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Introduction to Osborn Coal Crushers

INTRODUCTION TO OSBORN COAL CRUSHERS

As the ROM coal is received from the Mine, the preparation process commences with the crushing and breaking of
the coal and the removal of any unwanted material found in the coal feed by the use of the Rotary Breaker.
This machine is designed to reduce the ROM coal from mined lumps into a more manageable size for further
processing through the plant.
The sized coal produced by the Rotary Breaker can then be fed into a Rolling Ring Crusher which works on a
Hammermill principle with a rotor spinning at high speed delivering heavy blows to the coal lumps through impact whilst
it is in suspension causing the material to be thrown against a breaker plate to reduce it to a size that will pass through
the breaker plate.
For more specific and smaller sizing of the coal the Double Roll Crusher is generally the chosen machine particularly for
processing the sizes required for power stations and for export coal sizing where specifications are more precise.
Osborn manufactures all the types of coal crushers mentioned here with a broad range of sizes to meet relevant
product size requirements.
Serving the South African coal industry for more than 50 years, Osborn coal crushers have proved to be highly reliable
and have gained popularity as far afield as Australia and Turkey and closer to home with our neighbours Zambia
and Zimbabwe.

Osborn Rotary Breakers

The Rotary Breaker works on a gravity method to break the coal in a very efficient manner. Material is continuously
introduced at the feed end, repeatedly raised by the lifters and dropped until it is broken to size and falls through the
perforations in the screen plates to a collection hopper below.
Mine rock , refuse and other uncrushable debris is automatically carried to the end of the drum and discharged through
a chute.
Due to variations in the types of coal being processed, capacities and power requirements will vary from Mine to Mine.
Osborn Rotary Breakers are capable of processing up to 2000tph with a maximum feed size of 1200mm depending on
the type of coal to be processed.

1. The Rotor Cage is constructed with high strength steel longitudinal beams with extra peripheral segmental ties ,
situated between each row of grids, thereby ensuring robustness of the rotor cage and elimination of distortion of the
longitudinal beams along the weak axis. In the event of a longitudinal beam requiring replacement, all beams on the
Osborn Rotary Breaker are fitted with a flange at each end drilled to provide a bolted connection to the end plate. The
longitudinal beam is machined and also the flanges to ensure a perfect mating connection. This entails a major strip.
2. Screen Plates are of the patented fabricated type.
3. Adjustable angle lifter bars facilitate control of retention time and are of a deep profile design to assist with the
breaking and lifting of large size lumps.
4. Special alloy steel tyres are shrunk onto the machined end plates of the drum which run on steel support rollers
incorporating self-aligning spherical roller bearings .
5. Osborn Rotary Breakers are generally fitted with chain type drives.As an optional extra, higher specification trunnion
mounted girth gear and pinion drives (Mill type) are available.
6. A hand operated clutch disengages the main drive and switches to the barring drive to facilitate simple maintenance
procedures. The drives are electrically interlocked to prevent accidental starting and thus ensuring absolute safety
during servicing.
7. A dust tight housing incorporating hinged access doors are fitted to both sides. The top section is manufactured
from non-skid type plate with a removable hatch cover to provide crane access when required.
8. The entire Rotary Breaker can be mounted on a rigid base frame ready for site installation after workshop running
and testing. This is an optional extra.

Dimensional Data (Two Styles)

MODEL
CHAIN DRIVE

1020

5084

3050

3050

3200

3000

1040

2250

2340

2134

1076

980

150

1524

980

6860

1024

6284

3650

3650

3200

3000

1040

2250

2340

2134

1076

980

150

1524

980

8060

1227

6858

4115

4115

3700

3000

1345

2438

2949

2134

1127

1050

150

1270

1050

8850

1328

7278

4330

4330

4167

2800

650

2800

4000

2438

1422

1035

150

2438

1035

9348

3.0 X 4.5

4500

3005

2745

3000

1900

994

2020

1950

1500

860

680

150

1230

910

6090

3.0 X 6.7

6740

4165

3905

3000

2550

994

2020

1950

1500

860

720

150

1230

950

8410

4.2 X 9.0

8970

4845

5250

4200

2500

1500

2620

2550

2100

1017

1000

150

1750

1000

11385

3.6 X 6.7

6730

4330

4070

2200

1605

2360

2090

1028

975

150

1185

8890

3.6 X 7.6

7600

4765

4505

2200

1605

2360

2090

1028

975

150

1185

9760

MODEL
GIRTH GEAR &
PINION DRIVE

All dimensions are indicative only and should not be used for layout purposes. Contact Osborn for certified G.A. drawing.

FEATURES OF THE OSBORN ROTARY BREAKER

Features of the Osborn Rotary Breaker

FEATURES OF THE OSBORN ROTARY BREAKER

Fabricated screen plates are

manufactured as welded box section.
The coal lumps are lifted and
dropped onto the screen plates
minimising the amount of fines
passing through the square
apertures.
Cage fitted with lateral beam for
stiffness. Square aperature screen
plates with hole sizes to suit product
required.

Segmented drive sprocket bolted to

machined end disc.

Special wide faced trunnion rollers support

the breaker cage. Rollers are housed in selfaligning spherical roller bearings.

Uncrushable objects in the feed are passed

through an outlet scoop into a collecting bin.

Thrust Rollers positioned at each and of the Rotary Breaker to

prevent excessive axial float.
Osborn Rotary Breakers can accept a feed size of 1200mm of Coal
and are high capacity units up to 2000tph
Simplistic design and extremely durable and is the equipment of
choice in coal processing.

FEATURES OF THE OSBORN ROTARY BREAKER

Replacable steel alloy tyres shrunk onto the

machined end disc.

Osborn Rolling Ring Crushers

This hammermill design has the capability to reduce a coal feed size of 500mm to 25mm in one pass. Capacities are
in excess of 2000tph dependant upon rotor speed, percentage lump in feed, hardness, structure and moisture. The
crushers are fitted with cleanout doors to remove tramp iron and uncrushable materials from the metal trap at the
rear of the machine.

OSBORN ROLLING RING CRUSHERS

Construction Features

BEARINGS (NOT SHOWN)

Heavy-duty anti-friction bearings, which are enclosed
in dust and oil tight pillow blocks. The pillow blocks are
mounted and dowelled on machined surface. Split
bearings are optional.

1. ROTOR
Machined from heat-treated steel to minimize deflection.
Designed with excess on safety factor for critical speed
requirements.
2. FRAME
The housing is fabricated from top quality steel plate and
stress relieved prior to machining.

5. LINERS
The liners are of high impact and wear-resistant plate.
The liners can be easily replaced without dismantling
the machine.

3. BREAKER PLATE
Pre-screens undersize material through breaker grate to
minimize fines production, alleviate dusting and decrease
wear on crusher.

6. SHREDDER RINGS
Each ring has multiple cutting edges and is reversible.
The rings revolve at slow speeds and split the coal,
instead of crushing it, producing a granular product with
minimum fines. If rings encounter tramp metal, they are
free to deflect on their shafts.

4. ADJUSTABLE DROP CAGE

The machine is furnished with a drop cage. This feature
produces absolute size control within the product range
of the machine. It also permits quick cleanout in the event
of a power failure and blockage.

The Shredder Rings can be changed either through the

rear inspection panels or from the top of the machine
whereby the complete shaft assembly can be lifted out.

Adjustment of the American Rolling Ring Crusher (ARRC)

can be performed in 3 different ways.
(1) By the hand wheel
(2) By the handwheel
(3) By motorised gearbox

Access door for

shredder ring
change and metal
trap clean out.

Breaker plate, screen plates and rotor assembly.

Breaker plate
adjustment screw.
Both sides.

Pivot arrangement for ease of access is an

optional extra on all machines.

Heavy duty bearing and

plummer blocks for rotor shaft.

General product grade analysis @ 400RPM.

Access for inspection of drop cage

and screen plates.

Note: Crusher output gradations and

tons per hour products may change due
to variations in operating conditions and
application of the crushing equipment. This
information does not constitute an expressed
or implied warranty or guarantee, but shows
results of test crushing of samples provided
by customers. This is guideline information.

Crushing medium, hard bitumous coal.

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OSBORN ROLLING RING CRUSHER

Hand wheel (and gearbox

on large machines) for drop
cage adjustment.

H
K
E

OSBORN ROLLING RING CRUSHER DIMENSIONS

D
G
C

Dimensional Data - Osborn Rolling Ring Crushers

FEED

MODEL
WS 16 BG
WS 28 BG
WS 46 BG
WS 70 BG
AC 3B BG
AC 3D BG
AC 3F BG
AC 7C BG
AC 7D BG
AC 7F BG
AC 7J BG
AC 57G BG
AC 57J BG
AC 72H BG

A
667
667
667
667
667
667
667
864
864
864
864
1219
1219
1372

DISCHARGE
C
D
1346
508
1346
787
1346
1219
1346
1829
1632
1232
1632
1537
1632
1842
2038
1842
2038
1994
2038
2299
2038
2756
2571
2654
2571
2959
2931
2819

B
508
787
1219
1829
1232
1537
1842
1842
1994
2299
2756
2654
2959
2819

CLEARANCE
F
G
610
400
610
400
610
400
610
400
508
457
508
457
508
457
762
483
762
483
762
483
762
4832
914
521
914
521
1016
1118

E
610
610
610
610
915
915
915
965
965
965
965
1067
1067
1372

H
1270
1676
2337
3251
2261
2718
3175
2667
2896
3353
4039
4115
4572
4242

I
1755
1755
1755
1755
2248
2248
2248
2705
2705
2705
2705
3366
3366
3886

GENERAL
J
965
965
965
965
1168
1168
1168
1473
1473
1473
1473
2032
2032
2337

K
1525
1805
2237
2846
2470
2775
3080
3131
3283
3588
4045
4089
4394
4458

NOTE
Dimensions shown are approximate only and should not be used for plant layout. Contact Osborn for certified G.A. drawing.

Performance Schedule
MODEL
WS16BG

WS28BG

WS46BG

WS70BG

AC3BBG

AC3DBG

AC3FBG

70
65
55
35
25
20
250
1000
3400
22

25
110
100
85
65
50
250
1200
4080
37.5

200
180
160
140
110
75
250
1440
5200
75

250
220
200
170
140
110
250
1980
6100
90

300
270
235
205
160
300
2240
9210
110

395
350
300
260
205
300
2630
9980
110

480
430
380
320
260
300
3020
11480
150

Product Size
38mm
32mm
25mm
19mm
12mm
6mm
Max.Lump Size (mm)
Rotor Mass (Approx) Kg
Machine Mass (Kg)
Minimum Motor Kw

Performance Schedule
MODEL
Product Size
38mm
32mm
25mm
19mm
12mm
6mm
Max.Lump Size (mm)
Rotor Mass (Approx) Kg
Machine Mass (Kg)
Minimum Motor Kw

AC7CBG

AC7DBG

AC7FBG

AC7JBG

AC57GBG

AC57JBG

AC72HBG

640
580
500
440
360
350
4900
13600
250

760
690
600
520
400
350
5820
15900
300

870
800
720
640
520
350
5820
18600
350

1030
960
880
800
680
350
6510
20000
450

1200
1130
1050
980
860
400
10450
25900
350

1350
1300
1200
1150
1000
400
11350
27700
485

1700
1640
1560
1500
1160
500
15420
37650
700

Double Roll Crusher

Crushing Rolls and Drive

Each roll assembly comprises renewable and reversible toothed segments bolted and keyed to a robust hexagonal hub
with the nuts inside the hub. Locking nuts are securely located in fabricated pockets in the drum. This enables removal
and replacement of segments to be done from the outside using only one tool (Allan Key). Bolt heads are protected
from excessive wear, being sunk in recesses in the segments. Teeth are disposed in circumferential bands, so that
teeth from the opposing roll can freely move in the space between adjacent bands. Tooth proportions are designed to
provide the particular product required.
The rolls are separately driven by two identical motors, through sets of vee belts which are connected from the motor
pulley to grooves machined in the flywheels. The drive arrangement is free standing with the electric motors mounted
on adjustable base plates.

Frame and Canopy

The main frame members which support the rolls are fabricated box beams. Machined pads on low friction polymer
are provided for the sliding of the bearing pedestals of the moving roll and the fixed roll bearing pedestals. The low
friction polymer slide pads provide ease of adjustment. Large area feet permit mounting of the machine directly onto a
concrete foundation with grout. Separate sections over each roll are bolted to a fixed central section. Quick releasing
inspection doors are provided between both rolls and also at the roll ends on the non-drive side. A flange is provided on
the top for connecting a feed chute.

Release Mechanism
Pressure springs are fitted at one end of the unit and act on the bearing housings of one roll only. Spring compression
bolts and carrier plates are fitted for adjusting spring pressures. Uncrushable material entering the rolls will load the
springs causing them to compress and allow rapid movement of the roll and passing of the non- crushable objects.
Hydraulic roll adjustment and force relief cylinders can be supplied instead of the springs as an optional extra.
For the best results in sizing of materials, the Osborn Double Roll Crusher is particularly suitable for the Coal industry
where product sizes are often to a required specification. It is important to understand the material characteristics as
the type of coal will often vary considerably. Hardness, rock content, friability, moisture content are the major
factors that need to be known together with the crusher capacity, maximum lump size, required product size and the
amount of fines that are acceptable.
Efficient crushing will lower the power
requirements and the life of the crusher
segments will be increased when the
correct crushing ratio is used and the
optimum roll diameters are selected so that
the segments grip the feed material and do
not allow these pieces to roll on top of the
segments due to the incorrect nip angle.
Osborn has a wide selection of segments
tooth profiles which are asymmetrical in
order to allow the teeth of the one segment
to run in the valley of the opposing segment.

OSBORN DOUBLE ROLL CRUSHER

Osborns Double Roll Crushers can be used for primary and secondary crushing. Generally regarded as a 4:1 feed to
product ratio although in some instances, dependant upon material friability and hardness, it is possible to achieve a 6:1
crushing ratio. The feed material should enter the centre of the gap between the two rolls and spread across the full
roll width for maximum efficiency to obtain a uniform product size distribution.

APPLICATION DATA SHEET - OSBORN DOUBLE ROLL CRUSHER

Application Data Sheet - Osborn Roll Crusher

Dimensions - Double Roll Crushers
Crusher
Model
Dia x Width
610 x 760

2760

915

610

260

840

670

658

851

634

748

2760

920

610

260

1260

1270

873

1066

1530

748

2910

1500

620

345

1104

964

725

918

757

748

2910

1600

620

345

1700

1550

980

1230

N/A

N/A

2510

1000

600

345

2030

2190

1230

1315

N/A

N/A

3350

2400

1300

220

1400

1040

920

1122

799

750

(24 x 30)
610 X 1220
(24 x 48)
760 x 910
(30 x 36)
760 x 1520
(30 x 60)
760 x 2000
(30 x 80)
1220 x 1220
( 48 x 48)

Dimensions subject to change. Please consult Osborn for confirmation of dimensions

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Crusher Size
Dia x Width mm

Nominal Product Size

38mm
50mm
75mm

19mm

25mm

32mm

610 x 760 (24 x 30)

45

60

80

95

125

190

610 x 1220 (24 x 48)

72

90

120

143

188

285

95

120

140

190

284

378

567

760 x 1520 (30 x 60)

160

197

236

315

470

630

945

760 x 2000 (30 x 80)

210

263

315

420

760 x 910 (30 x 36)

1220 x 1220 (48 x 48)

100mm

150mm

630

840

1260

608

812

1218

150mm

NOTES
The capacities stated above are based on roll speeds of 110rpm and will vary proportionally with the selected speed
The roll speed will influence the amount of fines generated
Feed Size - depends on the product size required
Reduction ratios of 4:1 but not exceeding 6;1 are considered good practice
Maximum feed size at maximum settings should not be greater than the following sizes
Roll Diameter
Maximum Lump Size
610mm
300mm
760mm
600mm
1220mm
910mm
Tooth design on the renewable segments is selected according to product size required and feed size
Customers feed chute should incorporate a removable vertical section of at least 1 metre prior to
entering the machine

Double Roll Crusher - Product Analysis: Approximate

In MTPH and based on Material at 800Kg/m
Setting of Crusher mm - Peak to Valley

Product Sizes
mm

175

150

- 200 + 150

14%

8%

125

100

75

50

38

25

-150 + 100

36%

34%

26%

18%

-100 + 75

20%

22%

31%

32%

18%

- 75 + 50

14%

16%

20%

22%

32%

16%

9%

- 50 + 38

6%

10%

8%

10%

13%

20%

12%

- 38 + 25

4%

4%

7%

8%

12%

34%

34%

26%

- 25 + 10

4%

4%

5%

6%

13%

18%

18%

50%

-10 + 0

2%

2%

3%

4%

8%

12%

16%

24%

150

NOTES
These percentages are approximate only and are shown as a general guide
Tests were based on crushing medium - hard bituminous coal at a roll speed of 110rpm
Crusher used was a 760mm dia x 910mm
In a lower speed range of 55-65rpm the amount of fines will be
proportionally lower
Power requirements will depend on capacity throughput required, hardness & reduction ratio

Six sided drums for easy

segment replacement.

Located nuts require one tool.

Bolting is from outside only.

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CAPACITIES AND PRODUCT ANALYSIS - OSBORN DOUBLE ROLL CRUSHER

Double Roll Crusher - Capacity Schedule: Approximate

in MTPH and based on Material at 800Kg/m

Head Office:
PO Box 8182
Elandsfontein
1406
Johannesburg
South Africa
Tel: +27 11 820 7600
Fax: +27 11 388 1136
E-mail: osborn@osborn.co.za
www.osborn.co.za

Ref No. CC/09/Rev 1

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

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