Coal Crushers

Introduction to Osborn Coal Crushers

The preparation of ROM coal commences the moment it is received from the mine. The Rotary Coal Breaker crushes and breaks
the coal and removes the majority of the rock contamination.
The sized coal from the Rotary Breaker can then be fed into a Rolling Ring Crusher which produces a finer product.
For more specific and smaller sizing of the coal, the Double Roll Crusher is generally the preferred machine, particularly for
processing the sizes required by power stations and for the export market where tight specifications are required.
Serving the South African coal market for more than 80 years, Osborns Coal Crushers have proven to be extremely reliable and
have gained popularity as far afield as Australia, Turkey and neighbouring African countries, such as Zambia, Zimbabwe, Botswana
and Mozambique.

Osborn Rotary Breakers

Fabricated or cast screen plates are manufactured

from wear resistant materials. The coal lumps are lifted
and dropped onto the screen plates minimising the
amount of fines passing through the square apertures.
The drum is fitted with lateral beams for stiffness and
square aperture screen plates with hole sizes to suit
the product required.

Uncrushable objects in the feed

are passed through an outlet
scoop into a collecting bin.

Thrust Rollers are positioned at each end of the Rotary

Breaker to prevent excessive axial float. Osborn Rotary
Breakers can accept feed size of 600 mm of coal and
high capacity units process up to 2000 tph. Osborn
Rotary Coal Breakers have a simplistic design but are
extremely durable. For this reason coal miners choose
the Osborn Rotary Coal Breaker.

A segmented drive sprocket bolted to the machined end

disc.

Replaceable
steel
alloy
tyres are shrunk onto the
machined end disc to ensure
easy maintenance.

Special wide faced trunnion rollers support the breaker

drum. Rollers are housed in self-aligning spherical roller
bearings.

Chain Drive or Girth Gear and Pinion Drive

ITEM

DESCRIPTION

DRUM LENGTH
- A (mm)

CANOPY HEIGHT
- B (mm)

CENTRE HEIGHT
- C (mm)

TRUNNION
CENTRES - D (mm)

INLET DIAMETER
- J (mm)

3.0 X 6.7

8330

3970

1950

860

1500

3.6 X 5.6

7770

4582

2090

1028

1800

3.6 X 6.7

9040

4582

2090

1028

1800

3.6 X 7.6

9910

4582

2090

1028

1800

4.2 X 6.7

9310

5170

2550

1017.5

2100

4.2 x 9.0

11400

5170

2550

1017.5

2100

Mineral Sizers/Roll Sizers for Primary/Secondary

and Tertiary Applications
Osborns range of Single Shaft and Twin Shaft Roll Sizers are of a heavy duty low profile design capable of handling high
tonnage throughputs using minimal installed primary power.
The Roll Sizer can be configured to operate in two ways depending on the material output size required. These being either through the centre
(Centre Sizers) or down the side (Side Sizers). All Osborn Sizers are designed to operate with a single drive or a twin drive.
Osborns Roll Sizers are ideally suited for static, semi mobile and mobile installations. The overall weight and compact design with all the crushing
forces kept within the actual body of the sizer allows for a more cost effective design without any major foundations.

Slow speed Roll Sizer concept

The Mineral Sizers twin rotating shaft concept was developed in the late 1970s. It was discovered that by using relatively slow rotating shafts
fitted with large teeth, large volumes of material could be passed through. The high torque and shearing force would crush the oversize material
and reduce it to the required size producing minimal fines with lower noise and power consumption.
Generally the Osborn Mineral Sizer can work
at a crushing ratio of 4:1 and in some cases
up to 6:1 and can cope easily with handling
very soft sticky material as well as dry and
hard rock types. This new concept has
revolutionized the underground coal mining
sector, reducing blockages and transfer
points.
All kinds of applications have been presented
to the Sizer due to it being able to achieve
up to and exceeding 10,000 tonnes per
hour with material feed size over 2m3. The
Osborn Mineral Sizer has been designed
to be installed in primary, secondary and
tertiary applications with a final outfeed size
of nominal 50mm.

Centre Sizing Shafts rotate inwards

Side Sizing Shafts rotate outwards

Mineral Sizer

Mineral Sizers Range of Models

Osborns range of Mineral Sizers start at our 550 model through to a 1650 model. Model sizes are determined by the
centre distance in mm between the main rotors.
Model Number

Type of Sizer

550

Centre and Side Sizer

650

Centre and Side Sizer

800

Centre and Side Sizer

1000

Centre Sizer

1250

Centre Sizer

1450

Centre Sizer

1650

Centre Sizer

The working area length can vary between 1- 4 meters depending on capacity required (working throat). This is in 500 mm sections.

Tooth and Rotor Design

The basic concept of the Osborn Mineral Sizer is of counter rotating rolls turning towards each other in the centre Sizer design and
away from each other in the side Sizer design. The Primary Sizers can be configured with 3 tooth and 4 tooth segments.
Secondary and Tertiary Mineral Sizers would be constructed with multi tooth segments that are bolted to the tooth carriers mounted
on the main rotors.
The success of the crushing action is very dependent upon the tooth configuration with the size and shape of the teeth specifically
selected for each Mineral Sizer application. The teeth are designed to be locked into machined recesses on the shaft that ensures easy
replacement of the teeth caps without the need to remove the entire rotor assembly.
Heavy duty clamps hold the teeth in place on the rotor and each row of teeth is torqued through tensioning bolts which are located
outside of the feed stream.

Construction features of Osborn Mineral Sizers

Main frame
Fabricated from carbon
steel.
End plates are machined
from solid plate and
horizontally split along
the rotor shaft centre line.
Side frames are fully welded, of ribbed construction and
machined to size, spigotted and bolted to form a highly
robust assembly capable of containing any dynamic forces
created whilst the machines is in operation.

Shaft Assemblies
Rotor shafts and drive
gears are machined
from high carbon steel.
Shaft bearings are of the
spherical roller type.
Bearings and cartridges are retained on each end of the
shaft by large locking nuts so that all the thrust on the
teeth and shafts is contained inside the shaft and not
transferred onto the bearings.

Wear plates
Osborn mineral sizers
are fitted with wear plates
completely covering the
inside of the body and
sizing chamber.
The wear plates are made from high wear steel and are
bolted to the sizer to allow ease of replacement.

Modular Reduction Gear Box and Drive

Pinions and gears are machined, carburised and ground
from high tensile steel. All bearings are spherical roller type.
Gearbox selection is sized to include a high safety factor.

Sizing Teeth
Osborn provides a range
of sizing teeth suitable for
different applications. Type
and fitment thereof varies
accordingly.

Lubrication
All gears in the Osborn sizer are lubricated through an oil bath.
The reservoir is fitted with an oil level sight glass, magnetic drain plug and oil sampling point.

Drive Details
A TEFC electric motor drives through a fluid coupling which is fitted with an inspection cover for maintenance of the coupling.
A reduction gearbox is bolted to the transfer box which is also fitted with inspection covers. The final drive is via a spur gear which
is housed in the transfer box.
All rotor drive gears (in & output) in the transfer box are spline coupled onto their mating shafts for ease of maintenance,
replacement if necessary and timing adjustments. The reason for timing adjustment, is for rotor self-cleaning purposes.
Also different rotorshaft ratios can be obtained by fitting different spur gears other than the 1:1 ratio.

Features of an Osborn Mineral Sizer

Mineral Sizer Construction

Low shaft rotor speed

Low wear on working parts
Low noise levels
Low generation of fines
Minimum dust created
Crushing forces kept within the sizer housing
Modular construction of machine
Teeth wear parts can be easily replaced in situ
Low feed height

Electric Motor/s Prime mover

Fluid Coupling
Heavy Duty Design Gearbox (continuously rated)
Main Shaft Support Frame
Main Shaft and Support Bearings
Toothed Segments
Wear Plates / Cleaning Combs

The Osborn Mineral Sizer has counter rotating rolls,

driven by the electric motor prime mover through
a fluid coupling and connected to a heavy duty
gearbox.
The final drive to the rotors is from the reduction
gearbox through to spur drives which are located in
the mainframe link box.
The gears are shrink mounted onto their mating
shafts and when assembled into the gearbox
housing, provide a gear train to give the required
ratio. Input and output shafts are splined to give
simple assembly and better drive, thus reducing
damage through the continuous shock loading the
Mineral Sizer is subjected to.

Primary 3 Tooth Sizers

END ELEVATION

Breaker bar
support
Shaft Centres
Breaker Bar Assembly
SIDE ELEVATION

Inspection Covers

Prime Movers

Gearboxes

Drive End Wear Plate

Cleaning Combs

Supported Area

Working Area

Non-Drive End
Wear Plate
Fluid Coupling
Housing

Speed Sensors

Drive End Link Box

Side Frame

Working Area
PLAN VIEW

Main Rotors with Toothed Segments

Non-Drive End
BRG Housing

Non-Drive End

Rolling Ring Crushers

This Rolling Ring Crusher hammermill design has the capability to reduce a coal feed size of 500 mm to 25 mm in one
pass. Capacities are in excess of 2 000 tph dependent 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.

Construction Features

1. ROTOR

BEARINGS (NOT SHOWN)

Machined from heat-treated steel to minimize deflection. Designed

with an excessive safety factor for critical speed requirements.

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.

2. FRAME
5. LINERS

The housing is fabricated from top quality steel plate and stress
relieved prior to machining.

The liners consist of high impact and wear-resistant plates. 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. This may also be
used to lift out the whole shaft assembly.

Adjustment of the American Rolling Ring Crusher can be performed

in 3 different ways:
(1) The hand wheel
(2) The hand wheel with Reduction Gearbox
(3) The motorised gearbox

Pivoted arrangement for ease of access is an

optional extra on all machines.

Breaker plate, screen plates and rotor assembly.

Hand wheel (and gearbox on
large machines) for drop cage
adjustment.

Access door for shredder ring change and

metal trap clean out.

Heavy duty bearing and plummer

blocks for rotor shaft.

Access for inspection of drop cage and

screen plates.

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 72H BG
AC 72J BG

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

Breaker plate adjustment screws

on both sides.
B
508
787
1219
1829
1232
1537
1842
1842
1994
2299
2756
2959
2819
3105

C
1346
1346
1346
1346
1632
1632
1632
2038
2038
2038
2038
2571
2931
2931

D
1525
1805
2237
2846
2470
2775
3080
3131
3283
3588
4045
4394
4458
4743

E
965
965
965
965
1168
1168
1168
1473
1473
1473
1473
2032
2337
2337

NOTE
Dimensions shown are approximate only and should not be used for plant layout.

A
D
B

Double Roll Crusher

Osborn Double Roll Crushers can be used for primary and secondary crushing. The Double Roll Crusher is generally regarded as a 4:1 feed to
product ratio crusher, however in some instances, dependent 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 and this
ensures a uniform product size distribution.
For strict coal product specifications the Osborn Double Roll Crusher is preferred. It is important to understand the material characteristics, as
the type of coal will often vary considerably. Hardness, rock content, friability and moisture content are the major factors that need to be identified,
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 increase the life of the crusher segments. When the correct crushing ratio is used and
the optimum roll diameters selected, the segments will grip the feed material more efficiently and it will also not allow pieces to roll on top of the
segments due to the incorrect nip angle, this assists in reducing wear.

Crushing rolls and drive

Each roll assembly comprises of 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 from the outside
using only one tool (Allan Key). Bolt heads are protected from excessive wear by being counter sunk in recesses on each segment. Teeth are
arranged in a staggered formation on the segments to prevent tooth on tooth impact. Tooth proportions are designed for the particular product
requirements.
The rolls are separately driven by two identical motors, through sets of vee belts which are connected between the gearbox pulley and the flywheels.
The drive arrangement is free standing with the electric motors mounted on adjustable base plates.

10

Frame and Canopy

Fabricated channel beams serve as the main frame support. For ease of adjustment, machined low friction polymer pads are provided. Inspection
doors are provided at the roll ends on the non-drive side as well as on the crusher ends. Flanges are provided on the top for connecting a feed
chute.

Crusher Model
Dia x Width mm

24 x 48

608

1030

2820

920

30 x 36

608

1251

3125

1180

30 x 54

608

1251

3125

1180

30 x 72

608

1251

3125

1180

36 x 36

808

1880

3412

1430

36 x 54

808

1880

3412

1430

36 x 72

808

1880

3412

1430

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

Release Mechanism
Uncrushable material entering the rolls will load the springs causing them to compress and allow the passing of the non crushable objects.
Compression springs are fitted at one end and act on the bearing housings of one roll. Spring adjustment bolts and shim plates are fitted for
adjusting the roll position. Hydraulic roll adjustment and force relief cylinders can be supplied instead of the springs as an optional extra.

11

Head Office:
57 Jansen Road, Elandsfontein
PO Box 8182
Elandsfontein, 1406
Johannesburg
South Africa
Tel: +27 11 820 7600
Fax: +27 11 388 1136

All rights reserved. Unless otherwise indicated, all materials on these pages are copyrighted by OSBORN. No part of these pages, either text or image may be used for
any purpose other than personal use. Therefore, reproduction, modification, storage in a retrieval system or retransmission, in any form or by any means, electronic,
mechanical or otherwise, for reasons other than personal use, is strictly prohibited without prior written permission.

Companies of the Astec Aggregate and Mining Group

www.osborn.co.za

www.telsmith.com

www.rockbreaker.com

www.astrcmobilescreens.com

www.kpijci.com

CoalCrush/0412/Rev1

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