Jaw Crushers from Osborn South Africa
Your one stop materials handling source OSBORN ENGINEERED PRODUCTS SA (PTY) LIMITED
Shaping Materials Handling
Introduction Jaw Crushers are compression crushers consisting of a fixed jaw and a swing jaw and in a single toggle or a double toggle design. The single toggle crusher is designed for a high capacity throughput due to the elliptical movement of the swing jaw which also assists in the discharge of the crushed material. As the single toggle crusher will achieve far higher capacities than the double toggle design, they are often used as a primary crusher.
INTRODUCTION
PRINCIPLES OF OPERATION - SINGLE & DOUBLE TOGGLE CRUSHERS Jaw crushers process medium to hard quarry rock or other materials by compressing it between the fixed jaw and the swing jaw. The swing jaw being the moving part is attached to a rotating eccentric shaft. The fixed jaw is an integral part of the crusher frame. Both jaws are fitted with manganese jaw liners that can be replaced or reversed when worn. During the crushing operation, the toggle plate which acts as a pivot point for the jawstock, controls movement of the lower part of the swing jaw. Although the toggle plate is designed to bend or break if uncrushable objects enter the crushing chamber, this is only applicable if these uncrushables are in the zone around the toggle plate. If uncrushable objects are at the top of the crushing chamber, it is likely that bearing failure can occur. Similarly, if the uncrushable object have managed to get below the toggle plate movement plane and sit at the bottom of the crushing chamber this could result in the bottom of the jawstock being broken. Hence, it is important to understand the limitation of a toggle plate when these other factors are present. As the swing jaw opens and closes , it compresses and crushes the material against the fixed or stationary jaw and the crushed material then drops to the discharge opening at the base of the crusher. This opening is adjustable by adding or subtracting shims between the toggle beam and the crusher frame. This adjustment is necessary when setting the different types of crushing requirements and to compensate for wear on the manganese jaw liners. The basic difference between the single toggle crusher and the double toggle is the movement of the jaws. The single toggle has an elliptical movement whilst the double toggle has a pendulum movement. A rule of thumb selection for either a single toggle or a double toggle is that when the material to be crushed has a compressive strength of up to 400Mpa and with a production capacity requirement of up to 1600tph, the correct machine would be the single toggle. For much harder and highly abrasive materials with a compressive strength of up to 600 Mpa, the double toggle crusher would be the preferred machine. The double toggle is capable of handling extremely hard rock and Ferro materials, but rate of feed and reduction ratio’s are restricted. With the top of the hinged swing jaw almost perpendicular to the crushing chamber, high compression is achieved by the linear stroke of the toggle movement thus minimising wear on the jaw liners.
Jaw Crusher Components Swing Jaw
Moving weldment that crushes rock against the stationary jaw. Fits inside the main frame
Fixed Jaw
An integral part of the crusher main frame
Jaw Liners
Replaceable manganese wear surfaces fitted to the crushing faces of the swing and fixed jaws
Cheek Plates
Replaceable manganese wear surfaces bolted to the inner sides of the crusher frame Supports lower part of swing jaw and controls its movement
Tension Rod Assembly
Provides tension that holds the swing jaw against the toggle plate
Toggle Levers
On double toggle crushers the system of toggle levers that connect to the Pitman
Pitman
Main moving part in a jaw crusher connected to an eccentric shaft on the flywheel
Main Frame Bearing
Rotational surface between the eccentric shaft and the main frame
Swing Jaw Bearing
Rotational surface between the eccentric shaft and swing jaw
Eccentric Shaft
A shaft machined with a portion of its axis off-centre to create the swinging (crushing) motion of the swing jaw
Flywheel - Grooved
The input energy that drives the eccentric shaft through a series of vee belts
Flywheel - Flat face
Helps maintain crusher speed as load conditions change.
The closed side setting (CSS) of the crusher will require adjustment dependant upon the required sizes of the crushed material. This is done by the use of shims at the discharge opening of bottom of the jaw. Hydraulic adjustment is another way of changing the CSS.
INTRODUCTION
Toggle Plate
OSBORN SINGLE AND DOUBLE TOGGLE JAW CRUSHERS
Single Toggle Jaw Crusher K
C
H
E
I J
A B C D E F G H I J K
-
Swingstock Main frame Cheek plates Fixed jaw Swing jaw Toggle plate & beam Tension rod assembly Bearings Bearing mounts Eccentric shaft Flywheel
A B D G
F
Double Toggle Jaw Crusher •
The pitman runs on spherical roller bearings
•
Swing jaw pivots with bronze bushes, on a concentric shaft
•
Eccentric shaft actuates a vertical pitman connected to a pair of toggle plates, and is not directly exposed to crushing loads
BRONZE BUSH JAW LINERS
SWINGSTOCK ECCENTRIC SHAFT
FLYWHEEL
SHIMS
PITMAN TOGGLE PLATES
TOGGLE BLOCK
TENSION ROD
Osborn Hadfields Single Toggle - Heavy Duty CLOSED SIDE SETTING & CAPACITY (Depending on material type)
48” x 12” Max Lump 245mm 48” x 18” Max Lump 370mm 80” x 60” Max Lump 1 220mm
20
25
40
50
75
15
30
55
70
110
100
130
150
180
200
250
300
200
600
800
900
1000
1200
1400
to
to
to
to
to
to
680
900
1000
1100
1400
1600
to
to
to
to
to
30
45
70
100
140
70
110
150
to
to
to
to
100
140
190
260
Model
Kg Mass
Kw
RPM
48” x 12” 48” x 18” 80” x 60”
11000
75
375
16800
75
250
180000
220
140
Data based on Dry Limestone @ 1.6t/m3. Performance schedule setting is Peak to Valley on Heavy Duty machines. Max lump not applicable to small settings. Crushing ratio = Feed size to CSS = 6:1 on mined ore.
Screen Analysis PRODUCT SIZE 300
-400 -350 -330 -300 -280 -250 -230 -200 -180 -150 -130 -100 -90 -75 -60 -50 -40 -25 -20 -10 -5
CLOSED SIDE SETTING OF CRUSHER 250
200
180
150
130
100
90
75
60
50
40
25
20
100 93 89
100
85
95
78
90
70
85
100 97
63
78
91
98
100
56
70
85
91
98
49
60
76
81
92
40
50
65
71
82
92
31
40
51
60
70
80
95
100
100
22
30
39
46
56
66
82
89
96
20
25
33
39
48
58
73
82
90
17
20
27
32
39
49
62
72
83
93
100
14
17
22
26
31
39
52
60
70
81
95
11
14
17
20
23
28
41
47
56
65
80
97
9
10
12
15
17
21
28
33
40
48
63
80
100
100
6
7
7
10
11
14
18
22
25
29
43
54
81
98
4
5
5
7
9
11
14
16
19
22
30
38
61
80
2
3
3
5
6
7
10
11
13
14
19
25
41
60
1
2
2
2
3
3
6
6
7
7
8
12
16
20
100
100 100
100 100
Information for reading screen analysis
• 61% will pass through a 20mm square opening
To illustrate the approximate screen analysis from an Osborn Hadfields Heavy Duty Jaw Crusher, the following results can be read from the relevant table.
• 41% will pass through a 10mm square opening
Using a 48” x 18” as a typical popular crusher model and set at a 25mm CSS we can read off the screen analysis table that:
Note: On the Osborn Hadfields and Osborn Telsmith Heavy Duty Jaw Crushers, the CSS is measured from peak to valley.
• 100% will pass through a 40mm square opening
The CSS on the Telsmith Std Heavy Duty Jaw Crusher is measured from peak to peak.
• 81% will pass through a 25mm square opening
• 16% will pass through a 5mm square opening
For material below 500 MPa
SIZE OF FEED OPENING Width x Depth
OSBORN HADFIELDS SINGLE TOGGLE - HEAVY DUTY
Performance Schedule
Osborn Hadfields Double Toggle - Heavy Duty OSBORN HADFIELDS DOUBLE TOGGLE - HEAVY DUTY
Performance Schedule SIZE OF FEED OPENING Width x Depth
CLOSED SIDE SETTING & CAPACITY (Depending on material type) 25
40 15
24” x 13” Max Lump 265mm 30” x 23” Max Lump 470mm 36” x 25” Max Lump 600mm 42” x 32” Max Lump 650mm 48” x 36” Max Lump 730mm 48” x 42” Max Lump 850mm 60” x 52’ Max Lump 1 050mm
50 25
100 55
130 70
150
180
200
250
820
to
to
to
to
to
25
35
50
65
80
50
65
75
90
to
to
to
to
60
70
95
120
95
110
140
to
to
to
to
120
150
200
250
150
170
250
to
to
to
to
200
260
310
350
300
440
540
600
to
to
to
to
440
540
640
700
300
440
540
600
to
to
to
to
440
540
640
700
500
550
680
750
to
to
to
to
to
600
650
780
850
920
180
300
Data based on Dry Limestone @ 1.6t/m3. Performance schedule setting is Peak to Valley on Heavy Duty machines. Max lump not applicable to small settings. Crushing ratio = Feed size to CSS = 6:1 on mined ore.
Model
Kg Mass
Kw
RPM
Model
Kg Mass
24” x 13” 30” x 20” 36” x 25”
9500
37
330
90
225
55
270
71000
110
185
23600
75
270
42” x 32” 48” x 42” 60” x 52”
42000
19700
110 000
160
155
Kw
RPM
Screen Analysis CLOSED SIDE SETTING OF CRUSHER
PRODUCT SIZE
For material below 700 MPa and very abrasive material
75 40
300
250
-400
100
100
200
180
150
130
100
75
50
40
-350
92
97
-300
82
92
97
-250
67
80
92
95
100
-200
57
67
78
89
95
-180
52
58
68
79
87
96
-150
42
49
59
69
77
90
-130
32
38
44
56
65
77
95
-100
22
27
32
41
52
63
81
95
-75
13
17
21
28
36
46
60
-50
7
9
13
18
22
24
-40
4
5
9
13
16
-25
2
2
6
9
-20
1
1
4
-10
0.5
0.5
-5
0
0
25
20
81
100
100
38
54
80
88
100
18
26
38
62
72
92
100
11
12
15
23
38
46
72
92
5
7
8
11
15
28
32
52
70
2
3
4
5
6
9
18
17
32
35
1
1
2
3
3
4
6
7
14
17
100 100
100
100 100
Performance Schedule SIZE OF FEED OPENING Width x Depth 25 13 to 18 21 to 31
32 15 to 20 26 to 48 24 to 36
40 17 to 23 32 to 47 27 to 40 30 to 60
50
64
76
35 to 50 40 to 70 50 to 90
45 to 65 50 to 90 60 to 110 99 to 148 100 to 140
50 to 80 60 to 100 80 to 130 117 to 171 130 to 160 160 to 200
90
70 to 120 110 to 150 135 to 198 150 to 180 170 to 230 175 to 270
100
130 to 180 153 to 225 170 to 200 190 to 250 200 to 280 260 to 320
130
152
178
189 to 283
225 to 333
261 to 396
200 to 280 230 to 300 300 to 360
220 to 300 250 to 340 350 to 400
400 to 480
203
430 to 550
Data based on Dry Limestone @ 1.6t/m3. Performance schedule setting is Peak to Peak on Standard Duty machines. Max lump not applicable to small settings. Crushing ratio = Feed size to CSS = 6:1 on mined ore.
Model
Kg Mass
Kw
RPM
Model
Kg Mass
Kw
RPM
10” x 21” 10” x 30” 15” x 24” 20” x 32” 20” x 36”
2910 4000 5000 11034 12400
15 18.5 30 55 75
350 320 320 275 265
22” x 50” 25” x 40” 30” x 42” 30” x 55” 36” x 48”
18800 16100 24100 26300 34800
90 110 132 160 160
260 260 255 280 230
Screen Analysis PRODUCT SIZE -330 -300 -280 -250 -230 -200 -180 -150 -130 -100 -90 -75 -60 -50 -40 -25 -20 -10 -5
CLOSED SIDE SETTING OF CRUSHER 200
180
150
130
100
90
75
60
50
40
25
20
100 95 90 85 78 70 60 50 40 30 25 20 17 14 10 7 5 2 1
100 97 91 85 76 65 51 39 33 27 22 17 12 7 5 2 1
100 98 92 82 70 56 48 39 31 23 17 11 9 6 3
100 98 91 81 69 55 47 39 31 23 18 11 9 4 2
100 92 80 66 58 49 39 28 22 14 11 4 2
100 93 82 73 62 52 41 28 18 14 8 4
100 89 82 72 60 47 33 21 18 9 4
100 96 89 82 68 55 40 25 18 9 5
100 93 80 65 49 28 23 11 6
100 93 80 65 43 31 14 7
100 97 84 55 39 20 9
100 90 68 50 29 12
For material below 280 MPa
10” x 21” Max Lump 203mm 10” x 30” Max Lump 203mm 15” x 24” Max Lump 304mm 20” x 32” Max lump 406mm 20” x 36” Max Lump 406mm 22” x 50” Max Lump 447mm 25” x 40” Max Lump 508mm 30” x 42” Max Lump 608mm 30” x 55” Max Lump 608mm 36” x 48” Max Lump 731mm
CLOSED SIDE SETTING & CAPACITY (Depending on material type)
OSBORN TELSMITH SINGLE TOGGLE - STANDARD DUTY
Osborn Telsmith Single Toggle - Standard Duty
Osborn Telsmith Single Toggle - Heavy Duty OSBORN TELSMITH SINGLE TOGGLE - HEAVY DUTY
Performance Schedule SIZE OF FEED OPENING Width x Depth 12” x 8” Max Lump 162mm 24” x 5” Max Lump 100mm 30” X 42” Max Lump 608mm 42” X 48” Max Lump 850mm 50” X 60” Max Lump 1 015mm
CLOSED SIDE SETTING & CAPACITY (Depending on material type) 10
20
25
40
2
3
4
6
to
to
to
to
5
6
7
W9 17
7
9
12
to
to
to
to
10
12
15
21
60
75
90
100
130
150
180
200
230
300
180
220
260
300
to
to
to
to
210
250
290
340
410
450
to
to
500
550
600
700
to
to
to
460
to
510
560
610
660
770
580
600
640
740
820
to
to
to
to
to
640
680
720
810
890
Data based on Dry Limestone @ 1.6t/m3. Performance schedule setting is Peak to Valley on Heavy Duty machines. Max lump not applicable to small settings. Crushing ratio = Feed size to CSS = 6:1 on mined ore.
Model
Kg Mass
Kw
RPM
12” x 8” 24” x 5” 30” x 42” 42” x 48” 50” x 60”
1300
7.5
345
3700
22
350
31700
132
250
53000
160
220
112000
220
180
Screen Analysis PRODUCT SIZE
CLOSED SIDE SETTING OF CRUSHER 300
For material below 500 MPa
50
-400 -350 -330 -300 -280 -250 -230 -200 -180 -150 -130 -100 -90 -75 -60 -50 -40 -25 -20 -10 -5
250
200
180
150
130
100
90
75
100
60
50
40
25
20
100 93 89
100
85
95
78
90
70
85
97
100
63
78
91
98
56
70
85
91
98
49
60
76
81
92
100
40
50
65
71
82
92
100
31
40
51
60
70
80
95
100
22
30
39
46
56
66
82
89
96
20
25
33
39
48
58
73
82
90
17
20
27
32
39
49
62
72
83
93
100
14
17
22
26
31
39
52
60
70
81
95
11
14
17
20
23
28
41
47
56
65
80
97
9
10
12
15
17
21
28
33
40
48
63
80
100
100
6
7
7
10
11
14
18
22
25
29
43
54
81
98
4
5
5
7
9
11
14
16
19
22
30
38
61
80
2
3
3
5
6
7
10
11
13
14
19
25
41
60
1
2
2
2
3
3
6
6
7
7
8
12
16
20
100 100
100 100
How to determine maximum feed for a 3042 Jaw Crusher Crusher Gape (smallest dimension of the feed opening) 30” (760 mm)
30” 760 mm TOP 600 mm
Maximum Feed = 30” (760 mm) x 0.8 = 24” (600 mm)
How to determine maximum Jaw Crusher Feed
Settings in above case is as follows
Top Crushing leads to shaft and bearing damage. This is the weakest point of a Single Toggle Crusher.
30”
600 mm Lump ÷ 6 = 100 CSS (F:CSS) 6 : 1 Yield 600 mm Lump ÷ 4 = 150 mm Product Lump (F : P) 4 : 1 When setting below this ratio effective manganese wear increases Only the extreme ends of the liners are used
This condition will also occur when too large a crusher is used with small feed size.
Matching the material to machine: Important ratios to remember Feed to Closed Side Setting
6:1
Feed to Product
4:1
If you have gradings use: These parameters are not applicable to ferrous metals crushing. Contact Osborn for more info.
F80 / P80
6:1
Feeding the Crusher Feeding the Crusher Ideal Feed Conditions – Choke fed
For optimum performance from a Jaw Crusher it is extremely important to pay attention to the way the machine is fed. As the design requires the Crusher to be choke fed, at least 80% of the chamber needs to be full at all times. In other words, only about 20% of the top of the jaw liners should be visible. In choke feeding, a heavy load of material is fed into the chamber to press down on the material being nipped. It also extends the life of the manganese liners as much of the impact and abrasion from dribble feeding is eliminated.
FEEDING THE CRUSHER
Interparticle Compression
Better grip, less slippage
More attrition crushing
Feeding the Crusher Incorrectly
Finally, with the fines removed from the feed material, and with a full chamber of material, efficient attrition will ensure production throughput is maximised. Fines in crushing terminology is defined as material sized less than the CSS (closed side setting) and they should be removed by a Vibrating Grizzly Feeder/Scalper installed close to horizontal to keep discharge velocity into the jaw crusher at a minimum and to minimise high impact wear on the jaw liners. The major point to fully understand in crushing materials is knowledge of the feed material. It is highly likely that material from a quarry in the north of a country is different from material blasted in the south of the country. Wherever possible, a feed gradation should be done to determine its suitability for crushing and for the intended use of the product. A material analysis will also determine the abrasiveness and hardness of the material which would influence manganese liner life. Hardness of a material is generally referred to as the Bond Work Index and is a measure of grindability of a material and the higher the Bond Work Index (BWI), the harder the material is to crush. Therefore, as the WI increases, so does the power requirement.
Slippage, Percolation
Nip Angle The nip angle of the crusher jaw plates will determine the effectiveness of the machine. The crushing action takes place low in the jaw cavity and is referred to as the choke point. If the nip angle is too big then the jaws will not be able to grab the material and often in this case, the material is pushed upwards. This would result in extreme wear on the jaws and a significent production decrease. When determining the nip angle, the type, bulk density and general material characteristics will be influential in the correct nip angle/crusher selection.
Nip Angle Nip Angle is the angle created between the fixed and swing jaw liners.
Nip Angle
• Range 11˚- 23˚ optimal 19˚ for most material types • Maximum nip angle occurs at minimum discharge setting with curved liners Nip Angle
• Discharge setting usually expressed as closed side peak to valley or peak to peak dimension
Jaw Selection Most commonly used profile
Very hard or abbrasive material
Deep Tooth Curved Jaw
Smooth Curved Jaw
This provides very good breaking over the sharp tooth
Produces high percentage flat particles
Reduced flat particles
Generally used in the Ferrometals Industry and Andesite Quarries.
Very good life but costly
Peak to Valley setting
Can mix smooth jaw with toothed jaw
Setting between tooth and flat jaw
Jaw Selection Flat Tooth Small Curve
Curved Jaw •
Deep Tooth
•
Smooth Tooth
•
Square Tooth (flat)
•
Fine Tooth (shallow) This provides longer life by virtue of more contact area of manganese at the crushing zone
Straight Line Jaw •
Deep Tooth
Jaw Crusher Discharge Settings
x
“X” dimension equals Peak-to-Peak measurement. To set the Closed Side Discharge Setting, use a wood block with the same width as the desired setting. It should be long enough to span most of the crusher’s discharge area. NOTE: When the crusher is at rest, it is NOT in the closed position. Check your manual to determine the difference between “closed position” and “at rest position”.
The small curved Jaw reduces the angle of nip through the full length of the crushing chamber to a minimum degree at the discharge end
JAW SELECTION
The curved Jaw decreases the nip angle at the bottom of the crusher and moves the point of crush (choke point) higher up in the chamber
Customer
Contact Person
Phone No.
Phone No.
Fax.No
Date
MATERIAL Type Loose Bulk Density
Kg/m³ Mpa
Compressive Strength Abrasiveness
Medium
High
Moisture Content
Low % Min
% Max
Shape of Material DUTY Capacity
mtph
Max.Feed Lump Size
mm
Min. Feed Lump Size
mm
Feed Analysis
-
Size
mm
% Passing Product Size Req’d
/05&4
-
mm
%
-
mm
%
mm
-
mm
%
%
COMPILED BY
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Osborn Telsmith Single Toggle - Heavy Duty
Top of flywheel
Model
A
B
C
D
E
F
G
H
J
K
L
12” x 8”
1175
620
490
415
455
985
265
450
615
n/a
300
24” x 5”
1080
530
480
520
635
1220
445
735
1030
205
380
30” x 42”
2940
1995
1580
520
795
2650
745
1245
1635
350
400
42” x 48”
3860
2700
2145
875
965
3200
1015
1445
2210
480
455
50” x 60”
4215
2760
2345
1015
1365
3980
1120
1710
2660
540
510
B
A
Feed inlet
Model
A
B
C
D
E
F
G
H
J
K
L
48” X 12”
1820
980
810
820
895
1625
770
1065
1690
50
400
48” X 18”
2260
1585
580
1055
1115
1755
770
1130
1700
100
230
80” X 60”
5470
4200
2615
1335
1685
4600
1500
1920
3310
750
800
K
Osborn Hadfields Single Toggle - Heavy Duty C
D F
E L Drawback rod clearance
D F
E
Telsmith Single Toggle
Osborn Telsmith Single Toggle - Standard Duty B
10” X 21’
1320
10” X 30’
1370
15” X 24”
1735
20” X 32”
2290
20” X 36”
2080
C
D
E
F
G
H
J
850
565
400
735
685
335
1050
845
405
1455
945
540
1290
1250
620
K
L
615
1070
400
1170
380
655
510
815
865
n/a
305
570
100
200
470
1380
500
770
1005
70
245
605
1610
470
1805
590
965
1310
90
950
630
1100
1375
280
460 250
22” x 50”
2210
1375
1425
520
595
2100
845
2540
1810
200
25” X 40”
2300
1495
1450
460
535
2060
710
1185
1590
155
360
30” X 42”
2630
1680
1695
650
740
2525
735
1250
1645
395
635
30” X 55”
2630
1680
1695
650
740
2525
900
1415
1975
395
635
36” X 48”
2340
2150
1990
780
870
2950
815
2740
1795
175
150
Osborn Hadfields Double Toggle - Heavy Duty Model
A
24” X 13”
1510
930
870
460
30” X 23”
1755
1235
1070
330
36” X 25”
2060
1550
1525
655
1340
42” X 32’
2085
2345
2310
780
1405
48” X 42’
2465
2540
2365
1170
60” X 52”
2930
2895
3240
1510
B
C
D
E
F
G
H
J
K
L
995
2370
1070
2875
445
790
1040
160
150
545
1050
1245
270
200
3495
660
1025
1510
280
330
4040
737
1205
1745
300
350
1625
4445
890
1495
2045
455
535
1825
5380
1045
1545
2275
555
580
Top of flywheel Feed inlet
B
A
L Drawback rod clearance
K
Model
A
APPLICATION DATA SHEET - OSBORN JAW CRUSHERS
Application Data Sheet - Osborn Jaw Crushers
E D
C F
Hadfields Double Toggle NOTE: All dimensions are indicative only. Please consult Osborn for more information Head Office: PO Box 8182 Elandsfontein 1406 Johannesburg South Africa Tel: +27 11 820 7600 Fax: +27 11 388 1136 E-mail:
[email protected] www.osborn.co.za
Osborn, Designers and Manufacturers of Bulk Materials Handling Equipment and Minerals Processing Plant and Equipment
