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AIB 043
The Barmac Deep Rotor reduces cost
and increases tonnage - it’s a fact!
What do crusher operators want? In simple terms, they
wish to reduce their running costs while still making the
product they want. This means reducing downtime, wear
part usage and power consumption while still maintaining
product gradation.
The Barmac DTR Deep Rotor is the ideal tool for achieving
this because it has been developed specifically to increase
throughputs and reduce wear costs.
What are the differences between a standard rotor and
a deep rotor?
The Barmac DTR deep rotor has a port height that is one
split tip (105mm or 4 1/10”) greater than a standard rotor.
This means there is a greater distance between the
distributor plate and feed eye ring, as well as the upper
and lower wear plates.
Because there is more space, material isn't ‘throttled’ as
much between the wear parts that protect the upper and
lower portions of the rotor. As material enters the rotor
there is, therefore, less wear on the distributor and feed
eye ring and, as it passes through the rotor, there is less
wear on the upper and lower wear plates.
Why go deep?
Power consumption and rotor wear are both reduced by
creating more room for material to enter and pass through
the rotor. Since running an AC motor at less than full load
current is inefficient we can make the most of this power
saving in three ways:
• Increase rotor throughput - leads to gains in product
quantity.
• Increase rotor speed - leads to increased product quality
without loss of quantity.
• Install a smaller motor - provides gains in power saving.
This will give the customer:
• Lower wear costs per tonne. In some cases average wear
part lives have increased by 50%. This also means less
maintenance time and higher crusher availability.
• Lower power consumption/draw per tonne of throughput.
• Higher throughput for a given power consumption.
• Lower power consumption for a given throughput.
• Higher capacity. A denser particle population in the
chamber will cause more effective reduction and
improved shape.
• Improved flowability due to the higher clearance height
within the rotor, especially with coarse feeds.
Performance improvements
Extensive testing world wide has shown that capacity
increases of up to 30% (and sometimes much more) can
be expected with the addition of a deep rotor. In addition,
the capability to handle coarse feed fractions has been
improved.
Reduced energy consumption can be experienced with
potential savings of up to 20%, making the crusher more
energy efficient.
So, why waste your energy wearing out parts when you
could be using it to crush rock?
Above left A Barmac Deep rotor showing the three piece
segmented tip assembly.
Left If the rotor is tuned properly, to channel the material mid-
way between the upper and lower wear plate, the material
predominately passes over the centre section of tip (shown in
red). This helps reduce wear cost because only that section of
the tip assembly will require replacement.
 AIB 043 – PAGE 2/6

Wear part improvements Fitting a deep rotor

Average wear costs are, in many cases, reduced by 50%. Converting to a deep rotor can be as simple as increasing
This is achieved by a significant increase in the life of the height of the cascade assembly, using spacers, and
specific wear parts. directly replacing the standard rotor. In certain models,
converting to a deep rotor may require minor modifications
Longer life rotor and rotor wear parts give less down time,
to the crushing chamber interior.
more operating time and longer intervals between
servicing. Cascade spacers come as part of the standard deep rotor
retrofit kit and are required to lift the cascade assembly
The Barmac deep rotor comes with a segmented tip
and maintain the relative height of the feed tube holder
assembly. With the three piece assembly, for example, if
to the feed eye ring. They are designed to suit both old
the rotor is tuned properly to channel the material mid-
style and current style cascades (with centralised or offset
way between the upper and lower wear plate, the material
locating pads).
predominately passes over the centre section of tip
(105mm or 4 1/10”). This requires the replacement of just Where customers have decided to permanently change
this section rather than the whole of the tip (210mm or their machines to run with deep rotors, the spacers can be
8 3/10”) as in the standard rotor. welded into position.
Segmented tip assemblies allow for individual component Fitting to competitors machines
selection and replacement to match wear patterns. The
The Barmac Deep Rotor can be fitted to most of our
two and three piece (segmented) tip assembly provides
competitor’s machines. Once supplied with details of shaft
the customer with the following options:
dimensions and feed take assembly, we can help with
• The ability to change the position of the parts throughout advice and even parts, if required, to assist with the retrofit.
their life, ensuring total wear of each part and therefore
Although our Deep Rotor was specifically designed for the
reduced wear cost per tonne (ton) of product produced.
Barmac, there are other VSI machine models that can accept
This encourages maximum parts usage and contributes
them after an acceptable amount of modification. However,
to lower wear cost per tonne.
with different chamber size configurations and material
• The ability to replace half (2 piece) or one third (3 piece) exit angles, the customer may not fully realise the benefits
of the wear component assembly to accommodate the of installing one. Benefits will still be worthwhile, however.
wear pattern. This provides the customer with the
Case Studies
opportunity to drastically reduce wear costs when
compared with single piece assemblies (where Some case studies follow over the next few pages.
applicable). The ability to replace only the middle tips in
a deep rotor (when the wear pattern is centralised) helps
gives a lower wear cost per tonne.
• In the case of the rotor tip assembly, the customer will
have the ability to combine the different types of rotor Below Dimension comparisons between an 840 Standard rotor
tips in the dressing of a rotor. This will allow the customer and an 840 Deep rotor.
to take advantage of the individual rotor tip attributes
(high abrasion or high impact resistance) within the one A Standard (125mm or 5”), Deep (238mm or 9 ½”)
assembly. B Standard (170mm or 6 4/5“), Deep (275mm or 10 4/5“)

A
B
A B

Rotor comparison
Above 840 Standard rotor.
Right 840 Deep rotor.
 AIB 043 – PAGE 3/6

CASE STUDY # 1 UK
Industry type Quarrying & construction
Machine
Barmac B6900, fitted with a 110kW (147hp) motor. The rotor speed is 1677 rpm and they run the machine at 150 amps
(204 is full load current).
Material type
River gravel. The feed material is wet screened with +40mm (1 ½“) taken to a stockpile, -6mm (¼”)taken as final product
and the 40mm + 6mm is fed to the Barmac.
Objectives
To make a comparison test between the standard and deep 690 rotors to determine increase in the capacity and
compare product gradations.

Results
Operational
690 STD Rotor 690 DTR Rotor
Loaded current 150 Amps 150 Amps
Feed rate 37.7 mtph 58.2 mtph
(41.5 stph) (64 stph)

Efficiency
Capacity increase of 54%

Gradation
Above A Barmac B6900 MkI Duopactor.

100

90
Barmac Feed
80 Standard Rotor
Deep Rotor
70
Cum % Passing

60

50

40

30

20

10

0
0.01 0.1 1 10 100
Sieve Size [mm]
 AIB 043 – PAGE 4/6

CASE STUDY # 2 USA

Industry type Quarrying & construction
Machine
B9600 MKII Duopactor (converted from a Rotopactor), fitted with variable speed control single drive 225kW (300 hp).
The motor speed is 1760 rpm. The variable speed control provides the operator with instant speed change capability
and this is recognised as a key tool for increasing production, maximising various product sizes and assisting in controlling
the critical 30# and 50# fractions that seem to fluctuate with material changes.
Material
Quartzite, Sandstone containing 95%+ silica. Barmac fresh feed is 40mm - 20mm (1 ½” – ¾”)
Objectives
To initially identify the rotor speed that delivered the highest tonnage then to compare results from a Std 840 rotor and
a Deep 840 rotor.

Results
Operational
840 STD Rotor 840 DTR Rotor
RPM 1450 1450
Loaded current 350 Amps 350 Amps
Feed rate 242 mtph 297 mtph
(266 stph) (327 stph)

Efficiency
Capacity increase of 22.7%

Gradation Above A Barmac B9600 MkII Duopactor.

100

90
Barmac Feed Std Rotor
80
Barmac Feed Deep Rotor
70 Standard Production
Deep Production
Cum % Passing

60

50

40

30

20

10

0
0.01 0.1 1 10 100
Sieve Size [mm]
 AIB 043 – PAGE 5/6

CASE STUDY # 3 UK
Industry type Quarrying & construction
Machine
B8000 Duopactor fitted with a 132kW (177hp) motor. The rotor speed is 1313rpm.
Material
The feed material is a minus 50mm +10 mm (minus 2” + 2/5”) Flint gravel (98.5% silica).
Objectives
To improve operational costs and increase production tonnage.

Results
Operational
840 STD Rotor 840 DTR Rotor
No Load Current 122 Amps 117 Amps
Loaded current 170 Amps 170 Amps
Feed rate 106 mtph 142 mtph
(117 stph) (156 stph)

Efficiency
Capacity increase of 34%

Wear Part Cost

840 STD Rotor - 14 cents per tonne of throughput
840 DTR Rotor - 4 cents per tonne of throughput Above A Barmac B8000 Duopactor.

Gradation

100

90
Barmac Feed (est.)
80
Standard Rotor
70 Deep Rotor
Cum % Passing

60

50

40

30

20

10

0
0.01 0.1 1 10 100
Sieve Size [mm]
 AIB 043 – PAGE 6/6

CASE STUDY # 4 UK
Industry type Quarrying & construction
Machine
MKII Duopactor (converted from a Rotopactor), fitted with a 132kW (177hp) motor. The rotor speed is 1480 rpm.
Material
The feed material is a Minus 40mm (1 ½” )dredged sea gravel.
Objectives
To improve the rotor wear part lives and increase the efficiency of the machine.

Results
Operational
840 STD Rotor 840 DTR Rotor
No Load current 95 Amps 100 Amps
Loaded current 240 Amps 250 Amps
Feed rate 167 mtph 212 mtph
(184 stph) (233 stph)

Efficiency
Specific power saving of 13.8%
Capacity increase of 26.9%

Wear Part Life

Wear Parts Deep Rotor (hrs) Std Rotor (hrs) % Improvement

Rotor Tips 153 (centre piece) 125 22%
TCWP’s 153 87 76%
UWP’s 960 53 1711%
LWP’s 960 260 269%
FER 960 (1st turn) 130 638%
Dist. Plate 143 103 39%

Note Tremendous improvement of FER, LWP and UWP. This is directly attributable to the increased distance between
the FER and distributor plate.

Please Note These case studies have been included to highlight the type of improvement that is possible if you choose to use a Deep Rotor. Specific results
will depend on the selected operating parameters of the crusher and variations in the physical characteristics of the feed material.

Barmac VSI crushers are used in the industrial minerals, mining, recycling and general quarrying industries. A wide range
of materials are processed through Barmac VSI crushers worldwide. For more information on this or any other application,
please contact your nearest Metso Minerals representative.

Metso Minerals (Matamata) Limited

Mangawhero Road, Private Bag 4071,
Matamata, New Zealand
Tel. +64 7 881 9060, fax +64 7 888 5244
minerals.info@metso.com

AIB 043 – 3/04