization, Refurbishment
After-sales service
Training
Technical details subject to changed. Printed in Germany.
ThyssenKrupp Fördertechnik GmbH

Processing
Kreiselbrecher 02 D 03.07
Schleebergstraße 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.eprocessingplants.com

1-402-11144-0 - Bahia Mineracao-Appendix 3

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1-402-11144-0 - Bahia Mineracao-Appendix 3

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Appendix 3 : Technical Specification

Project: 1-402-11144-1 Bahia Mineracao Ltda, Brazil

Pos Qty Description

BAHIA MINERACAO LTDA, BRAZIL

SMCP PROJECT, BRAZIL

1. Process and Equipment Data

Pos Qty Description

1 Process and Equipment Data

1.1 Material and Process Data

Operating mode : Direct dump into feed hopper by trucks with

Feed material : ROM Iron Ore

Feed size ROM : 0 – 1,000 mm

ROM size distribution:

Feed size ROM F100 : 1,000 mm

Nominal Capacity : 5,400 mtph

Product : 0 - 250/X mm measured on square mesh

Specific density : 3.0 t/m³

Bulk density : 2.0 t/m³

Moisture content : T.b.a., max. 3 % assumed

Crusher work index : T.b.a., 13 kWh/t assumed

Compressive strength : max. 150 MPa

Pos Qty Description

1.2 Equipment Data

Installed Power: Max. 650 kW

Weight: 217 t (with Accessories)

Discharge Conveyor: Width: 2,4 m

Capacity: max. 6,500 t/h design

Installed Power: 350 kW

Acessories: Standard Maintenance Car

Truck Ramps: Trucks: 220 mt payload (to be

Plant Weight: Total including optional items: Approx. 1430 t

Truck Ramp Truck Ramp

Height from Plant

Processing technology from They are the core components of

Whether direct at source or at High-capacity components for

Relocation of two semi-mobile crushing

Crusher plants _______________________________________________________________________

Mobile crushing plants _________________________________________________________________ 5

Feeding, classifying and separating ______________________________________________________ 14

Process technology ______________________________________________________________________ 19

Filter technology _______________________________________________________________________ 24

Planning, consultation, engineering, modernisation, refurbishment ______________________ 26

Service, erection, spare parts _____________________________________________________________ 27

Product range _________________________________________________________________________ 28

Mobile, semi-mobile and Up-to-date manufacturing tech-

While mobile crushing plants are

Semi-mobile crushing plants are

ThyssenKrupp Fördertechnik That’s the reason why

Each raw material to be crushed

The wide range of

Gyratory crushers are real 1

as primary crushers in ore 2

Whatever the material to be 1

double-toggle jaw crushers from 2

Crushers of Other applications are in the

crush coal, potash, limestone, 2

MULTIROK vertical shaft impact production of high-grade

RollSizers and roll crushers of ThyssenKrupp Fördertechnik roll

Crushing plants can only

For the production of

Whatever the material and wher-

Wobbler feeders are used to

Reciprocating plate feeders are

Appendix3:TechnicalSpecification

Project:1-402-11144-1BahiaMineracao Ltda,Brazil