Introduction

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A Cone Crusher, often referred to as a Gyratory Cone Crusher can be used for Secondary or Tertiary crushing sometimes even Quaternary crushing. Ideal for crushing medium to hard feed materials with varying moisture content but not suitable for sticky materials. Used extensively throughout the quarrying industry to produce a variety of sized products as required by the construction market. Osborn Telsmith manufactures 3 series of Cone Crushers at their Elandsfontein factory. The “C Style”, the “D” style and the latest design SBS series.

The difference between the “C” style and the “D” style is in the adjustment and locking mechanisms and are of the older spring type design. The SBS series uses hydraulics to lock and adjust the machine. Within the SBS series, several mod-els of a Heavy Duty design are available. The HD models have a reduced stroke and thicker main shafts. Caution is advised when selecting a HD model as throughput capacities are on average 10% lower then the standard SBS machine. With all of Osborn’s Cone Crushers, manganese liners are available in a range from extra coarse to fine configurations. These crushers are most suited for feed material having a compressive strength of around 350 Mpa.

PRINCIPLES OF OPERATION & MAJOR FEATURES OF SBS CRUSHERS

The crushing action is produced by the closing of the gape between the head and the bowl caused by the eccentric mo-tion of the verticle spindle inside the crushing chamber. Both the head and the bowl are fitted with replaceable manganese liners. This cam and lever crushing action provides maximum efficiency and distributes crushing loads over a large bearing area. The unrestricted feed opening allows easier passage of large or slabby material. When required, the hydraulic relief system automatically releases upper frame clamping pressure to ensure tramp iron or other uncrushables do not damage the crusher.

If needed, the entire upper frame can be hydraulically raised to clear large obstructions and jammed material. Power rotation allows quick push-button adjustment of the discharge opening, even while crushing is in progress.This feature also allows high speed extraction of the support bowl assembly for liner replacement or maintenance activities. An automated anti-spin device (optional) prevents the head from turning with the eccentric when the crushing chamber is underfilled or empty.This anti-spin feature helps prevent excessive liner wear during low feed rate conditions. This zero maintenance equipment requires no adjustments or re-settings and is just one of the innovative designs from Osborn Telsmith that improves crushing costs. The external oil lubrication system provides a continuous supply of filtered oil to the crusher’s internal parts. The electric oil pump allows warm oil to be circulated through the crusher before start-up. A shut-down alarm immediately stops the crusher in the event of low oil pressure, low oil flow or high oil temperature. The hydraulic and lubrication systems can be integrated with the crushing plant controls for remote operation and crusher automation through the TRAC 10 automation control.

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Crusher Features & Benefits

Zero Maintenance Anti-Spin System:

In most installations an anti-spin system will provide longer manganese life and promote a more cubical product. In the Osborn Telsmith design, a small hydraulic motor is attached to the shaft preventing the head from spinning when running with intermittent feed. No adjustments, resetting or regular maintenance schedules are needed. Your crusher keeps right on performing.

Eccentric and thrust roller bearings create cam and lever crushing action.

Large crusher feed opening yields high performance.

Labyrinth seal and piston ring provide a dual sealing system, keeping oil clean and reducing wear.

External locking cylinders are accessible for maintenance.

Internal counterweights enable the crusher to be balanced at all times.

Head skirt protects counterweights and seals.

Countershaft assembly uses tapered bearings to reduce end play and extend gear life.

Optional hydraulic anti-spin system reduces manganese liner wear, requires no resetting or maintenance.

Long inner and outer bronze sleeves allow radial crushing forces to be distributed over a wide area.

Easily replaceable frame liner, frame-arm liner and countershaft box liners offer decades of protection.

Maintenance-free overload relief manifold and valve.

Dynamic AdjustTM system allows fast adjustments and remote control.

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RecommendedMinimum

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Feed Opening at MinimumClosed Side Setting

Open (A) Closed (B)

24 ‘C’ 5S-Extra Coarse 12 117 105

S-Coarse 10 88 75

S-Medium 6 63 47

FC-Medium 5 44 28

36 ‘D’ 7S-XX Coarse 19 196 165

S-Extra Coarse 19 180 158

S-Coarse 12 133 117

S-Medium 10 114 95

FC-Medium 6 50 28

27 SBS S-Extra Coarse 19 140 110

S-Coarse 13 120 90

S-Medium 10 100 70

FM-Fine Medium 10 80 50

FF-Fine Fine 8 60 30

38 SBS C-X Coarse 25 175 146

C-Coarse 16 133 98

C-Medium 16 121 86

F-Coarse 16 108 73

F-Medium 13 95 57

F-Fine 10 83 44

44 SBS C-X Coarse 25 203 165

C-Coarse 19 149 108

C-Medium 16 124 89

F-Coarse 16 108 67

F-Medium 13 95 57

F-Fine 10 89 44

52 SBS C-X Coarse 25 260 235

C-Coarse 19 187 146

C-Medium 16 140 95

F-Coarse 16 127 89

F-Medium 13 114 73

F=Fine 10 92 48

57 SBS C-X Coarse 32 273 235

C-Coarse 25 229 216

C-Medium 19 219 184

F-Coarse 19 152 111

F-Medium 13 117 73

F=Fine 10 89 45

68 SBS C-X Coarse 41 292 260

C-Coarse 29 264 222

C-Medium 19 225 178

F-Coarse 19 168 127

F-Medium 16 124 79

F=Fine 13 86 41

CSS

Typical “F” Arrangement

CSS

Typical “C” Arrangement

Crushing Chamber

Open Circuit Crushing Capacities - One Pass - Cone Crushers

Crusher Total throughput at discharge setting (CSS) shown

Model 6mm 10mm 13mm 16mm 19mm 25mm 32mm 38mm 45mm 50mm

24 “C” 14-18 19-23 24-28 28-33 33-38 42-48 48-55

36 “D” 31-37 37-42 50-57 66-72 78-85 85-90 98-107 95-120

27 SBS 60-68 68-78 78-85 80-95 90-115 100-130 120-140

38 SBS 81-104 104-131 126-153 140-171 171-207 198-243 212-261

44 SBS 111-144 135-180 162-212 180-234 221-288 257-333 288-374 324-410

52 SBS 158-203 185-239 207-270 252-329 288-378 329-428 369-477 410-527

57 SBS 270-344 302-392 360-473 392-504 437-563 509-657 572-738

68 SBS 423-549 482-626 531-689 572-743 635-825 702-905

Closed Circuit Crushing Capacities - Cone Crushers

Crusher Total throughput at discharge setting (CSS) shown

Model 6mm 10mm 13mm 16mm 19mm 25mm 32mm 38mm

24 “C” 16-20 21-25 26-30 31-36 35-40

36 “D” 26-30 34-40 40-45 55-60 70-75 75-80

27 SBS 64-72 75-80 85-90 95-98 98-120 110-135 123-145

38 SBS 104-126 117-144 140-171 153-189 185-230 216-270

44 SBS 135-176 153-198 180-234 198-257 243-315 275-351

52 SBS 158-203 180-234 203-261 230-297 279-360 320-405 342-437

57 SBS 270-347 297-387 333-432 396-518 428-540 455-512

68 SBS 410-527 437-503 468-603 527-684 585-756 617-774

Model SBS Typical product gradations (one pass)

Sieve % passing closed side setting

Size 10mm 13mm 16mm 19mm 22mm 25mm 32mm 38mm 45mm 50mm

125 100

100 100 99

87.5 100 99 97

76 99 97 93

64 100 97 93 83

51 100 98 91 79 66

44 100 99 95 84 69 54

38 100 99 96 88 73 58 44

32 100 99 96 89 76 61 45 35

25 99 95 87 78 63 47 35 27

22 100 95 89 79 69 54 39 30 23

19 100 98 92 81 70 60 45 33 26 20

16 98 93 83 72 58 48 35 27 22 17

13 95 84 72 59 47 38 27 22 18 14

9.5 86 69 56 43 35 28 21 17 14 11

6.4 66 49 39 31 25 19 15 12 10 8

4.7 52 39 31 25 20 15 12 10 8 6

2.4 31 23 19 15 11 8 7 6 4 3

1.2 22 15 12 10 7 5 4 4 3 2

0.6 15 10 7 7 5 4 3 2 2 2

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Osborn Telsmith Gyrasphere Crusher - Screen Analysis (one pass) Models 24 & 36 Typical

Product Closed side setting of crusher

Size 6 8 10 12 16 19 22 25 32 38 45 50-90 100-75 100 90-60 100 90 79-50 100 85 81 59-45 100 94 72 60 48-38 100 100 95 75 59 48 38-32 100 98 88 75 54 44 36 29-25 100 94 79 65 53 38 30 26 21-22 96 82 67 54 43 33 26 22 19-19 100 84 69 55 44 36 28 22 19 16-16 94 70 56 43 36 31 25 19 16 14-14 100 89 63 49 39 33 28 22 17 15 13-12 100 97 87 55 43 35 30 26 20 15 13 10-11 99 90 79 47 38 32 27 24 18 14 11 9-9 93 83 70 40 33 28 24 21 16 12 9 7-8 85 73 58 34 29 24 21 18 14 10 8 6-6 74 60 43 28 24 20 17 15 12 8 6 5-4 60 44 32 23 19 16 14 12 9 6 5 3-2 34 22 17 13 11 9 8 7 5 3 2 1-1 16 12 9 7 6 5 4 3 2 1 1 0

The Osborn Telsmith 36 “D” Style Gyrasphere Cone Crusher

The Osborn Telsmith 24 “C” Style Gyrasphere Cone Crusher

Mainly for the replacement of existing Gyrasphere Crushers , the Spring Style machine is often selected for their low upkeep and high reduction ratio. The most popular models are the S for Coarse and Intermediate Crushing and the FC for Fine, Secondary and Tertiary crushing. These spring type cone crushers are ideally suited for those remote mining areas where the level of operator’s skills can easily cope with maintenance and shutdowns.

Generally very simplistic in design but extremely robust and very popular in smaller plants with a fairly low capacity requirement.

For smaller settings, please contact Osborn

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SBS Dimensional Data

Dimensions (mm) - Cone Crushers

A B C D E F G H I24 “C” 1700 1270 N/A 430 N/A 700 580 1070 125

36 “D” 2160 1730 N/A 430 N/A 900 750 1340 150

27 SBS 1850 1450 400 150 1035 540 665 965 85

38 SBS 2310 1569 740 510 1219 865 790 1380 140

44 SBS 2440 1700 740 475 1365 940 865 1310 140

52 SBS 2535 1730 810 570 1365 1160 1020 1425 190

57 SBS 2900 2090 810 550 1607 1220 1170 1680 190

68 SBS 3140 2235 905 710 1708 1550 1440 1980 122

with Power Rotate

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Reliable Hydraulic System Control

One simple power unit in a Osborn Telsmith SBS series cone crusher is used to power all it’s hydraulic systems:

• Hydraulic Overload Protection• Dynamic Adjustment• Hydraulic Lock• Hydraulic Clearing • Hydraulic Anti-Spin System

Powered by an electric motor, the system utilizes a pressure compensated variable displacement pump to provide the correct hydraulic flow and pressure at all times.No accumulators are used, which means a more consistent pressure and less maintenance and downtime. Adjustments and clearing are easily accomplished with the touch of a finger. Hydraulic systems on the SBS can integrate with your plant controls for remote operation and crusher automation.

Better Overload Protection

Osborn Telsmith’s exclusive, patented design limits the amount of force a cone crusher needs to absorb when it encounters overloads or tramp metal- providing the best protection for internal parts. A limited force is maintained as the crusher relieves, unlike spring or accumulator systems that experience increasing forces (see graph).

At the heart of the patented system is a manifold and relief valve. Whenever crushing pressure exceeds the relief valves setting, the valve opens and allows hydraulic fluid to pass through to the tank. Since the crushing pressure is limited by the relief valve setting, the internal parts are protected from overload.

Dynamic Adjustment and High Speed Extract

The SBS Dynamic Adjust system is designed to maximize plant efficiency.

It enables possible adjustment under load (but not advisable) through local push buttons or remote computer automation. Adjusting the crusher is just as simple as pushing a button.

The SBS hydraulic console includes a digital display to show the current setting. As you adjust the crusher, the display continually changes to let you know exactly what the setting is.

The dynamic adjustment system also includes a high-speed extract mode (used when changing liners). The result- faster crusher disassembly and cost savings.

A Hydraulic Locking System

Osborn Telsmith’s hydraulic lock system works with the crushers dynamic adjustment feature to provide adjustment under load. A uniform locking pressure keeps the setting fixed during crushing operations. When it’s time to adjust, the lock cylinder pressure drops to approximately 750 kPa to allow for dynamic adjustment. This low pressure keeps the threads in gentle contact to prevent damage from chatter.

The lock cylinders are mounted on the outside of the crusher, easily accessible for repair without dismantling the crusher.

Hydraulic and Lubrication Systems: SBS Series

Quicker Chamber Clearing

Power failure or tramp metal in the crusher? An SBS crusher clears in minutes with the push of a button, avoiding hours of downtime. Simply flip the switch from the “crush” mode to the “clear” mode, and the upper frame is lifted vertically allowing material to fall easily and safely through the crusher. You’re back in production with minimal loss of time and profitability.

Complete Lubrication Protection

Thanks to a packaged oil lubrication system, the SBS comes equipped with all the modern features you need for the longest possible service life at the lowest cost.

Pre-assembled onto a skid module for ease of installation, the package includes:

• Oil Tank • Immersion Heaters• Electric motor-driven oil pump• Oil cooler• Multiple element filtration • Alarm system with multiple layers of protection- - High oil temperature - Low oil flow - Low oil pressure

Options are available to provide 4-20mA signals for monitoring a crushers operating parameters from a remote location.

This table compares the forces exerted on the crusher using the most common system types (spring, accumulator and relief valve.) The spring system forces increase quickly asthe spring compresses. The accumulator system forces also increase, although not as quickly as the spring system. The Osborn Telsmith manifold and relief valve system is a successful way to limit overload force, providing better protection, longer parts life and less crusher downtime.

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Osborn Telsmith Gyrasphere Crusher

Lubrication Pack and Cooler (Air)

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Liner Selection

There are a number of different criteria to consider when selecting the right chamber for your crushing needs. There is one, however, that must always be considered. That you have well-graded feed to the chamber. A well-graded feed is generally thought to be 90-100% passing the closed- side feed opening, 40-60% passing the midpoint and 0-10% pass-ing the closed-side setting. ( Fig.1)

Feed Problems

A feed that is not well graded will invariably cause one or more problems with the crushing operation. If the feed is too coarse or too fine, the following problems could develop. • Reduced TPH through the crusher.• Feed too coarse = low horsepower consumption, too fine = high horsepower consumption• Coarse feed will not produce as cubical a product as it should be.• Feed too coarse will cause the upper part of the crushing chamber to wear out• Feed too fine can cause upper frame movement• Oil temperature will rise if feed is too fine• Most importantly is the difference in capacity from a new liner to a worn out liner as the reduction in capacity is

caused by the lower portion wearing faster than the upper portion which causes the feed operation to close off. Choke Feeding Is A Proven Aid

In order to maintain the maximum levels of capacity, gradation and cubical product, a crusher must be choke fed at all times. The best way to keep a choke feed to the crusher is with a surge bin ( or hopper) and feeder that are located prior to the crusher. Choke feeding is almost impossible to achieve without a hopper and feeder. When the crusher feed is reduced, the product tends to become coarse, with slivers and flats occuring.

Liner Replacement

When should you replace a liner in your crusher?

If the liner is wearing evenly throughout the chamber, you should consider changing out the manganese when it has worn down to about 25mm thick at the bottom. At about 19mm to 16mm thick, the manganese will crack, causing the backing material to begin to disintegrate. This in turn will cause the liners to break loose. If this happens, continued operation could destroy the seat on the support bowl or the head of the crusher.

Fig 1. A well graded feed

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Osborn Telsmith cone crushers are designed to be compatible with automated plants with our remote control TRAC 10TM SYSTEM that monitors crusher operations, provides automated calibration and setting controls, and protects the crusher from overload. Optimum crusher settings are maintained via remote adjustment using the TRAC 10.

The operator can initiate an automated calibration process via the touch screen monitor, that automatically “zero’s out” and resets to the proper setting. Operators can also modify the crusher setting at any time even while crushing.

Sensors continually monitor crusher lubrication, hydraulic and electrical systems, making adjustments and providing advanced warnings, even though the operator may be busy in other areas. The Osborn Telsmith TRAC 10 can be installed economically into any plant. Alternatively, as a stand alone crusher con-trol system, the TRAC 10 provides SBS crusher operators with many of the advantages of automation without the cost of a complete rework of plant controls. The remote system includes:-• Push button adjustment• Crusher setting display• Push button calibration for liner wear• Display of approximate liner wear remaining• Auto-protect mode• Display of lubrication and hydraulic conditions• Tracking of alarm conditions and trending of operation data. The TRAC 10 consists of 3 items provided by Osborn Telsmith : Crusher Panel, PLC Panel and Operator Interface (touch screen monitor) Other options are available to expand the system to broaden automation capabilities. Please consult Osborn for more information or request our Osborn Telsmith TRAC 10 brochure.

TRAC 10TM

Remote Automation Control SystemSBS Crusher Series

Application Data Sheet - Osborn Cone Crushers

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Osborn, Designers and Manufacturers of Bulk Materials Handling Equipment and Minerals Processing Plant and Equipment

Head Office:PO Box 8182Elandsfontein

1406Johannesburg

South Africa Tel: +27 11 820 7600 Fax: +27 11 388 1136

E-mail: osborn@osborn.co.za www.osborn.co.za

• All the parameters referred to above must still take into consideration the actual capacity of the crusher at required settings as the cavity has a volumetric constraint. So correct sizing of a crusher is also influenced by the actual capacity required.

• In many cases an oversized crusher needs to be selected to handle the capacity whilst the lump consideration is less important

• This is more common in ConeCrushers• The industry standard of rating various size crushers is based on crushing dry limestone with a loose bulk density of 1,6t/m³.• Factors affecting these capacities are excessive moisture, clay content, feeding method, feed gradation, bulk

density and crushability

Customer Contact Person

Phone No. Phone No.

Fax.No Date Enquiry.No

CRUSHER TYPE Hydraulic Controlled Feed

Spring Uncontrolled Feed Anti-Spin req’d ( Hydraulic Machine only)

TYPE OF INSTALLATION Mobile Semi-Mobile

Fixed

SITE CONDITIONS

Location

Altitude Metres

Ambient Temp °C Max °C Min

MATERIAL

Type

Loose Bulk Density Kg/m³

Compressive Strength Mpa

Abrasiveness High Medium Low

Flowability Free Average Sticky

Moisture Content % Max % Min

Shape of Material

DUTY

Capacity mtph

Max.Feed Lump Size mm

Min. Feed Lump Size mm

Feed Analysis Size

% Passing

Product Size Req’d mm Preferred Oil Cooling Air cooled

Req’d CSS mm Water cooled

ACCESSORIES

Base Frame Yes No

Vee Drive Yes No

Guards Yes No

Electric Motor Kw Voltage Phase RPM

Other ( Please Specify)

SPECIAL CONDITIONS

NOTES COMPILED BY

DATE :