CHAPTER 3.4 Gyratory and Cone Crushers Richard (Ted) Bearman GYRATORY CRUSHERS The gyratory crusher was originally patented by Philetus W. Gates in 1881, with the frst crusher installed at the Buffalo Cement Company. Duting this period of mining and quarry ing, the performance sequirernente forthe orushero were mod est, as there was little mechanization and production rates ‘were low in comparison to current times. From this early point in the development of gyratory crushers, a range of crusher types evolved, Westerfeld (1985) discussed some of the gyra- tory types, including the long-shaft suspended and fixed- spindle variants, and noted that both of these variants were falling from favor, with the development and deployment of the hydraulically supported short-shaft gyratory erusher. In the intervening years since Westerfeld’s work, this move has ‘now been fully completed. All major manufacturers now use the hydraulic shaft-supported machine, and it is rare to find any of the previous variants, In all upcoming descriptions and discussions, the only type of gyratory crusher that is considered is the hydraulic shaft-supported machine, and hence all mentions ofthe gyra- ‘ory crusher refer to this type. For reference, a typical hydrau- lic shaft-supported machine is shown in Figure | yratory crushers ate commonly used as primary ‘machines, where the feed material displays moderate to strong breakage characteristics and the throughput rate is in excess of | that from an equivalent jaw crusher installation. The gyratory crusher uses a compressive crushing action, with the material progressing through the chamber under gravity. As with other {types of cone crusher, the gyratory crusher has an inner mantle that gyrates eccentrically within a fixed outer crushing surface known as the bow! or concave. The eccentric action gener- ates a crushing position that moves from a fully open posi tion (open side seiting [OSS)) through to a minimum distance between the mantle and concave (closed side setting [CSS). Figure 2 shows two views ofthe discharge seting. Because of the rotation of the eccentric driving the mainshaft in a gyrating motion, the position of the closed Side and open side between mantle and concave constantly ‘moves around the crushing chamber. Typical primary gyratory cerushers have an evcenttic speed of 150-200 gyrations per minute, Figure 3 provides a schematic diagram of the gyrating mechanism used in gytatory erushers. In most gyratory crusher installations, there is no attempt pass through the crusher along with the oversize feed. Fines are typically considered as a particle size of less than 50% of the OSS. The gyratory crusher is regarded as an all-purpose machine and as such is used without restrictions across mast feed typor, Food material that ie not genorally euited to treat- meat in a gyratory crusher is mostly wet and sticky feed, with, ‘or without clay and in certain instances, very fine feed can ‘compromise the operation of such machines, Given that a majority of gyratory crushers act as primary machines, the feed size is typically run-of-mine (ROM). Gyratory crusher notation is usually of the form “feed opening-mantle diameter.” hence a common size is a (60-89, thats, a 60-in (1,524-mm) feed opening and an 89. (2,260-mm) mantle diameter This designation is shown ‘graphically in Figure 4, Essentially, the feed opening dictates the largest rock that ‘ea be lnuadled, sd the inauile diameter is indicative of the maximum throughput. In terms of feed size, the general rule is that the maximum feed size should not exceed 60%-80% ‘of the maximum feed opening (j.c., in the preceding figure, this represents 914-1,219 mm [36-48 in.}), withthe feed mea- sured in the second dimension. As with all compression crush fers, the product size is dictated by the OSS and CSS, whereby the maximum product size is equal to or less than the OSS, ‘and the CSS influences the degree of size reduction. The ree- ‘ommendation for the maximum size of feed relative to the feed opening varies, and suppliers should be consulted for advice specific to a given application ‘An issue to consider with primary gyratory crushers is that, in essence, ther role is to reduce the feed to a manage- able size and let fine material pass through as quickly as pos- sible. Because the feed ean contain large amounts of fines, the product size distribution from a typical machine is more chord (led) Bacrman, Disco, Boor Rock Slvion Py Ui, Atadle, Weeern Avsolio, Avira 91 Cong ©2018 Soci for Mining, Meagan Expration. lights eseved392 'SME Mineral Processing ond Extractive Metallurgy Handbook Spider Cop Spider Grea Lines Minha Concove Per Mande Core one Heo Upper Mane tine lower Man ine Coumracight (Over Eceni Bash Iona Ecce Bush Sep for tres Baring nm: |} Pestioning System Oil tine Spr Bash Spr Ae Les Head Maine Top Shel Meilrone Middle Shall. Maine Bom Shall Meike Lines Oar Ecentic uth Oi Feed Counters ond Bearings Seley Coupling [nt town Dive Pion and Bevel Gear Inne Eccenvc ond Moinhoh MeinshaltPostenng Sytem Clade Couiany aio Figure 1 Sectional view of a typicol hydraulic shaf-supported primary gyratory crusher pen Sic Sting Closed Side Sting lon View Locking Down the Crushing Chombor <= 3 eee Ma ea cee Sectional View Courmey of aio Figure 2 Discharge setting, comprised of open side setting and cosed side setting ‘controlled by the feed particle size distribution than the OSS ‘or CSS—this makes primary gyratory crushers distinely dif- ferent from cone crushers ‘The feed particle size distribution is also the major contributor t the throughput, Book values provided by manufacturers all need to be corrected to account for free throughput, that is, material passing through and adding 10 the throughput, but too small to require crushing. All manufactur cers have proprietary equations to generate this correction. The corrections can be large, with many large gyratory ‘crushers deployed on fine feed reporting throughput values ‘equal to twice the book values. ‘The lange throughputs also explain why power consump= tion values for primary gyratory crushers can appear to be very low. It is not unusual to see values of 0.1-0.2 KW-hit (0.09-0.18 kWWvst), but these values are a result of high throughput and relatively low power draw. Until the 2000s, traditionally installed motor power in primary gyratory enushers Was approximately Z0U-40) KW (268-536 hp). Itis now reported that 1,000 kW (1,341 hp) is installed on large crushers of the 60-89 and larger sizes. ‘As mentioned earlier, gyratory crushers are designed to accept a given feed size, and in most cases, this is fixed forthe duration of the life of the machine, In a recent development, Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved3.4 | Gyratory and Cone Crushers 393 load Sie Sting (Open Side Sting is fie byEccntic Angle Moin As ‘cca Metion parted Though Geos ond Pree ery Spider Elaged hd oied br Row feocore Borgo Mamnnct Figure 3. Gyrating action of mantle in a primary gyratory i tat Figure 4 Size designation for primary gyratory crushers Metso developed a concept known as the super spider (Figure 5) ‘A super spider $70-89 MK-AII primary gyratory crusher is an $60-89 MK-II ited with an arched spider and also an Additional upper top shell (with extra coneave now) and new ‘mainshaf.. The combination of an arched spider and an upper top shell increases the feed opening to 1,828 mm (70 in.) com- pared with 1,524 mm (60 in.) for the S60-89. ‘An existing S60-89 can be upgraded to an S70-89 by installing a new spider, upper top shell, mainshaft, concave act, mantle, arm guards, ond rim Liners. The erusher top abell, bottom shell, eccentric, and drive components are not changed Alternatively, the $70-89 is offered as @ new machine. The height of the $70-89 to the top of the rim liners is 756 mm (30 in.) higher than an S60-89. Because of this and in the case of an upgrade, the inerease in crusher height Conny ase Figure 5 Metso super spider concept may necessitate modifications to the dump hopper structure. ‘Consideration also needs to be given tothe design of supporting sirueture, as Metso reports a marginal inerease in the dynamic Toads eaused by the crusher’s center of mass being raised, In addition to the increased feed size, Metso also suggests ‘that the super spider configuration can inerease throughput by 12%-15% compared with an $60-89. Principles ond Terminology “The gyratory style of crusher relies onthe same principles as the cone-type erusher, that i, an eccentric movement of the crushing head (mantle) induced by the rotation ofan eccentric sscombly around a cental axis The mantle finer that provides the moving crushing surface is usually cast in ethera single piece or, more commonly with larger machines, into pieces. Because of the size of the casting, the thickness and diam ctr, and the required wear resistace, the material favored is fn austenitic manganese steel. This type of material exhibits the phenomenon of workchardening. Inthe as-cast and heat treated condition, it will have a hardness of 300 (Brinellhard- ness [BH], whereas once crushing takes place and the liner is worked, the surface hardness can increase to 550-650 BH. Depending, on the crushing duty, the manganese content can be varied from approximately 12% to 24% and stil retain the workchardoning characteristic, The inrensing peresatage of tmanganese potentially offers an extended wear lif, butt does come at the cost of ductility; that is, the higher manganese castings will be more susceptible to cracking from the ingress ‘of tramp metal, Some manufacturers uso add elements such 48 nickel and chromium to manganese stel crushing parts to synove intial Ides, avy, eae chases, ‘Typically, an 18% manganese crusher liner may also contain up to 3% nickel and a small percentage of chromium, “The outer fixed crushing, surface is made up of a series of circumferential rows, with each row containing multiple ‘concave plate or segments. Depending on the size and design Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved394 'SME Mineral Processing ond Extractive Metallurgy Handbook Figure 6 Examples of manile profiles ‘ofthe erusher, the plates are supplied in three-, five, six, oF seven-row versions. As multiple rows are used, this provides the opportunity to use different materials for the various rows ‘of concave plates. In applications where sliding wear is pre- ‘dominant and the presence of unerushable items is unlikely, white cast-iron plates can be used in all but the upper row: White cast iron is highly resistant to sliding wear and ean pro- vide a longer wear life, but itis britle and will therefore have a higher chance of eracking, which may lead to loss ofthe sea ment and lost production time for the repait. Where gouging \wear is more common and uncrushables may be seen, the risk associated with white east iron may be judged as unacceptable and as such, itcan be replaced with materials such as throughe hardened martensitic steel alloy. A martensitic ste! will have slightly reduced surface hardness but a greater resistance 10 cracking. Harder materials are mostly deployed in the middle and lower rows, but toward the top of the crushing chamber, where impact can become the predominant concern, a more impact-resistant material is preferred, To address this point, the top one or two rows often revert to a manganese stcel com position that can resist the impact and offer work-hardening. Chamber design and liner profiles in primary gyratory ‘rushers need to be appropriate for the required duty. Many performance issues (both process and mechanical) ean be ‘attributed to inappropriate and/or mismatched concave and ‘mantle profiles. Typical problems seen include + Inability to set a required discharge setting, + Localized and excessive wear on lower area of the mantle, + Abnormally high power dras, + Excessive hydraulic pressure, and + Low throughput Cf these problems, one that is commonly seen is the exces- sive wear just before the discharge zone on the mantle liner This phendmenon has several colloquial names, including ski- ramp, op-hat, or duckbil! weat. An example of such a wear profile is provided in Figures 6B and 6C. ‘These terms deseribe a situation whereby the mantle develops a dish of wear just prior to the discharge point, but a lip of material remains at the very bottom of the mantle. Such a wear pattern can have serious effects on the crusher, a the flow of material through the chamber is hampered (low throughput). There is also the tendeney for excessive power and pressure, as crushing can occur practically up against the base ofthe final row of concaves, ‘The development of such a wear profile is usually associ ated with either of the following situations: + A mismatch of the mantle and a concave profile only allows the required discharge setting 0 be achieved higher on the mantle (compared to the normal position near the discharge area). + Theresa lack of mantle adjustment for wear so that wear is localized, This is often associated with the type of mis- match just highlighted. One of the complexities of primary gyratory crusher chamber design occurs because optimizing the wear life of the otal chamber—concaves and mantles—is required. As the ‘wear ofthe mantles is more rapid than forthe static concaves, the ratio of mantle-to-concave-liner changes can vary from 2:1 ta $11. Asam exannple, a size 60110 gyratary crusher may hhave mantle diameters of + 2,718 mm (107 in, (standard), + 2,769 mm (109 in.) (oversize), or + 2,819 mm (111 in.) (double oversize) The design and designation of the series of mantles will vary according to the concave set used, the ype of wear, and the required discharge setting, so the sizes just mentioned are simply an example, The main point to consider when seeking to optimize the sequence and size of replacement mantles is to ensure that the required discharge setting can be achieved when the now mantle is installed. At the same time, the posi- tion of the mainshaft should be a minimum (i.e, at position in the range of 0%-10% of operational travel ofthe mainshafl) ‘when the mantle is new, as this will allow the maximum wear to be obtained for the mantle. In stating that the mainshaft should be low within the operational travel range, under no Gitcumstances should dhe zevv puiut uf die operational tavel be lowered into the safety zone between the operational zero set point and the absolute mechanical zero point, Such an action compromises the ability to use the hydraulic system to relieve an overload and provide protection to the machine, Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved3.4 | Gyratory and Cone Crushers The use of laser, or optical chamber profiling, for ey tory crusher liners has recently grown, and Flias etal. (2015) describe a chamber optimization exercise that was undertaken using a laser scanning technique. The level of detail available ‘rom laser scanning systems an the speed of the systems offer ‘practical option to determine wear over time and invaluable input for the customization of liner profiles, Another point often discussed is the difference between choking and nonchoking chambers. The essential difference is that nonchoking chambers have a relatively straight con- cave profile from top to bottom, while choking chambers have 4 curved concave profile. Nenchoking chambers promote throughput but provide less control of product size and are prone to loss of CSS control because of localized wear. Choke chambers tend to generate reduced throughput but ean oper- ate at lower discharge settings, give better control of product size, and usually offer longer wear life. In this author’s opin- ‘on, the differentiation hetween these siyles of chamber design should be replaced by a discussion based on the required duty ff the crusher, Specialized chamber design needs to address feed size distribution, material properties flow characteristics, and mantle and concave change-out strategy. Given the com- plexity of this, the choke versus nonchoke discussion is 100 simplistic, and the specifics of liner designs are therefore best handled by specialists in the area who can provide a design customized 10 the required crushing duty AAs with all compression-based crushers, the distribution fof energy within the erushing chamber is the critieal element of the design. In gyratory crushers, the force is transmitted from an electric motor through a bevel gear set into the gear ‘mounted on the outside of the eccentric assembly. The eccen- tric assembly is then free to rotate within the mainframe via aa bronze bush (outer eccentric bush). The eccentric assembly hhas a concentric outside face, but the inner bore it e2cer trically located or offset to the main centerline. The inner (Couey of Tyserap doa Slutons jure 7 Jow gyratory crusher showing enlarged, single-sided feed opening 395 eccentric bore houses a bronze bush (inner bush) that allows ‘the mainshaft to freely rotate within the body of the eccentric. ‘The motion of the eccentric therefore causes the main- shaft to gyrate and, with its integral mantle surface, cycle from the OSS to the CSS in relation fo the fixed concave liners, ‘When running empty, the mantle may be seen to rotate at up o approximately 6 pm. With the introduction of feed into the chamber, the rocks act like epicyelic gears and cause the rotation of the mantle to reverse and the rotation to slow to 1-2 rpm. This rotation in either direction is simply the result of frictional forees and transfer of momentum between the ‘eccentric and the mainshaft, It should be noted that this rota- tion is not the crushing action of the machine. Crushing is ‘caused by the gyrating motion of the mainshaft, which cre- ates a constant cycling between OSS and CSS. This cycling. applies force to rocks traveling down through the chamber under gravity. As the gap between the mantle and concave reduces the chamber, the degree of size reduction increases. In the operating crusher, the large rocks are eaptured and broken high in the chamber with the progeny particles falling lower into the chamber to again be crushed, oF ext if the size is sufficiently small. Typically. feed particles entering the top ‘othe chamber may undergo anywhere between 5 and 10 com- pressive strokes before exiting the chamber. Use of primary gyratory crushers in underground mines has increased with the popuilarity of block eave-type opera- tions (Hemandez et al. 2014). In cave operations, the ROM top size to the erusher ean be very large andl as such, gyratoe ries offer advantages equivalent to jaw erushers. One specific derivative of the gyratory crusher has found particular favor in block cave operations, and ths isthe jaw gyratory crusher (Figure 7). Essentially, the jaw gyratory crusher is normal ‘gyratory machine with the top shell modified and the spider ‘enclosed filly on one side to enable only one-sided feeding, ‘The feed opening is deliberately flared to take larger rocks, and the mainshaft is lengthened to allow capture of the rocks very high in the chamber: Currently it appears that only ‘ThyssenKrupp Industrial Solutions manufactures and supplies, this hybrid type of gyratory crusher, Construction and Design ‘The construction and design of primary gyratory crushers has ‘evolved based on the requirement to mect the needs for higher tonnages, greater size reduction (i.e, use of high installed power), and easier maintenance. The main components of the tmachine include dhe following (for Further infosiation, see Figure 1): + Mainframe + Bottom, middle, and top shells + Spider arm + Mainshaft + Boventric + Drive train, including the countershaft and gear sets + Hydraulic Shaft support (also known as the mainshaft positioning system) The mainframe and the outer shells remain as cast steel stems, but mereasingly, various forms ot split shells are being «developed, where the shells can be split both horizontally and vertically. Traditionally, the botiom, middle, and top shells have been east as single items and then bolted together. With the increased need to locate crushers into remote locations ‘and underground spaces, suppliers have designed shells with Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved396 'SME Mineral Processing ond Extractive Metallurgy Handbook special flanges that allow each shell to be split vertically. Split spider arms are also available. Figure & shows splitshell arrangements from one of the main manufacturers. ‘The main changes in the mainshaft and eccentric assem- bly have been in the increased specification of the materials to ‘absorb higher loads and greater consideration of lubrication and contro] of heat inthe system, Essentially, the arrangement ‘of the eccentric assembly remains similar across all manufac- turers, with a typical arrangement seen in Figure 9. [Because athe greater motor power and higher forces, the ‘countershaft and the gear sets have received more attention. ‘The countershaft material specification has been increased, and in several models, tonque couplings have been deployed to give protection to the crusher under overload conditions. In tandem with this change has been the increasing move 10 spiral bevel gears. Such gear sets allow greater efficiency and ‘contact area to transmit the high forces. A typical modern direct-drive countershaft arrangement is shown in Figure 10, ‘A development aimed at improving maintenance access is the Top Service erusher from FLSmidth. In this design, the ‘manufacturer has introduced the ability to maintain all major components through the top of the erusher. Such an innova- tion is particularly useful for maintenance to the major com ponents lower in the machine, that is, eccentric assembly and hydraulic shaft adjustment components. Previously, the lower components were only accessed from underneath the crusher, which involved clearing the discharge vaults under the machine, working in confined spaces, and the need for a specialized maintenance trolley for removal and refitting of the hydraulic shaft adjustment assembly. ‘Two important considerations in the operation of gyra- tory crushers are the lubrication and hydraulic systems. For ‘modem gyratory ctushers, thete is a trend to install higher ‘motor power. Such input power allows the rusher to work harder and therefore generate more heat, particularly in the eccentric bush region. Because of the duly eyele of crushers, the eccentric bushes still rely on the use of leaded bronze as the base material. One of the key features of leaded bronze is the ability to bleed lead if bushes are subjected to local- ized heating from a hich-force event. or altematively. from Frictional heating. To provide lubrication and to mitigate high- temperature events, the flow of lubrication, specification of the oil, and pressure of delivery must all be matched to the system. A critical part of the lubrication system isthe monitor ing of the oil temperatures in both the feed and return lines, with manufacturers having limits on the differential temperae ture. Ifthe feed-retutn differential exceeds the recommended set points, then process control systems are programmed to ~ ® co E 7 Gosh Sid, D. Sky Cong Sie conidge Ema Sk CbplsGacSeel Coch EMetorSde wks % S a Figure 8 Gyratory crusher splitshell arrangement Cours of TyssokGupp cos Scons Figure 10 Countershaft showing moin components, Hab fall ert nt shown _— Hl (ul esto shoe) (er Eecanic Bush lve Ecreic Bash Contony oeto Figure 9 Eccentric ossembly (associated components excluded for cority) Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved3.4 | Gyratory and Cone Crushers provide alarms to the operator. To ensure that the tempera {ure differential stays within the acceptable bounds, crushers are fitted with heating and cooling systems, whieh must be ‘matched to both the duty and environmental and climatic con- ditions of the operating site It is also important to consider the cleanliness of the cil and ensure that any debris or contamination is removed Gyratory crushers usually have two stages of filtration, with a coarse irash screen usually located under an inspection cover inthe top of the storage tank and a fine 20-m cartridge-type filter in the feed lin. Several generations of gyratory crusher have incorpo rated hydraulic support of the mainshat to allow + Easier setting adjustment (and ability to adjust for liner wear), + Ability to keop pressure on step bearing components in the event of the mainshaft jumping upward, + Overload protection, and + Chamber clearance following an unplanned stoppage. The basie design of the hydraulic circuit used by most ‘manufacturers consists of a fluid storage tank. a motor-driven ‘gear pump, control and relief valves, and a eylinder assembly (with of without a separate accumulator). Under normal operating conditions, the hydraulic circuit is simply used to raise or lower the position of the mainshatt, with the position monitored through a setting measurement device tha is integrated into the eylinder below the mainshaf ‘The measurement device can be either a potentiometer or a lincar variable differential transformer. This raising and low- ering function can also be used in the event of a crusher stall here the crusher stops with a chamber full of feed Under certain crushing conditions there isa tendeney for the mainshaft ta jump upward, and if not addressed, this will release load off the step bearing components located under the ‘mainshaft. When the mainshaft drops back, damage ean occur to the step bearing plates, To avoid this situation, the balance cylinder in the circuit forces oil into the system to ensure that load is maintained on the step beating components. The balance eylinder incorporates a section with nitrogen under pressure, and itis this that controls the stiffness of the system nd the ability w respond to the rapid upward movernent of | the mainshaft, Depending on the manufacturer, the cylinder ‘may have an infegral nitrogen system, or this ean be separate through the use of an accumulator. An example ofthe function fof the Metso system is shown in Figure LL ‘Another protection function of the hydraulic system is to detect an overload situation in the erushing chamber. In such an instance, a relief valve in the circuit is actuated and the hydraulic uid is dumped back to the storage tank, Outside of the functions just described, there is a strong ‘rend to Start using this shaft adjustment as'an active crusher control. One example of this approach is the Gyramatie sy tem from ThyssenKrupp Industrial Solutions. In this system, power, pressure, and mainshaft position are continually mo {ored. Logic can be applied to incrementally open the crusher iffpower exceeds certain values and then return the crusher to {the previous position after the peak power has passed, Application and Operation The application of primary gyratory crushers should be based ‘onthe information available from manufaeturers with the main information relating to dimensions, masses, feed size, feed 397 material characteristics, throughput, product size distribution, ‘and required crushing power. All manufacturers provide this, information in a variety of forms, but it is also important to seek examples of similar applications and installations from around the world, ‘As a guide to the type of information available, manu- facturer data is reproduced in the following tables. Table | shows typical dimensions and weights of significant compo- nents and assemblies. Table 2 shows the typical throughput for various models of crusher based on the feed size opening ‘and mantle diameter. Manufacturers will state the density of the feed material used in the calculation of throughput. For all applications, the actual density of the feed at the site should be compared to that used by the manufacturers and a correc tion applied. In Table 1, the KB 63-130 gyratory crusher is listed. ‘This machine is notable, as itis currently the largest gyratory crusher available (Carter 2016). Carter states that “despite a roughly 14% larger mantle diameter of 130 in. (3.3 m), it weighs less than its predecessor, the KB 63-114, at 490 ¢ [metric tons). ts rated throughput of up to 14,000 th is more than 30% hicher than that of the preceding model.” The other main information supplied by manufacturers is guidance on the potential product size distribution, as seen in Figure 12 For general information regarding feed, manufacturers also often provide guidelines on the fines content of the feed, moisture content, clay content, and the degree of stickiness. Fines ean he defined as the percentage of feed passing the CSS, or alternatively the percentage passing CSSI2, and cer- tain manufacturers will additionally state a limit for the fines content, beyond which the mechanical performance of the ‘crusher may be compromised. The other major consideration with fines content is the direct relationship with throughput Al gyratory erusher throughput tables give a base through- put with defined feed properties. Should the fines content of he feed increase, then there will be a proportional increase ‘throughput. Most of the calculations for the throughput increase are proprietary and are not publicly stated, Kawasaki (now Earth Technica) states in the technical information for the KG series primary gyrotory erushers that the following, ‘correction factor should be appiied to a base throughput: correction factor ~ @; “ays (y/1.6) where ‘0, = compressive strength coericient ‘a; = feed size coeticient ‘4; ~ crushability, presence and frequency of facture lines. lk density ofthe feed 1 According to the a coefficients, fine material less than the CSS can have a multiplying impact on capacity ranging from 1.0 to 3.0. This is significant compared to the two other ‘coefficients that provide a range of 0.6 to 1.5 for the impact of ‘compressive strength andl a range of 0.9 16 2.0 for the erush- ability coefficient “Moisture content, clay content, and the dearee of sticki- ness are usually covered by a generic statement that feed material should be free-flowing. There are no specific tests to ‘determine the limits for these factors in relation to crushers, ‘and therefore input from manufacturers is required 10 assess ‘any constraints that may be caused by elevated levels. Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved398 'SME Mineral Processing ond Extractive Metallurgy Handbook Nivogen Under Pesre Balers ft ty finer vind i" Presce Charing eve vera npg of loot supboatng components Inara coved by on Faire ‘Wen the mained mps he ‘rectal eck poston Foon baler ender forces of ronp toni ching er piston ae he pion chonbe. clamp lot, pon por wear iH pl. ep worse. ord i press sss on trogen ‘hak igh ooeter previa Shan retire when maith imps ‘eporaion and dong ey Fre fo of trough ‘heck vale rien ‘ponte dracon Chea Yoho Coon tha Figure 11 Balance cylinder operation Table 1 Typical masses for primary gyratory crushers woe ‘Nome | Speed of | Maximum Feed | piometer | Eecenvic | Motor | Tl Wit Heaviest | Bottom | Moinshof, hydrate Grrocry | Opening, | (oversized, | Brushing, | Power, | of Crusher, | Spidect | "shall | Shall? | AssemblyS Giinder tush Type_| rom int | emia | rpm | Who) |" kgfb)” | Kail) | to) | kg ti | kg igi) iwseor | va750| 17007 | ta | 0] ano | arcco | soso | 37100] 32500 3100 sen oq | seas | aass9 | pezzi | wizen | vaso wasn wosers | raven] isos | 7 | 4 | aiso0 | 2200 | s2000 | wosco | sncco 500 ism joa | wan | case | parsy | essen | gar rope ress | amen wx | eo | zoom | srs00 | sso | sa500 | sooo 00 eva | saa | rss | casscs | sso | ozay osaa wocsae | reco | 2200/0 | 10 | 10 | ss20% | asso | 700 | sao | sco 14000 arora) say | garsae | ccasts | csesza | mies | sa22y 0385 reese [recon | veo | re | 20 | saoom | 65300 | 73.00 | r2<00 | 124000 17.000 esesinia wv20 | cisaaey | gasany | cose | azsava | rraars, see, rees.i90 | room| sanerzo | 12s | 1300 | aeson0 | aao00 | 97500 | assco | 120000 "3000 .00/t0a coia_| woeraen | wassos | arasea | ve6aos | esson re ‘Cosma ot Tyaeonkinpp dl Solifons *Averayecomporert weighs Inding itera slay mergns or slectingieg oor ret incades 1 acuing wear oo. 4 Excdng hydro oyinder Eh ed 1+ Ths dela users ovleble on rue ‘none dione, ining cushing elamen’ Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved3.4 | Gyratory and Cone Crushers 399 Toble 2 Typical throughputs for primary gyratory crushers at voriaus open side settings Throvghput UR of O55. mnt Srey nea |e | | | im arai7oaysean | 1200 7.900] 1500 2500] 800 3700] 2000 «300 va jarisasisa [1.300 2400) $00 3200 1900 4200] 2.c0 1.80] 2000 530 10 40090575 1700 9200) 2000 400] 200 5,00] 2400 400] 2460 400 1.600.226 2-091 2300 4500) 2500 5.100] 27c0 3900) 100 6700] 2200 7.500|2500 8c] 100.2096 0-1 3000 5500/3400 +00] 3900 7,200] 4000 9,00] 4.700 1030 1.50.3 302 4-190) 3.700 79004300 +20) 4700 10100 5.100 19800] 5420 12,000] 5800 v3200| 5200 14400 Cures of Tyserup idol Sauions * Ta covet Far bie lor pac hou Fo shat on er hou (ph, iy by + Min = pica fed motril wih minimum eccanticty ond FO (880 ro [27] Max, = typical fad maar with maximum ecco and FEO (230 mm [in Bulk deny = 1,600 kg/m? [100 To). {Ta corart rm mint [oa inches in, vid by 25. tis wodel of eres ove on reqs, oa eh 10} Mb, 10-15) a 215 em ri hind i (anny rh nin} Ba eam om Size of Opting in Fl Tsing Screen Squre Feccont Fong Couey of Maso Figure 12 Product size gradation curves for Metso Superior Mill primary gyratory crushers Reference lists are available from suppliers, and these can assist the identification of similar duties throughout the world Typical lists are shown in Tables 3-5, Once the ability to achieve the required duty is defined. ‘the major consideration isto examine the installation required forthe application in question. Because of site-specific issuss, installations are not necessarily the same between sites. The ‘major considerations for installation are cong ©2018 Sait for Ming, Me Feed material and performance estimation, Mining method (e.g., pen pit blasting vs. sublevel block. cave), Feed arrangement, Discharge arrangement, ‘Topography, Geographical location, and Requirement for relocation, Ore testing and ealenations fir gyratary onisher installed power requirements are quite limited and stil, to large extent, rely on the Bond crusher work index equation, Every manufacturer has introduced modifications to the basic ‘equation, which are based on their experience database. The crusher Work index uses what is usually referred to as the impact strength ae the strength characterization parametar. ‘This parameter is primarily obtained using derivatives of the twin hammer device. In the use of the twin hammer test, eau tion is advised inthe interpretation of the test data. The spread ‘of values fiom the test can be significant, and the repeatability ‘of the test should be carefully examined prior tothe use of the ‘alc in the equation For installed power Over the last 10 years, some alternative approaches have been developed to provide improved predictive capability for primary gyratory crushers. Details of the mechanistic and numerical approaches are provided in Chapter 3.6, “Crusher Selection and Performance Optimization.” During dhe past ovo decades, fuite elewment model (FEM) has grown in use to determine stresses in the mechani- «eal components of crushers. These simulations allow identi fication of stress raisers in designs and points of weakness. Redevelopment of designs based on FEM is now common and has led to the ability to deploy designs that have required lev- ‘ls of strength, without the need to rely purely on the mass ‘of steel in the design. Such FEM approaches have been par- ticularly useful in the design of splitshell machines so that shell stiffness is maintained while still allowing the machines 1 safely apply high forces For primary gyratory crushers, the main feed arrange- meat for open pits 18 by direct tipping from mine haul trucks. Most mine haul trucks are of the back-tipping arrangement, although side-tippers are sometimes encountered, and for these some extra safety considerations will nced to be examined. gy, and Explain. Al hs eseved400 'SME Mineral Processing ond Extractive Metallurgy Handbook Teble 3 ThyssenKrupp large* primary gyratory crusher models and clients ‘Grosher Medel Quoniy Chen! Proje) Contry alr Teor aK 17-170 T ‘CBM! Constucion Co, ba. (AnwroEDO) Niger Unesone 2016 8k 140-199) 2 Falun ini Cory Suu A coe 201s 8 140-290 ' Cosco! (Ani) Chie Coppa oe 2018 8 160-230 1 (OISC Apa Koehn Rusio Onerburdon 2018 xs 140-230 ' Mineral Technsogits Group (Dahon) Monga kono rola xB 160-200 ' Southern Pars Copose Corporation Cusine] Pers Copper ee 2014 KR r4nat0n) ' fearonng Ces inant mia Che ha moa 8 140-230 2 Kansans’ Mining (Kasorsi mie] Zonbio Copper xe 2019 8 140-190 1 Shougang Hire PeruSAA, Maton) ers on oe 2013 x 160-230 a Kolunbio Miner Lire [Senne Zonbio Copper ee zon 8 140-230 5 FT Freep indonesian Joy) Indonesia Copper oe 2011 8 140-230 1 Corso (Min Mineo Hales hie Coppa 8 2011 Coun of ThyaceKopp dl Soliens * larg feed openings mecca 21.6 m 63 in). ‘ nsalion gues since 2007. + Codeleo = Corprosén Nocona del Cabre de Chie Table Lomi large” primary gyrorory crusher models ond ellennt Throughput per Crashers Feed Arongemert Machine ond Product Inseled Motor Crusher Modell _ Supplied Sito County __Commaiy__ond Food Sze “Top Sie, /h sph) Power, W hp) _Yeor Texavs T_Akogay Kazckhvan Copperore __Ranahnine ROM) 4.250 44680) 750 (,005) 2012 fire fed tax 2978, 1 Botshokol Kazakstan Copperore ROM direct eed 4250 14080) 7501008) 2012 lax atts 1 Mision Asoreo Untad Shier Copperore ROM dec eed 2980 24) 450 403) 2012 14x 2018 1 Contancia Paw CCoppar/nely re ROM diet feed {6000 16408) 1,000 (1,40) 2012 vax 21 T9u 1 Sekar gld mine Foye Gade ROM dec feed 2.000 2203) 600 (804) 2012 tax 2918 5 Smidh SA Nerh Aico Copperore ROM dec ead 4900 (4736) 750,008) 2019 Ns1etsu 1 Korma ee Copparcre ROM diet ead 700 77) 450. (603) 2013 vax 21180 1 RainyRiver Gonadal evo ROM direct ead 1300 (1.487) 600 904) 2014 16x 24780 1 Pena Colorado Menco Magni. ROM direct eed 250 (3.139) ——750/(1,005) 2015 vax 21 T3u 1 Reser Mourteria Geld re ROM direct eed 1880 037) 6000) 2018 Cowon ef FSi Stage fed apeinge mantis 31-4 m2 in 1 InflloionSgue since 2012, 1 FiSniethmodel designation i of he fomat 16 x29 fn, 1,600 2,900 rm. 7S = Tap Serves TSU = Tap Service ude {Throughput may nt he mosinum pole er the mocking ‘Two-sided tipping is also common for large gyratory ‘eruchers, whereby two trucks can tip into the eruchor from ‘opposite sides (Figure 13). Regardless of the tipping configuration, it is normal practice to tip in line with the direction of the spider arm, ‘This practice allows the spider arm to act asa feed splitter to improve the distribution of material to the crushing chamber ‘end to minimize particle sie segregation or bias, In open pits, direct tipping is the most common feed arrangement, although in some instances a ROM bin is used ‘with material drawn from the bin into the crusher using a heavy-duty feeder. There area range of features that should be ‘considered regarding discharge of material from the crusher, "The pritnary Function of te discharge pocket uta prisnaty ‘eyratory crusher isto physically decouple the crusher from the downstream processes, By the nature of the equipment, the ‘crusher isa discontinuous process with a throughput rate that is largely determined by the characteristics of the feed mate- rial, Fine material (with a lot of the feed being smaller than + yoarrdatd conan may op the crusher setting) will flood through quickly, while highly competent large material will be held back ar it progressoe down the crushing chamber. As most primary gyratory erush- ers are direct fed by trucks, the discharge pocket allows these variations (which ean occur between trucks) to be smoothed out, If sufficiently large, the discharge pocket can also absor’ short stoppages in the downstream process without forcing a crusher stoppage. This aspect becomes more important the harder the material isto crush because repeated crusher stop- pages and subsequent loaded starts can lead to crusher dam- age. The size of pocket required will depend on the truck size feeding the crusher. Some crusher manufacturers recommend two times the truck size asthe live capacity in the discharge pocket, however, dis is uot band and fas ule. The size of the pocket will be a trade-off between capital cost (of steel- work and the reinforced ROM pad wall) and the flexibility allowed to operations, Accurate level sensing in the pocket is critical for making best use of the pocket volume, Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved3.4 | Gyratory and Cone Crushers 401 Table 5 Metso large” primary gyratory crusher models installed since 2010 ‘rash Model Quoniy Che Canty aleral Teor e089 2 BaF Blow ‘slo en re 2014 connor 1 rs Pune Roots ouluw 019 e089 2 Mineo Mono S.A. do Moco Copp ove 2013 co-ti0e 1 enone Ms Conod Cope: oe 012 cos 1 usson Copper Company Miheeabye) Rio Copper oe 2012 60.89 1 Consdaed Thompion Bom Lol Conede on re 2012 e089 1 Yen ming Mining Co, Chin ober 2012 eo-i0e 1 1sco China en oe 2011 00-89 2 BRPBInon veralio eno zon e275 1 Sage Belgien Porhiy 2001 sono 1 Associa Mongoose Mins (Beethol) South Abica hon fe 2010 e089 1 Conponhia Vale i Coe/Selobo Made Seon Coppa ore 2010 0-89 1 SCT Belg gen Unesone 2010 60-89 1 Dosing China Copper ore 2010 10-89 1___Sio Mines Conoda Copp ore 2010 Conny o Mao ange Ted perings maosie 21,924 en 8 i) es “ep View Side View of Compal lt one of Tyesenkgp adh Saloons Figure 13 Directip feed arrangement wit the design of the pocket should include wall liners capable of withstanding rolling impact of material discharg- ing from the crusher iself, Although these liners should be very long lasting, maintenance access to change them is still required, The greatest maintenance load in the pocket is the discharge slot, which should be designed as self-relievi (where the width of the slot becomes wider and higher off the receiving feeder as it moves toward the front of the bin) Maintenance access to the bin should be through large barn door-style access, which will be required anyway for crushers that neod bottom access for maintenance ofthe hydraulic shaft adjustment assembly. Large doors allow easier movement of people, tooling, and parts into the pocket. Lifting equipment is also requited to enable the heavy lip liners on the discharge slot to be replaced, Feed control (whether automatic or manual) should bbe based on limits associated with the levels in the crusher « dual-tip configuration ‘chamber and the discharge pocket or vault. Ihe standard arrangement is to have fed and green traflie management Tights to indicate o the truck if tipping can be undertaken. In general, the feed level in the erushing chamber should be suf- ficient fo protect the linets from direct impact from the rocks discharging from the truck. In underground applications, trucks designed especially for underground use may tip into the crusher, or alternatively Toad-haul-dump vehicles may be used, When compared (0 ‘open pits, using vehicles with relatively small payloads some- ‘times requires installation of bin and feeder arrangements 10 ‘ensure choke feed to the crusher. Discharge arrangements for gyratory crushers usually ‘consist of a discharge pocket of vault with a heavy-duty belt ‘or apron feeder taking the material from the pocket onto a ‘conveyor for further transport. The iascanianeous through- put of a large primary gyratory can fluctuate of surge widely Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved402 'SME Mineral Processing ond Extractive Metallurgy Handbook ‘depending on feed type and size distribution. The use of the discharge pocket and feeder allows designers and operators to ‘control the rate of discharge to downstream conveying sys- tems, enabling a more efficient, lower-powered conveyor and drive system to be used. ‘Topography will mainly impact the earthworks require- ments for the crushing installation, and in some cases these ‘can be significant, particulary given the height of lange pri- mary erusher and associated equipment, Geographical location has major impacts on supporting ‘equipment. One of the main factors is the ambient tempera- ture, Al crushers have recommendations regarding the maxi ‘mum absolute temperature of the lubricating oil and the delta between the inflow and outflow. Such cooling and heating systems are integral (0 the erusher to ensure that Tubrieation remains effective, Relocation of erushers and the likely frequency is a mat- ter that must be considered early in the design study. Large primary gyratory erushers are tall and heavy, and relocation is not a trivial exercise. Ifthe mine plan dictates thatthe primary ‘rusher will need to be moved, then the design of the crusher Station will need to incorporate this requirement. and support ing equipment such as low-profile transport crawlers will be needed (Boyd and Utley 2002). The factors that need to be ‘considered in terms of relocation are as follows: + Required degree of mobility + Dump and feed arrangements + Discharge arrangement + Site topography + Access and maintainability + Decommissioning or recommissioning Safety — Complexity ~ ‘Time and duration In particular, the required degree of mobility should be care fully examined, as mobility comes at a cost, For example, is the deposit amenable to strategic planning and scheduling to ‘accommodate and effectively utilize erusher mobility? The following additional elements should also be considered: + Deposit variability and number of sources or working faces + Geographical spread of sources andlor working faces + Speed of advance along strike + Trade-off between haul distance and haul climb against crusher location + Deposit topoaraphy + Crusher mobility and the overall materials handling system + Truck size, fleet number, haul profiles, and economic haul range ‘CONE CRUSHERS (Of all crushers throughout the world, the cone erusher is, by far, the most common deviee for post-primary crushing Gaties, Rasentially, the come crusher employs the same crash: ing action as the gyratory crusher, but the cone crusher head has a much shallower angle and the cecentric speed is higher. ‘Cone crushers are designed to reduce the size of feed in a number of steps and therefore generate a well-defined product size distribution, Such definition of the product is essential, because in many cases the product size ean be the primary determining step in meeting the specification of a final prod- ut, asin quarrying, or alternatively, it can be a crucial inter- ‘mediate, or preparatory step, in the mining process ‘The role of crushing plants has changed over the years. Prior to the 1980s, large multistage erushing plants were used to generate suitable feed sizes to rod or ball mill eireuits. Major examples of such plants include Bougainville Copper Limited, PT Freeport North-South, and RAssing uranium mine. However, with the introduction of semiautogenous milling, the need for ths type of erushing plant fell away. Interestingly, however, the last 10 years has seen renewed interest in cone crushing plants, with this resurgence eaused by the introduc- tion of high-pressure grinding roll technology and the move- ‘ment fo examine more energy-efficient comminution circuits that include crushers in semiautogenous grinding (SAG) mill pre-crush and pebble-crushing roles, New plants built with some of these revised views include the plants at Newmont Boddington (Hart et al. 2011), Karara Mining, First Quantum Minerals Sentinel, and FCX Certo Verde (Koski etal 2011). ‘The design evolution has led to two dominant cone crusher designs emerging: 1. Bow! agjustment + Fixed-mainshafl, base-supported machines with CSS adjustment and overload protection via movement ‘of the upper frame (containing the bowl or concave Liners) ‘+ Mainshaft mounted within a long, tapering eccentric bush, providing eccentricity to an integral crushing head, with CSS adjustment and overload protection via movement ofthe upper frame (containing the bowl ‘or coneave liners, e<., Symons eone crusher) 2. Head adjustment + Top supported (spider bush) machines, with CSS adjustment via hydraulic raising and lowering of the ‘mainshaft (with integral cone head and mantle liner) The fixed-mainshaft, base-supported design now pre- dominates in the bowl-adjusted machines. Itis seen in a vari- ety of forms, although the most common are the MP and HP. seties cones from Metso (Figure 14), with others available from FLSmidth (Raptor) and Terex Corporation (Rollercone and MVP). The other type of bowl-adjusted machine using a ‘mainshaft mounted in an eccentric bush has & more direct lin- cage 10 the Symons crusher. The Symons crushers (Figure 15) Were the mainstay of erushing plants for the majority of the 20th century, and there are still an enormous number of these units in mines and quarries around the world. The Symons style of machine uses bow! adjustment and has a base- Supported mainshaft that moves within an eccentric assembly. CSS adjustment is via a serew-threaded bow! assembly in an adjustment ring supported on the upper frame. The overload protection mechanism is generally spring based, although in the later machines, hydraulic eylinders were intreduced. Such ‘machines are still produced; for a detailed commentary on the ‘Symons crusher, the reader is directed to Flavel eta. (1985). In some instanees, developments of the base concept seen in the Symons machines have spawned modern variants, and ‘one of the main manufacturers of this style is Astee with their range of Telsmith SBS (Figure 16) and SBX crushers. With Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved3.4 | Gyratory and Cone Crushers 403 Hoop feed Poe lectin Net Tor ig Hood ol Socket nar Adin Cop Upper Heed Bushing Cnping indo ante Bashing Hyde DiveAsotly Eccone lower Hod ting ounsrsigt Gerd Ssotonory Shield Tromp favs GyindeAvanbiy ‘ecinee Maine ee Siam / im Gad Gece / Ths! Bearing upped / “rt Borg owe) Maina i ‘Wedge Asenbly ‘Adusrent Cop Seal Diver tag Due Shel Clonpina Ba Ajman ing fowl acme Fi ‘oinkame Sea! tne Bowl Liner ‘Aasipin etch yp) are Heed Oi Finger Coxeter Box (Finger Cover Ccoumershok Box shits Comnerssight CCounrsh Box Gud Labyrinth Sele CCounrshaf Bushings Pinon Droahole ube Out (Coane of Mase Figure 14 Metso MP series bowl-advated cone crusher ‘bowl-adjusted machines of both types, the terms standard and shorthead, are still used, although they were originally used in relation to the Symons style of machines. A standard arrange ‘ment ie a crusher head and bow! assembly that is designed predominantly for coarse crushing, where the feed size is large fand the product size will undergo further erushing or trea ‘ment. The term shorthead is reserved for machines that have a shorter crushing chamber and are designed to accept smaller top size and target fine erushing. lead-adjusted machines, or top-supported_ machines, were first pioneered by Allis-Chalmets under the Hydrocone brand and are still widely encountered. Because of various ‘mergers and acquisitions, the Hydrocone-style cone erusher is ‘now manufactured by Sandvik, although in moder versions, the brand name has been replaced by new designations such as CS sand CH, Hea-adjusted rchines are also available from other manufacturers including Metso (GP cones) and Earth ‘Technica (Cybas cone). An illustration ofa Sandvik CH hea adjusted crusher is shown in Figure 17, Outside oF the cone crusher types just mentioned, the only other current models of cone erusher that differ funda- ‘mentally are the latest version of the Kubria crusher trom ThyssenKrupp and the MX range from Metso. Both machines ‘are new entrants to the market with limited information avail- able. The Kubria has appeared in a couple of forms with the older version being similar in principle to the head-adjusted ‘cone crusher of a hydrocone type. The newer version is also head-adjusted, but there is no supporting spider arm for the top of the mainshaft. In this regard, itis essentially a hybrid aching, and ite elsimed to offer the advantages of hydraiic setting adjustment via the mainshaft and head, but with high ‘eccenitie throw and without the need fora spider spanning the top of the machine, A description ofthe new HKB 2300 is pro- vided by a 2014 AMining Magazine article (“A Fresh Approach to Cone Crushing”), although further details and the success ‘ofthe design are not currently known. ‘The Metso MX cone crusher (igure 18) is a fur ther attempt to blend the best features of the bowl-adjusted and hydraulic shaft adjustment-style cone crushers. In the ‘ThyssenKrupp HKB 2300, the manufacturer relies entirely on 4 hydraulic shaft adjustment style for all setting adjustment na overload protection. Metso's MX ctustir uses it design where the CSS adjustment is still controlled by a serew thread Dow! adjustment, but a hydraulically supported mainshaft is, used hoth as an overload device and to temporarily remove Toad, so that CSS adjustment can be performed without the need to stop the feed to the crusher. Using this patented "Multi-Action” concept, which allows automated control of CSS adjustment and wear compensation, the manufacturer claims that productivity of the machine is increased and liner life is extended (Metso 2017). Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved404 'SME Mineral Processing ond Extractive Metallurgy Handbook Feed Pattern — Fee Adjvtnen Poa Maina Na Torch ing ‘Adina Cop Feed Cone Cover ae Bowl Seo ines Bo ond Won ‘Adjstnan Rag Dust Cllr Mane einshat ea —— Socket Sealing fing — ‘Aen Goad Firion Tht Washer loner Ecce Bashing Eccemic — ‘Suter Een Buin Mian Sep Booting Pees Mainhame Cop Fk Lock Foe _ Mainshal Sloore ‘Ajuoeent Cop Adjuvant Ring onl Adjuinent Ram — Seng Bot Maiskome Pn Upper spaing Segre Sing Socket nae eiton et om Spina Seare! Se Sect ‘Cours Box Guard __- Ot Finger ire Housing Caer Cortera Bushing loner Counter Bushing ‘Countsshah Box Course Box Soo! outa of Maso Figure 15 Cross section of standard and shorthead Symons cone crushers Principles and Terminology ‘When considering cone crushers, itis erucial for operators and ‘engineers to understand that the energy distribution within the ‘crushing chamber of the cone crusher is of paramount impot= tance. There are many ways of categorizing the parameters of importance in cone crushers, and one approach (Bearman et al, 2011) is to consider what controls the energy application. “The following are the main topics: Machine design variables (MDVs) Food material variables (FMVs) ‘Machine operating variables (MOVs) Muchine lies ~ Volumetric ~ Power = Fore + Flow-sheet design and interaction with other equipment MVE are those parameters that are part af the inher ‘ent design of the erusher and will vary between designs and manufacturers. In most eases, the parameters can either not be ‘changed or can only be changed with the input of the manu- facturer. la summary, the MDVs are as follows: + Pivot point, In head-adjusted cones, the pivot point of the cone head is within the spider bush area, whereas in bowl-adjusted cones, itis located in space within the ‘geometry of the head or, in modern versions, above the ‘cone head, Eccentric throw and motion. This is accomplished through an eccentric assembly, which is also sometimes referred to as a wedge plate in Rollereone crushers. The assembly sits on the vertical centerline of the crusher, but the assembly has a bore that is eccentric rather than ‘concentric. This eccentricity provides the gyration of the ‘cone head and the movement from OSS to CSS. Eecentrie speed. Most crushers can be run at speeds within a 15%-20% range above and below the design fig- ure sot by the manufacturers, Chamber and liner design (Including feed opening) parameters are a follows Designs vary depending on size reduetion duty = Modifications ean dramatically influence energy distri= bution in the chamber, ~ There is variation in the nip angle between the mantle tnd bow! (or concave) down the length of the ehamber. Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved3.4 | Gyratory and Cone Crushers 405 \exge toot od feed epening alow extacoore sono How smocty ino he chember, debverng ‘exttanding pelomarce Dynamic At sion eral ocing elders re lows odsiments der ‘cele fer molenance food ac by romeo conto, Lol ong system combines layin seal an pion ng provide superior prowl, Cerood call mono and ale provide Head si proses courorwoight rim protecton tnd sos fom wer (en al tring sive perlermonce and relly, long ine nd outer bronze slooves ‘Optnal hyo anipin tem ‘dl vod cking orcs tobe Feder marganet nr wr, no ‘absed over wi oreo ‘esaing or mointonnte reqied Couey enh Figure 16 Telsmith SBS-style bowl-adjusted cone crusher Couey of Sordi ire 17 Sandvik CH head-adjusted cone crusher Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved406 'SME Mineral Processing ond Extractive Metallurgy Handbook Conte Mao Figure 18 Metso MX cone crusher MOVs are those variables over which the operator has some control and these fall into two areas, as follows: LES. Minimum distance between the mantle and bow! (concave) liners varies. 2. Feed = Feet Feed positioning and distribution ~ Segregation of particle size into the erusher FMVs are the properties of the feed that will impact the performance of the crusher. Some FMVs are simply character {etic of the material found atthe mine or quarry site, but others such as the feed size distribution or the maximum feed size ‘are somewhat within the control ofthe site and the flaw sheet: + Feed material strength and abrasi ~ Higher sirength requires greater power input to achieve size reduction, Highly abrasive feed will inerease liner wear rate and can lead to the development of poor wear profiles and. the generation of high crushing forces. See Chapter 3.6, “Crusher Selection and Performance Optimization,” for further information. + Bulk density High bulk density can restrict the amount of erushing possible and ean lead to a volumetre limit. The aly affected. + Feed size tion. Directly linked to bulk density, the length of size distribution and percentage of fines ean dramatically influence performance and crushing force requirements + Maximum feed size. To meet nip angle requirements, the feed opening and liner design vary + Feed moisture content. For most. materials, mois- fie content af <4% has na material impact. hut higher moisture levels can exacerbate packing and thus erushing force requirements. The handling characteristics of the feed must also be considered. There is no test for materi- als handling specific to crushers, bu if bulk handling tests show a propensity for material to resist Flow, then this is 4 strong sign that erushing problems may be expected, Feed containing clay, either naturally occurring or from alteration of minerals in the parent rock, will cause flow impediments in the chamber and this will greatly increase the chance of packing. Where such feed exists, removal ‘of the material prior tothe erusher should be targeted, or im situations where this is not possible, alternative types ‘of erusher should be considered. Cone crushers have been subject to a significant amount of development over the last 30 years and much of this devel- ‘opment has becn around the MDVs, inercasing the through- put and size reduction and developing systems to protect the crusher from overload conditions. In the preceding discussion about MOVS, only feed pre= sentation and CSS are given as parameters. This is correct, but recently, manufacturers and researchers have examined ic use Uf variable-speed Urives (VSD) 90 tha hie excentate speed of cone erushers ean be varied in real time. The ability to apply VSD technology is now possible because of the sig- nificant reduction in the cost of VSD systems, particularly for the larger drive sizes. Hulthén and Evertsson (2008) examined optimization of an aggregate crushing plant, with the VSD ‘system applied to the tertiary Metso HP300 cone crusher. The application of speed control was eredited with extending the liner life inthe tertiary crusher by 27% and also increasing the operational throughput of the crushing plant by 4.2%, A pilot study examining the issue was presented by Jacobson ‘and Lamminmaki 2013) where one of the main conclusions stated that the speed adjustment 1s best used to “account for changing ore/feed conditions, or to use the speed as a dynamic input parameter into a conteol system,” Regardless of the type of crusher used, cone crusher applications can be summarized: + In Hine hao secondary tertiary, and quaternary stages giv ing increasingly fine crush. + Reeyele (or pebble) uses the machine to recrush oversize from SAG or autogenous grinding mills, + Other are often not distinetly different from the preced- ing applications, but they are named to show a distinct purpose. An example would be SAG pre-crush, where a cone crusher is used to reduce the feed size, or portion “of the feed size distribution, prior to SAG treatment. Secondary crushing is used to treat material that has been primary erushed and therefore usually involves a feed top size ranging from 150 to 350 mm (6-14 in.) with CSS values at approximately 25-60 mm (1-2 in.). Despite varying opin- ions, the removal of fine material from the secondary crusher feed is still the main recommendation, The definition of fines inthis case is usually based on the CSS of the crusher; that is, ‘any fine material less than the CSS should be removed from the feed via aralping cream Remaving the fines fern the feed ensures that there i sufficient space inside the crushing, chamber to allow crushing and the associated increase in the bulk density of the material within the chamber. Under these circumstances, secondary crushers are usually power lim- ited. If fines are not removed, the bulk density in the erush= ing chamber is already high bofore crushing commences. Ae Cong ©2018 Soci for Mining, Meagan Exploration. lights eseved3.4 | Gyratory and Cone Crushers crushing of the larger particles takes place, the fines generated add to the already high bulk density, and the crushing cham- ber reaches a point whereby it becomes packed. Packing is 4 term indicating that the volumetric capacity of the crusher hhas been exceeded and the input power cannot cause Turther breakage. At this point, the force is transmitted through the packed chamber and into the overload system of the crusher. In fixed-shatt, base-supported machines, the upper frame will relieve, either hydraulically or via springs. The reli system will allow the material to pass and then try to return to the original CSS to continue crushing. In top-supported machines with hydraulically supported mainshafis, the hydraulics will relieve and cause the mainshaft and head to drop before trying to return tothe operating CSS. Packing is undesirable and fr {quent events will eventually cause damage to certain mecha cal areas of the crusher. Packing can be deseribed in various terms, with small-scale movement without relief being termed “fluter and major relief events often deseribed as tramping or ‘ring bounce. These terms are references to the fact that relief is often caused by the ingress of «ramp metal or other uncrush- able material, and in Symons style machines, this was seen as the upner frame and adjustment ring bouncing. Operationally, secondary crushers with fines in the feed suffer as they often reach both power and packing limits simultaneously, which prevents the machines from perforn ing to the required levels, Tertiary crushing applications typically take a feed top size of 30-80 mim (13% in ) and porate at CSS values of approximately 10-20 mm (!4-% in.), depending on the feed ‘material and required output. Quaternary crushing is usually the most extreme duty for cone crushers, and this will often involve feed top sizes as small as 6 mm (14 in.) and up to 20 mm (4 in). In this stage of crushing, the aim is often to produce the finest product possible, and henee CSS values can bbeas lowas 3-4 mm (approximately % in.) but more typically 6-12 mm (/-% in.) As with secondary crishers, fines should be removed; for tertiary and quaternary duties, the removal of fines is even more critical, because in most cases the feed bulk density is already high. The result of the fine, high-density fed is that these stages are more often controlled by packing, and volumetric Timits. Wear of the liners can often exaggerate the effect of high bulk densities, and in many eases, the need fora liner change isa trade-off between liner life and machine ‘operational stability Recycle or pebble crushing has emerged as one of the tung uses OF cone cluslers, and ia Unis duty, the idea is crush pebbles from SAG mills to improve the efficiency of the srinding. Pebble ports on SAG mills usually have apertures ‘measuring approximately 40-100 mm (14-4 in.) and hence the top size ofthe pebble erusher feed is dictated by the aper- tures. The lower feed size is mostly controlled by the aperture lof the sereen receiving the pebbles ffom the mill, Its com= ‘mon fo have a lower feed size of 10-12 mm (approximately ‘4 in.) The deployment of pebble crushers is reliant on the plant design, but the product from the crushers ean either be introduced into the mill feed or alternatively directed back to the pebble screen atthe mill discharge. Pebble crusher duties are often considered to be a rea- sonably tough duty because the pebbles themselves tend to represent the harder material. In addition, there is always the potential for worn mill balls to enter the pebble crusher. Various metal detection systems are available to prevent ingress of mill balls with most being linked to a diversion 407 system fo dump the part of the feed containing the mill balls prior to the feed chute. Crushers can also be used for other duties, with one being to treat material prior to semiautogenous milling. This ‘rend has fluctuated in popularity, but under certain circum stances, it ean prove to be highly beneficial. Although the duty is referred to as SAG pre-crush, itis essemially a secondary ‘crushing duty. Reducing the mill feed size ean generate higher throughput, although careful consideration needs to be given to ball charge, mill speed, slurry pooling, and grind size Construction and Design ‘The two styles of cone crusher discussed in this section have ‘range of common design features, as would be expected Both styles rely on applying an eccentric motion to generate the usual open side and closed side discharge settings, that i, ‘OSS and CSS, respectively. “The major components of cone erushers can be summa- rized as follows: + Upper frame, including adjustment ring and crushing bow! liner + Crushing lead, including nant He, + Eocentric assembly + Mainframe + Countershaft and gear set + Overload protection In the bowl-adjusted machines. the upper frame isa ‘all description for the section containing the bow! assem- bly (including bow! liner or concave), setiing adjustment ring {including clamp ring, clamp eylinders, and adjustment mech anism), and feed hopper assembly. The main components of ‘the upper frame are shown in Figures 14 and 15. ‘The function of the total assembly is to socure and lock the upper stationary crushing surface against the forces gener- ated. The other main functions are to provide adjustment of the CSS via a serew thread and to offer overload protection in the case of uncrushable material entering the chamber. There are not 100 many major variations from this design, with the only significant exception being in corse smaller cone erush cers whereby the adjustment and overload is based on the use ‘of hydraulics and a frictional wedge to lock the upper frame in place. The Terex Corporation Automax is one cone crusher that has this type of arrangement Within the upper frame, the bow! liner is securely: mounted. The liner is the stationary crushing member, and it is usually the liner that controls the maximum feed size that ‘can be presented tothe crushing chamber. full discussion of ‘crushing chambers is provided later inthis section In the head-adjusted machines, the mainshaft is supported ina top bearing within a spider arrangement, not dissimilar in appearance to w primary zyratory crusher spider, The main- shaft i free to turn and slide within the bearing, and so, unlike the base-supported machine, the upper section of the machine ‘only needs to provide a pivot point for the erushing action, via the location of the mainshat, The crushing head in bowl-adjusted machines usually has ‘ahead angle of approximately 39-43 degrees. A mantle ner is located on the head via a combination of a head nut and in some cases backing material poured into the cavity between the liner and the head. The mantle liner casting has a machined surface around the lower circumference of the liner, which seats onto the head. In current versions, the head itself is free Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved408 'SME Mineral Processing ond Extractive Metallurgy Handbook totum on the eccentric assembly that, in tur, is free to rotate around the stationary mainshaft. The rotation is facilitated via 1 spherical seat on the top of the shaft and through the use of bronze bushes or roller beatings near the top and bottom of the head, Head-adjusted machines tend to have a steeper head ‘angle and the head is integrally fitted to the mainshafl. Unlike the bowl-adjusted machine, an eccentric motion is applied 10 the lower portion of the mainshaft below the crushing head. “Mantle liners for these machines tend to use a machined finish so that they are secured to the crushing head via a threaded ring and backing material is not commonly used. ‘The coventric assemblies that provide the motion and the total throw vary in design between the two types of cone ‘rusher being discussed. In the bow-adjustable version, there fare two mainshaft arrangements, In the fixed-mainshafl vari- ant, the mainshatt is stationary, being shrunk into the main- fame. With the mainshaft stationary, the eccentric is designed to rotate around the mainshaft and within the crushing head. In ‘most machines, the eccentric is separated from the mainshaft by a bronze bush and then the eccentric is separated from the ‘rushing head by upper and lower bronze bushes. This general arrangement is widesnread. and the only major modification is that in some machines, the bushes ure replaced by roller bear ings, Smaller cone erushers from ElJay, Pegsoo, and JCI all use some form of the roller bearing design. Because of market rationalization, the Rollereone, Autocone, and Aulomax now sit “within the Terex Corporation as the Rollercone MVP and the ‘TC, respectively. KPI-ICT are now within the Astoc aryanizae tion, and they manufacture the LS and the Kodiak cone erushers, ‘again using a roller bearing design. Figure 19 shows the various methods of imparting eccentric motion to the cone head. The ‘other version for bowl-adjusted crushers is where the mainshaft sits inside a long eccentric bronze bush, freely mounted inside the rotating body of a concentric mass, with the mass driven by bevel gears from a countershatt, This is essentially the principle ‘employed in the Telsmith cone crusher (Figure 16), and it was the basis ofthe original Symons cone crushers. Head-adjusted machines use an eccentric assembly simi- Jar to gyratory crushers in thatthe eccentric is located within the mainfmame at the base of the crusher, The eccentric i allowed to rotate within the mainframe through the use of a bronze bush. The mainshait is located within the eccentric and is fice to rotate courtesy of another bronze bush. With the ‘eccentric being rotated by the gear driven from the countet- shaft, the inertia of the system causes the mainshaft to rotate tuwve fio one eatrente oF the event position 1 Ure ‘other, which is essentially moving from a minimum to a maxi- ‘mum throw position, ‘The mainshat in a bowLadjusted stationary mainshaft machine is secured by a temperature-induced fit into the body ‘of the mainframe and is a relatively short, squat shaft. The “dimensions of the shan are deliberately short and roBUSt, ast is only supported by the mainframe and therefore has to resist, ‘rushing forces. The Symons style bow-adjusted crusher has 8 lighter mainshat, integral withthe crushing head. The main- shaft i supported for a majority ofits length ina long eccentric bush; again the mainshaft is relatively short. The mainshaft in ‘8 head-adjusted machine s a different proposition and is delib- ‘rately much longer, as it is supported within the spider bearing atthe top and located within the rotating eccentec atthe base, This difference in mainshaft function translates into a difer- ‘ence inthe pivot point of the cone head. The evcentric offset is also canted from the vertical, and thus both types of machine will have a point of zero motion, that is, a pivot point, In the hhead-adjusted machine, the pivot point is 2 physical position Usually ata point on the mainshaft within the spider bearing. In the bowl-adjusted crusher, the pivot point isa location in space ata distance above the center of the crushing head. Egcentric assemblies are driven by a bevel gear set, with the gear ring fited to the outside of the eccentec itself and the drive gear mounted on the end of the countershaft. There isa sig- nificant speed reduction between the countersbaft specd and the speed ofthe eccentric. Examples inelude countershaft speeds of approximately 800 rpm for larger cone erushers, which trans- late into cvcentric speeds of approximately 250-350 rpm. ‘Overload protection is used in cone crushers to protect the machines during the ingress of uncrushables or where the packing density in the crushing chamber becomes 00 high and the mass in the chamber effectively becomes unerush- able. In Symons style crushers, the protection was imple- ‘mented using an array of springs around the circumference of the crusher. Bowl-adjusted machines now predominantly use a hydraulic version of the spring system, whereby hydrau- lic cylinders and rams allow the increased pressure to relieve aainst a set of (or a sinsle) hydraulic accumulators. thus permitting the bowl and adjustment ring assembly to lif and pivot away from the upper frame, allowing uncrushable ‘material to pass. A hydraulic system for a bowl-adjusted cone cnusher is shown in Figure 20. In top-supported cone crushers, the mainshaft sits on hearing plates located on top of the hydraulic system. When crushing, the mainshaft and integral crushing head operate in a raised position, but if significant pressure increase is detected because of uncrushable material or packing, the hydraulic sys- tem will relieve and allow the mainshaft and head to drop. Key to the process performance of cone crushers is the design of the crushing cavity that ia formed between the bow! and mantle liners. All manufacturers have a range of liner configurations that allow varying feed size and minimum CSS values. Typically the chamber that will accommodate the larg- est feed size is designated as extra coarse, and then the liner range will move down in feed size through multiple variants tofine or extra fine. Liner design is erucial to the correct appli- cation for a crusher and also for the optimization of erusher performance, Figure 21 shows a typical range of erusher eavie ties for a cone crusher. ‘The key design features ofa liner set include + Ability o handle maximum feed size, Application of staged size reduction down through the cavity, Ability to achieve the required CSS, Ability to pull material into the chamber and effectively capture and break material, AA smooth progression of nip angle throughout the cham ber, and + Ability to maintain an effective chamber profile even as wear takes place. ‘The crushing chamber dictates the change in sectional volume throughout the cavity, and therefore the design of the profiles detines the choke point. Lhe choke point is the mini- ‘mum cross-sectional area in the chamber from a plan view perspective, The concept of choke is very important in cone crushers, because once the volume of material in the cham- ber exceeds the minimum sectional volume, the material will build up above the choke point. In this scenario, the choke Cong ©2018 Soci for Mining, Mealy, an Expration. lights eseved