Products

Overview of all Osborn Products

Hard Rock Processing

Single Toggle Jaw Crushers

Jaw crushers are most often utilized in mines as a primary crusher, reducing run of mine ore to manageable sizes for the next stage in the process. Both heavy duty and standard duty models are available and are applied depending on the type and hardness of the ore.

Double Toggle Jaw Crushers

Double toggle jaw crushers are heavy duty designs primarily utilized to crush the hardest of ores and ferro materials. Although extremely rugged, these models typically present reduced feed rates and reduction ratios when compared to single toggle jaw crushers.

Cone Crushers

Making daily, monthly and annual numbers means keeping a constant eye on the bottom line. You can’t do that if you’re concerned about keeping your machinery up and running. Osborn's patented cone crusher innovations provide the efficiency needed to minimize downtime and maintain a high level of productivity.

Track Mobile Crushing

A variety of models are available to provide track mobile in-pit or underground crushing. Relatively low profile units can quickly relocate within the mine to provide low cost, self-contained crushing near the ore source. Primary, secondary and tertiary crushing plants may be combined with track screening plants to provide complete crushing systems.

Vertical Shaft Impact Crushers

The efficient and versatile design of vertical shaft impact (VSI) crushers deliver highly consistent end products for jobs that demand precision. VSI crushers are available in both stationary and portable configurations and crank out up to 500 tph. With the capability to run in standard, semi-autogenous and fully autogenous, our models meet the most stringent material specs.

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Jaw 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.

SINGLE TOGGLE JAW CRUSHERS

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.

HADFIELDS SINGLE TOGGLE

  • Production capacity up to 1,600 t/h
  • Rock compressive strength up to 400 MPa
  • Excellent nip angle
  • Fabricated main frame and swing jaw
  • Reversible jaw dies for maximum wear
  • Relief / adjustment

TELSMITH  SINGLE TOGGLE

  • Production capacity up to 1,000 t/h
  • Rock compressive strength up to 500 MPa
  • Patented hydraulic beam locking system
  • Excellent nip angle
  • Fabricated main frame and swing jaw
  • Reversible jaw dies for maximum wear
  • Relief / adjustment

DOUBLE TOGGLE JAW CRUSHERS

Double toggle crushers are the preferred machine for harder and highly abrasive materials with a compressive strength of up to 600 Mpa.

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.

OSBORN DOUBLE TOGGLE:

  • Production capacity up to 600 t/h
  • Rock compressive strength up to 600 MPa
  • Excellent nip angle
  • Fabricated main frame and swing jaw
  • Reversible jaw dies for maximum wear
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Osborn Telsmith Cone Crusher Gyrasphere

To produce a powerful crushing action, a cone crusher Gyrasphere uses the combined force of a cam and lever action. To reduce stresses to an absolute minimum, the power of the two forces distributes the loads evenly over a large bearing area. The fabricated counterbalanced rotary seal ring offers greater machine balance, resulting in smooth operation, while the non-contact seals reduce costly maintenance and minimize wear.

Productivity & Reliability

For productivity and reliability, the Telsmith Cone Crusher Gyrasphere offers unbeatable value. The machine offers great structural strength, the use of improved alloys and heavy components. Heavy, fast acting springs offer positive protection against tramp iron.

The long throw spherical head action easily handles large and slabby feed, prevents bridging and keeps capacity at its maximum.

Maintainability

To prevent dirt and dust from entering the crusher lubrication system, the manganese mantle can be replaced without removing the head and shaft assembly. The Hydraulic rotate mechanism gives high speed adjustment as well as support bowl insertion/extraction.

Locking of the concave support bowl is by positive action Belville washers, when using hydraulic unlock cylinders alternatively by wedges.

Incorrect oil temperature and pressure activates an alarm and stops the crusher.

Other Features

  • Hydraulic power rotate to provide rapid adjust and unscrew features
  • Fabricated counterbalanced rotary seal ring offers greater machine balance, resulting in smooth operation, while the non-contact seals reduce costly maintenance and minimize wear
  • To prevent dirt and dust from entering the crusher lubrication system, the manganese mantle can be replaced without removing the head and shaft assembly
  • For control and safety, the crusher boasts a safety shut-down system - incorrect oil temperature, flow or pressure activates an alarm and stops the crusher
  • Anti spin device option.
  • Thrust roller bearings.

 

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Rock Breaker Systems

BTI’s BXR Series Breakers offer outstanding power to weight ratio, and exceptional efficiency with the oil regeneration system. Overall system designed for harsh, continuous duty for use in demanding rock breaking applications.

  • Two speed hydraulic pilot power control; controls blow energy in varying material conditions.
  • Oil regeneration system; increases bpm's without decreasing energy in harder material applications.
  • High volume nitrogen charged accumulator; provides constant blow energy and recoil absorption.
  • Extra-long stroke pressure balanced piston in conjunction with oil regeneration system; optimizes impact energy and bpm's.
  • Button nose piston design; maximizes energy transfer to the tool.
  • Anti-blank fire interlock; protects front head and retainer pins.

The design of the BX Series of Hydraulic Breakers produces stable high-speed percussion, and exceptional value and durability for all construction, demolition, and rock breaking requirements.

  • Breaker mounted manual high / low stroke selector (BX8-BX40); improves production capability.
  • Long stroke piston design; provides high levels of constant blow energy.
  • Anti-blank fire on / off selector (BX8-BX40); alternate modes when operating in varying rock conditions.
  • Optimal sound dampening (BX6-BX40) further lowers noise levels, pertinent in high density population areas.

When considering what size of pedestal rock breaker system you need for yours or your customer’s unique crushing application consider the following.   Its not only the equipment you select but the level of support available to you that makes a significant difference.

Breaker Technology, Inc. (BTI) provides the most comprehensive packages in the industry and are the perennial market share leader.   BTI has been in the business of servicing the harsh and demanding mining and quarrying industries since 1958.  We learned early on that being a supply partner requires more than just top quality equipment. We learned that it is about relationships.  We listened and the result was a game plan that you can easily follow to achieve success.

This starts with properly sizing and selection of the right system to best suit your needs.  BTI provides site specific assessment, coverage and site proposal drawings so you are assured of achieving the correct system to fit your application.  BTI provides an expanded area of coverage compared to our previous designs and those currently offered by the competition.  Our support continues with installation guidelines and detailed engineering made simple so there is no guess work regarding how to anchor and support your system.  BTI provides thorough, on-site start-up and commissioning service and operator and maintenance training.  We also have several warehouse locations and regional distribution so you are assured to have the support you need to sustain your equipment and operation efficiency

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Vertical Shaft Impact Crusher

A full range of robust vertical shaft impact crushers has been added to the product offering of Johannesburg-based Osborn. Manufactured in the USA by sister company KPI-JCI, these versatile, low-maintenance vertical shaft impactors (VSIs) have proved their mettle in the USA, Canada and Europe.  The VSI has the advantage of fracturing stone through impact, which typically creates a more cubical product vs. the cleavage fracture from a compression crusher. 

Versatility

A unique feature of KPI-JCI’s vertical shaft impactors is their versatility. The same machine can be configured to run in standard, semi-autogenous and fully autogenous modes. This is what really sets them apart from other VSI crushers on the market.  Customers can configure their machines according to their needs, to suit their applications. This versatility provides for significant cost savings, since one VSI can effectively be turned into three different machines, with some simple adjustments and changes within the internal components.  Compared to a standard VSI, a semiautogenous VSI will save about 33% in wear costs, and a fully autogenous VSI will save an additional 33%.

Consistency

The KPI-JCI VSI crushers deliver highly consistent end products, are available in both stationary and portable configurations and crank out up to 500 tph production output. They are best applied in tertiary and quaternary applications and various secondary applications.  Rock fed to the crusher’s accelerator mechanism (table or rotor) is flung outwards by centrifugal force against the stationary anvils or hybrid rock shelf for free-body impacting. The proper chamber configuration is application dependent. As a fully autogenous crusher, this VSI features a rotor and hybrid rock shelf.

Rock-on-rock crushing occurs with variable reduction ratios between 6:1 and 3:1 achievable. As a semi-autogenous crusher, with rotor and anvil, the crushing chamber has an autogenous rotor and standard stationary anvils for specialised crushing and problem materials. With feed sizes of 38mm to 51mm, reduction ratios between 8:1 and 3:1 are achieved. With a standard configuration, featuring shoe and anvil, with a maximum feed size of 152mm, variable reduction ratios between 10:1 and 3:1 are possible.

Precise Gradation Control

Major crushing advantages of the KPI-JCI vertical shaft impactor include precise gradation control; the production of chips and asphalt aggregates fines; and compliance with cubical and fracture count specifications for today’s tight specification requirements in asphalt paving.  The autogenous configuration of the VSI produces more in spec material in a single pass than that of more conventional compressive crushers. The autogenous rotor and hybrid rock-self design delivers proper internal crusher geometry for maximum production at the lowest cost.

Other noteworthy features of the crushers include feed tube inspection doors and a unique, low-maintenance lubrication system.  The externally adjustable, reversible and replaceable feed tube allows for quick, easy adjustment though the Inspection door located on the top lid for easy access to the impact chamber. Bearing housing on this VSI runs in an oil lubrication system, so there is little to no maintenance on bearings and housing, and no hassle with greasing every eight hours, as required with other machines.

Safety

Safety is also a key element in the KPI-JCI VSI crusher’s design and a hydraulically operated arm, called the “Hydra-Arm”, is available as an option on the machine, to lift and rotate the crusher lid, allowing safe and unobstructed access to the crushing chamber for maintenance. Bolt-on wear liners protect the tub and lid surface, for long service life, and allowing safe and easy maintenance with no welding required.

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Modular Plant

Osborn's Modular Plant options support the more popular range of machinery offered by the company. Key design criteria include:

  • well designed structural support for crushers and screens
  • proper feed and removal of material
  • ease of maintenance on site

All modules have the option of packing into open top containers for shipment. Established designs and costs provide ease of plant layouts and tender purposes as well as rapid deployment and erection on site. Standardisation ensures accurate lead times even when units are not supplied ex-stock.

Presently Osborn offers a 30 x 42 Jaw Crusher Module that also accommodates:

  1. a 30 x 55 Jaw Crusher
  2. a 6 x 20 Triple Deck Screen Module
  3. a Cone Module with option of surge bin and feeder for the 36D, 38H and 44H crushers
  4. a universal screen structure that can accommodate a 6 x 20, 7 x 20 and 8 x 20 Triple Deck Screen

Osborn are currently designing modules to allow companies to establish a nominal 200 ton per hour crushing plant. This system will include the 30 x 42 Jaw Module, two Cone Modules, a 4 x 12 Scalping Screen Module and a 6 x 20 Triple Deck Screen module.

Thereafter a 40 ton per hour plant will be developed and then stockpile conveyors that pack into containers. Market demands will ultimately steer the course for future designs and will be monitored closely. Clients are requested to contact Osborn about their requirements.

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Toothed Roll Crusher for Cobalt Plate

Designed by Osborn South Africa, this machine is designed specifically for processing cobalt plate. It is used for 4mm thick plate, and works at a feed rate of more than 5 tons per hour.

The two non-adjustable rolls are supported on heavy duty bearings to withstand shock. The rolls are cast in high quality steel with hardfaced tips to extend life. The rolls are machined internally and machine fitted onto the keyed centre barrel.

The rolls are easily replaced by undoing the retaining bolts on either side of the crushing segment and sliding off the centre barrel. The teeth on either roll are timed to mesh perfectly to produce a product of 20 x 20mm which crushing 4mm thick cobalt plate. The rolls rotate at 10rpm.

Rolls are connected via heavy duty straight cut gears to ensure timing of the toothed segments. A simple grease lubrication point is provided.

A heavy-duty Flender gearbox with 22kW flange mounted motor is used for 4mm thick feed size. For thicker plates this may change.Material is fed into the Crusher by hand via the built-in inlet chute. This ensures that material is presented to the rolls at the correct angle and feed rate. Inlet width is 900mm. Roll size is 380mm diameter by 940mm diameter.

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Osborn Laboratory Crushers

Laboratory Jaw Crushers

Osborn's Laboratory Single Toggle Jaw crushers are designed to reduce most materials to a fine granular consistency for chemical analysis. The machines are highly efficient for rushing batch quantities.

Osborn's Laboratory jaw crushers are available in 6 sizes. the Three crusher models with a feed opening of 1010cm or more, are roller Bearing design and can be run for extended periods. The three smaller units are designed for laboratory use only and should not be used over prolonged periods.

Operating Features

  • Reversible manganese steel fixed and swing jaws
  • Fabricated or cast steel structure
  • Simple closed side setting adjustment
  • Jaws easily removed for cleaning

Laboratory Cone Crushers

Osborn Laboratory Cone Crushers reduce 13mm feed to as fine as 1,85mm in a single pass. The product delivered is ideal feed to:

  • Bell or rod mills
  • Laboratory pulverisers
  • Gravity concentration equipment such as tables
  • Sink/float or spiral concentrators
  • Sizing analysis
  • Sampling

Operating features

  • Choke or free fed
  • May be stopped or started under full load.

The Osborn laboratory cone crusher is available in one size only, and compliments Osborn's extended product offering.

 

General features

  • The inner cylinder and lower main frame are of fabricated steel with coincidental axes held in a fixed relationship.
  • Crusher base, fabricated with the motor base, is composed of two parallel channels secured by a V-shaped chute.
  • Upper main frame consists of a threaded cap and houses the precision manganese steel concave. A threaded connection provides an accurate means of adjusting the crusher set.
  • Head is the shape of a cone segment with a pitch of 45°. A pan-shaped manganese steel mantle is bolted onto the head core.
  • Spindle consists of a rugged steel shaft that rotates on taper rolling bearings mounted on the inner cylinder and the lower main frame.
  • Spindle drive is composed of the spindle pulley, motor pulley and V-belts.
  • Wear parts are of manganese steel designed for metal to metal fit against the head surface and the upper main frame surface.
  • Clearing between operations is convenient and complete, salting of samples is eliminated.
  • Quiet operation due to absence of gears.
  • No cooling accessories required.
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BTI Rock Breakers - civils & demolition

BTI’ breakers are well known for underground and mining applications, but also have growing applications in civil construction and demolition.

The BTI breaker can be fitted, as an attachment onto a suitable hydraulic carrier – from excavators and mini-excavators to TLBs, skid steers and loaders. There are two ranges of BTI breakers – each offering different energy ratings and designed for use on different size carriers. The BX Hydraulic Breaker series includes eight models ranging from an energy rating of 550 Joules for the BX4 to 5 400 Joules for the BX40. They can be fitted onto smaller equipment – carriers up to 20 tons.

The larger BXR Series includes six models ranging from an energy class for the BXR50 of 6 800 Joules to the mighty BXR160 with an energy class of 21 500 Joules.  This series is suitable for 20 – 100-ton carriers.

The machines boast a host of features that enhance speed and efficiency for construction site applications like foundations, trenching and demolition.

A BTI unique feature on the hydraulic breakers is the narrow nose design which enhances visibility as well as minimal over-breaking in trenching applications. The oversized, full length, oval retainer pins on the BX10 through BXR160 have excellent resistance to blank fires and expansive load transfer area to front head. The large tool diameters deliver longer life and superior transmission of impact energy.

All BTI hydraulic breakers feature a high strength alloy plate steel construction with abrasion resistant plating which allows for continuous duty in harsh environments. The noise dampening material used throughout the breaker eliminates metal-to-metal contact, reducing wear and noise. 

Every BTI breaker is fitted with top and bottom isolators to absorb recoil energy. The cryogenically enhanced, heat treated alloy pistons and precise tolerances deliver high breaker efficiencies. The short length, large diameter tie rods with integral vibration dampeners provide an exceptionally strong structure.

The remote air breather is positioned above the main control valve on the BX10 through BXR160 models, which provides easy access and clean air intake and a connection for underwater operation when required.

On the BX10 through BXR160 there are remote grease line connection and hydraulic porting on the power cells that allow for easy accessibility for use with carrier or breaker mounted greasing systems.

BX Series

Looking specifically at the BX Series, Booyse notes that these all have breaker mounted manual high/low stroke selector (BX8-BX40) which improves production capability and the long stroke piston design provides high levels of constant blow energy. 

The pressure balanced piston optimises blows per minute (BPM) and blow energy, while the anti-blank fire on/off selector on the BX8 through the BX40 models alternates modes when operating in varying rock conditions.

On the BX6 and larger models, BTI offers an optional sound dampening to further reduce noise levels, which is especially pertinent in high density population areas.

BRX Series

The BXR Series models are equipped with a two speed hydraulic pilot power control. This controls blow energy in varying material conditions. 

The BRX oil regeneration system increases BPM without decreasing energy in harder material applications and the high volume nitrogen charged accumulator provides constant blow energy and recoil absorption.

The button nose piston design maximises energy transfer to the tool and the anti-blank fire interlock protects front head and retainer pins.

The BXR Series uses recoil sensing technology with operator actuated two-speed control and an oversized piston. “This combination maximises blow energy and BPM under varying rock conditions,” Booyse notes. “For example, in hard rock conditions, the BPM is increased providing up to 80% operating efficiency versus 50% efficiency of a conventional breaker. This translates into maximum production and minimal costs,” he stresses.

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BTI Underground Mobile

Mobile breakers

BTI's Low Profile Mobile Breaker Systems eliminate disruptive, costly and unsafe blasting in stopes, drawpoints and grizzlies, providing efficient, safer alternatives to secondary blasting.

Scalers

BTI Scalers perform safe, precision scaling of tunnel roofs, drift walls and ribs by matching the output of the hydraulic breaker to scaling conditions. Our unique telescoping and knuckle combination positioner incorporates high rigidity and torsional strength to absorb accidental shock while scaling.

Shotcrete vehicle

BTI's mechanized shotcreting systems, available in either wet or dry system configurations, offer economical solutions to unstable ground situations

ANFO Loading system

The BTI ANFO Loading System is a complete line of modules designed for various short or long hole explosive loading and is available with single or dual charging vessels for various capacities

Mine support vehicles

Utilizing a single basic carrier in combination with various working end configurations, BTI's rugged, economical and utilitarian service vehicles support mine maintenance, safety and production functions. Configured as stand-alone service vehicles or as interchangeable Cassette/Carrier combinations these vehicles can be configured as Crane, Fuel/Lube, Pipe, or Mechanic's Trucks, Personnel Carriers and Scissor Lift or other basic service and support vehicles

Please see this link for brochures on above equipment –

http://www.rockbreaker.com/index.php?option=com_content&view=category&la...

Coal Processing

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, Osborn’s 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.

Mineral Sizers

Astec’s range of single shaft and twin shaft roll sizers are rugged by design and engineered to handle high tonnage throughput using minimal installed primary power. The mineral sizers can be configured to operate in two ways depending on the material output size required.

Horizontal Shaft Impact Crushers

Impact crushers may be applied as primary or secondary crushers in applications processing soft, low abrasion materials.

Double Roll Crushers

Equipped with adjustable clearance between the rolls, double roll crushers are typically applied where greater control over product sizing is desired. Larger models are capable of accepting 600 mm (23.6”) feed.

American Roller Ring Crushers

Well suited for most coal crushing applications requiring a top size output from 12 mm to 38 mm (.47” x 1.5”). Larger models are capable of accepting feed particles as large as 600 mm (24”). Available in sizes that range from 30 HP.

Rotary Coal Breakers

Rotary coal breakers are typically utilized for the primary breaking and cleaning of run of mine coal. An assortment of lifters and plows are installed in various arrangements to control flow rates for optimum efficiency.

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Osborn Rotary Coal Breaker

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, Osborn’s 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.

The Rotary Breaker works on a gravity method to break coal in a very efficient manner through attrition. 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. Any hard rock present in the feed material assists with breaking the coal during the raising and dropping action.

The Osborn Rotary Breaker is designed to reduce soft to medium coal and is not entirely suitable for hard coal or coal with a high moisture content. Mine rock, refuse and other uncrushable debris is automatically carried to the end of the drum and is discharged through a chute.

The Rotary Breaker design incorporates a chain and sprocket drive arrangement which drives a heavy duty reinforced drum. Renewable perforated plates are fitted around the interior of the drum. Interchangeable lifters and ploughs are bolted on the inside of the drum. 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 2 000 tph with a maximum feed size of 600 mm depending on the type of coal being processed. Generally, the machine is fitted with perforated plates to continuously produce one product size. Should the product size need to be changed, new sized perforated plates would have to be fitted.

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.

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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.

FRAME & 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.

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.

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BTI Rock Breakers

BTI’s BXR Series Breakers offer outstanding power to weight ratio, and exceptional efficiency with the oil regeneration system. Overall system designed for harsh, continuous duty for use in demanding rock breaking applications.

  • Two speed hydraulic pilot power control; controls blow energy in varying material conditions.
  • Oil regeneration system; increases bpm's without decreasing energy in harder material applications.
  • High volume nitrogen charged accumulator; provides constant blow energy and recoil absorption.
  • Extra-long stroke pressure balanced piston in conjunction with oil regeneration system; optimizes impact energy and bpm's.
  • Button nose piston design; maximizes energy transfer to the tool.
  • Anti-blank fire interlock; protects front head and retainer pins.

The design of the BX Series of Hydraulic Breakers produces stable high-speed percussion, and exceptional value and durability for all construction, demolition, and rock breaking requirements.

  • Breaker mounted manual high / low stroke selector (BX8-BX40); improves production capability.
  • Long stroke piston design; provides high levels of constant blow energy.
  • Anti-blank fire on / off selector (BX8-BX40); alternate modes when operating in varying rock conditions.
  • Optimal sound dampening (BX6-BX40) further lowers noise levels, pertinent in high density population areas.
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Vibrating Screens

Osborn has probably the largest range of vibrating screens available in South Africa. These include the Telsmith, JCI-KPI and in-house Osborn brands. The range extends to twin motor out-of-balance exciters to standard eccentric mechanical shafts or heavy-duty gearbox exciter types. Osborn designs offer unique screening solutions for extreme screening applications. Models include the SuperKing Screen, the Osborn Linear Dewatering Screen, the Osborn Exciter Driven Screens and the Osborn Obex Screens.

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Exciter Driven Vibrating Screen

Osborn Exciter Driven Screens use finite element analysis to provide optimum performance and structural strength. The Exciter Driven Screens are built in our Elandsfontein works, which has an ISO 9001 rating, providing quality workmanship.

The Exciter Driven Unit is designed to handle high amplitude vibrations without decreasing life expectancy.

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KPI-JCI Mobile Screens

KPI-JCI and Astec Mobile Screens engineer the toughest, most versatile, most efficient screens available.

High-frequency screens

Astec Mobile Screens’ high-frequency screens are engineered to provide higher production capacities and more efficient sizing compared to conventional screens. High-frequency screens feature aggressive vibration applied directly to the screen that allows for the highest capacity in the market for removal of fine material, as well as chip sizing, dry-manufactured sand and more.

BENEFITS

  • Large-capacity hoppers make big jobs easy to handle.
  • Hydraulic screen angle adjustment reduces downtime by making adjustments quick and easy.
  • Easy-to-reach engine controls and grease points allow routine service to be conducted efficiently.

 

Multi-frequency screens

High frequency for sorting small diameter material and high amplitude for screening larger aggregate, the Multi-Frequency Screen can handle any job you throw at it - without sacrificing an ounce of performance or a penny of profit.

With the combination of both conventional and high-frequency screen movements integrated, the screen is able to maintain the higher production rates of a PEP screen, at a lower angle, while handling higher moisture content materials.  Coarser material requires more amplitude and less frequency, while finer material requires less amplitude and more frequency.

When these two theories are combined, it provides a versatile screen that is easy to apply in a variety of applications. By working at a lower operating angle, the overall height of the machine is less—making the machine safer to work on and operate.  With high-frequency and high-amplitude vibration, there’s no job this screen can’t handle.

BENEFITS

  • Better performance than a conventional incline
  • Lower Operating angle than a High-Frequency Screen
  • Rotary Tension design allows quick screen cloth changes
  • Screen cloth won't blind
  • Versatile for almost any application
  • High-frequency and high-amplitude
  • Superior performance
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Osborn Linear Screen

Osborn Linear Screens are designed in Austria utilizing finite element analysis to provide optimum performance and structural strength. The Osborn Linear Screens are built in our Elandsfontein works, which has an ISO 9001 rating, ensuring quality workmanship. The Unit is designed to handle high amplitude vibrations without decreasing life expectancy.

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Osborn Obex Screen

Osborn Obex Screens are locally designed and built to meet the needs of Southern African mining and quarrying operating conditions. The extensive range of vibrating feeders have been tested and proven in ongoing programs of intensive field research, through years of use in mines and industry throughout Southern Africa.

Two vibrating motors rotate in opposite directions, synchronise and impart a vibrating force in a longitudinal direction. This lifts the material and carries it forward on each rotation, providing a constant feed rate. The amplitude can be varied by adjusting the out-of-balance weights on the vibrating motors to the required stroke.

The frequency depends on the use of 4-pole and 6-pole motors, as dictated by the applications.

 

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SuperKing Incline Screens

The Osborn Telsmith Superking range of heavy duty inclined screens have set the standard on most primary screening and scalping applications through exceptional reliability and high productivity in the toughest industrial environments. Adjustable counterweights ensure optimal stroke for each application. The patented counterweights also help the Superking screen to keep its composure during start-ups and shutdowns.

Osborn Telsmith Superking Screens are capable of a wide variety of applications from heavy duty scalping behind large primary crushers to final sizing down to 4 mm.

With one of the largest and most modern facilities in South Africa, Osborn also offers installation, commissioning, spares, reconditioning and after sales service, plus the capability to supply the right unit for any type of inquiry.

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Feeders

For heavy-duty feeding, Osborn offers a range of apron feeders suitable for the most arduous conditions encountered in the mining and quarrying industries. The company’s apron feeders handle heavy, lumpy and abrasive materials with accurate feed rate control.

Osborn also designs and manufactures a complete range of vibrating feeders including the Osborn Linear Grizzly & Pan Feeder, the Osborn Obex Feeder and the Osborn Apron Feeder.

Osborn Apron Feeder

Our Apron Feeders are designed and built in a wide range of sizes from 900 mm to 3500 mm wide to handle heavy, lumpy and abrasive materials, and provide a reliable means of controlling the feed rate to prevent surge loads to primary crushers, belt conveyors and other plant and equipment.

Apron Feeders are usually installed under a hopper or bin and can accept direct dumping by trucks or bulldozers, shovels or a dragline.

Osborn offers a complete range of standard and extra heavy duty apron feeders suited for the most arduous conditions encountered in the Mining and Quarrying industries. Feeders can be supplied in lengths to suit customers' requirements.

With one of the largest and most modern facilities in South Africa, Osborn also offers installation, commissioning, spares, reconditioning and after-sales service, plus the capability to supply the right unit for any type of inquiry.

In addition, these units complement Osborn's wide range of mills, screens, jaw crushers, gyrasphere cone crushers, feeders, scrubbers and idlers. A turnkey plant capability is also available.

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Pan Feeders

Osborn Pan Feeders (Volumetric Feeders)

The main feature of this feeder is the low power consumption, low noise and little maintenance required. Osborn Pan Feeders are generally installed at a 10 degree downslope to provide the best efficiency for the free flow of material. Fitted with replaceable liners and can be floor or suspension mounted.

Skirt boards should be fitted to give an approximate clearance of 30 mm minimum between the deck and the side plates when operating with 4 pole motors and 60 mm for feeders with 6 pole motors. These recommended clearances are measured at the feed end of the deck and will increase to approximately double at the discharge end.

Of significant importance when installing an Osborn Pan Feeder is the design of the feed hopper. (see hopper /chute design). Incorrect hopper design will cause the feeder to underperform to the specified duties. Osborn Pan Feeders are manufactured in many different widths and lengths from 300 mm wide up to a 2400 mm wide and up to 4000 mm long.

Osborn feeders all work on the same principle, that being the extraction of materials from under crushers, bins, hoppers etc, or fed by a conveyor with a regulated flow to promote a steady supply to maximise production in the processing plant.

Sometimes fed by a dump truck or a front end loader, or directly from under a stockpile. Whatever type of feed is required and dependent upon the type of the feeder installed, the feed rate is controlled by the machines vibration frequency and often the controls, which can be manual or automatic and can be programmed to receive a signal from a PLC.

Types of Drive Mechanism

  • Twin Motor Type (OBEX)
  • Double Shaft Type (Linear)
  • Gearbox Driven (GBEX)


Osborn Spreader Feeder

Designed to accept a fast material flow from a relatively narrow feed and convert this into a low velocity and uniform flow across the width of the machine. The Osborn spreader feeder is highly recommended for this.
These feeders are capable of handling a wide range of products including materials such as damp clay and limestone and are ruggedly built for arduous trouble free service. There are two types of Osborn spreader feeders.

These are:

  • Transverse Feeder
  • Central Feeder

 

Reciprocating Plate Feeder (Push-pull Feeder)

The reciprocating plate feeder is generally installed at a primary crushing site and receives a positive feed of material from a bin or hopper. Its “push-pull” action is generated by a link arm that is connected to a crank shaft which is in turn connected to a variable or fixed speed drive unit .

Plate feeders generally operate at low frequencies. Often used in the drawdown of a coal stockpile where large lumps and moisture in the coal is being handled as the flow characteristics of coal are perfect for a reciprocating plate feeder. The hopper or bin cannot be emptied by the plate feeder and feeding is discontinuous thus ensuring a cushion of material on the plate to protect the feeder. The feeding of the material takes place in the return stroke only due to the reciprocating action.

The main advantages of a plate feeder over other feeding equipment are:

  • Minimum damage from impact of large lumps due to cushion of material on the plates
  • With no carry-back of material, plate feeders operate with minimum spillage
  • Wedging damage is minimal
  • Low maintenance and operating costs
     
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Vibrating Grizzly Feeders

Vibrating Grizzly

The vibrating grizzly is used to separate ROM feed material into fractions prior to the primary crushing stage of the process. The pan deck is usually no more that 1 meter long whilst the grizzly bar section can be over 5 meters in length with varying widths from 900mm to 2400mm.

This feeder take a bin load and is often fed by an apron feeder or a pan feeder to feed and scalp the material prior to the primary crusher. Very similar action to the Pan Feeder these robust machines are frequently used in the quarrying and mining industries. The grizzly is generally installed horizontally but to improve material flow they can be installed up to a maximum 10 degree downslope.

Grizzly bars can be arranged as a single, double or even triple row dependent upon the amount of scalping required. Capacities range from 250tph through to 2500tph. The vibrating grizzly can be used as a heavy duty high capacity, non accurate screen due to the grizzly bars being tapered to allow elongated particles to pass through. The Osborn grizzlies operate at a minimum of 4G’s force with an approximate amplitude of 10 mm.

Vibrating Grizzly Feeder

Osborn has a wide selection of VGF’s from the light duty Osborn Obex machines with a vibrator motor drive, a middle duty Osborn Telsmith series with a twin shaft drive (very often used for aggregate production) the heavy duty Osborn Linear series with a twin shaft or quadruple shaft drive and the Osborn Gbex machines with a gearbox drive used extensively for very heavy duty mining applications.

Designed to incorporate a long pan deck and a short section of grizzly bars the VGF is generally used to feed the primary crusher and to take the impact of dumped loads of material from trucks or front end loaders. Often referred to as brute force feeders due to the constant impact loads to which this feeder is subjected which is the main difference between this equipment and the vibrating grizzly Tapered grizzly bars prevent plugging of material and improves separation.

The material load is taken on the pan deck and the grizzly section removes unwanted fines that would otherwise go through the crusher. Available in single or stepped decks configurations with a minimum grizzly length of 1.2 meters up to 3.6 meters. VGF widths are available from 900 mm through to 3000 mm. Also available is a second deck made up of wire screen cloth to provide additional scalping and/or separations in certain sizes.

Types of Drive Mechanism

Twin Motor Type

  • OBEX
  • Double Shaft Type (Linear)

Gearbox Driven

  • GBEX
  • Osborn Double Shaft Type (Telsmith)

BROCHURE: Vibrating Grizzly Feeders

 

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General Equipment

Classifiers

Screw classifiers are used to separate water and silt, and other unwanted fines from sand while dewatering. Screw classifiers are built in single or twin-screw configurations with a large settling and are for best salvage of fine sands.

The Osborn range of equipment is renowned for its ruggedness. Years of design improvements and field experience gleaned from crusher installations throughout the world are represented in our line of classifiers.

Screw Classifiers

Telsmith Screw Classifiers come in a wide range of sizes to cover nearly all requirements and specifications. Screw classifiers are used to separate water and silt and other unwanted fines from sand while dewatering and are built in single or twin-screw configurations with a large settling area for best salvage of fine sands.

Sand Classifiers

Telsmith Sand Classifiers are elevating screws operating at a slow speed to separate sand 10 mm and smaller so it can be dewatered sufficiently to be carried on an inclined conveyor. Unwanted clay and debris is floated over the adjustable weirs.

Normally, feed to sand classifiers comes from a washing screen or from the discharge of a dewateirng and classifying tank. Telsmith Sand Classifiers are available in capacities from 6 to 364 tph.

Telsmith classifiers for years have been a major factor in high volume production at plants where product requirements are strict, capacities huge, and up-to-date low maintenance machine design is a must.

Now they have been made even more productive with better surge control techniques, faster sand settling, separating and dewatering. Full three side overflow distributes water over a wider area, turbulence is reduced to a mere ripple, sand settles in a quiet pool area, while waste is flushed out smoothly and effectively.

Telsmith does carry a coarse material washer type screw classifier for the +10 mm to 50 mm material range. This classifier is used mainly for washing. The beaters or arms create a big turbulence in the pool area, to move the material around for better washing.

Conveyor Idlers

In underground, overland and in-plant conveying applications throughout industry, Osborn idlers have proven their worth to thousands of satisfied customers. Osborn offers a complete range of standard and custom designed idlers and underground structures.

A stage-by-stage quality controlled manufacturing programme ensures a product of the highest quality is produced, providing our customers with the benefits they seek.

Benefits:

  • Low Maintenance
  • Minimum Downtime
  • Long Equipment Life

These are just three of the operational rewards you receive when you invest in Osborn idlers.

You may wish to know the mass of the rotating parts in our rolls, or more about our sealing arrangements or lubricating requirements. Our product managers will gladly advise you on recommended pitching of idlers, shaft deflections, bearing life expectation and the type of idler best suited for your applications.

 

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Grinding Mills

New Concept Projects formed a Joint Venture Agreement with Osborn and now supply the new Osborn Grinding Mill Range.

Our capability includes the supply of new mills, based on existing proven Osborn designs, engineered with assistance of modern design techniques and 3D simulation packages. We also offer after sales support and spares backup to all Osborn mills currently operating in the market.

Mill sizes range from 1.6m (5ft) diameter through to 11.6m (38ft) diameter, all carrying gear driven designs. The Grinding Mills are supplied to clients worldwide.

For projects carrying restricted budgets or accelerated timing requirements, NCP incorporates the supply of refurbished Grinding Mills into the portfolio to match project requirements. These options can be refurbished back to OEM specification and be supplied with warrantees equivalent to new equipment.

NCP Mill Design Capabilities

  1. Process Modeling through an NCP developed Specific Energy Breakage Model
  2. 3D Drafting
  3. Structural Design FEA
  4. Bearing Fluid Film Analysis
  5. Drive Train Design (Including Variable Speed Drives)
  6. Drive Train Torsional Analysis
  7. Casting Simulations & Foundry Methodology Review
  8. DEM Charge Analysis & Liner Design Optimization
  9. Project specific chute design based on Trajectory Theory

New Equipment Offered

  1. Osborn Grinding Mills & Comminution Circuit Equipment
  2. Osborn Crushing & Screening Plants & all related equipment
  3. Scrubbers are offered by both Osborn (<3.5m Diameter) and New Concept Projects (>3.5m Diameter)
  4. Mill Spares for all Mill makes

AG/SAG Mills

AG/SAG Mills can accept feed up to 350mm and used as primary grinding units. The mill is thus fed with the product from a Primary Jaw or Gyratory crusher. Grinding action is by particle-on-particle impact (AG Mills) and a combination of ball & particle-on-particle impact (SAG Mills). SAG applications include both wet and dry operation.

The discharge of the AG/SAG mill is fitted with a grate discharge, where ground material passes through slotted apertures into a pulp chamber that then lifts the material out the belly of the mill. The lifted material is then deflected into the trunnion and exits via a trommel into the mill discharge sump.

Rod Mills

Rod Mills can accept feed up to approximately 25 mm and are generally selected to grind products in the 4 mm to +0,5 mm range. Grinding action is by line contact between rods which extend the length of the mill. Rod Mills are usually operated in open circuit. Most rod mill applications involve wet grinding where material is reduced in size from crusher product size to a size suitable for ball mill feed. To avoid breakage or tangling of rods, the L/D ratio of rod mills is kept within the limits of 1, 3/1 to 2/1.

Osborn supplies the three most common rod mill types: overflow, end peripheral and center peripheral discharge.

Overflow:
An overflow mill is constructed with a feed opening at one end and a discharge opening at the other, both on the axis of the mill. Material leaves the mill by overflowing at the discharge end. Used for producing the finer end of the product range.

End Peripheral Discharge (EPD):
The end peripheral discharge mill's steeper gradient produces a shorter retention time and thus a coarser product than the overflow type. Product is discharged through port openings equally spaced around the periphery of the shell at the discharge end. Grinding may be accomplished wet or dry. End peripheral discharge is used to good advantage in damp grinding of coke on steelwork sinter plants.

Center Peripheral Discharge (CPD):
Feed is from both ends and is discharged at the center through discharge ports. The fact that the particles only travel half the mill length makes the CPD rod mill an outstanding unit for coarse grinding and rapid removal of finished material.

Ball Mills & ROM Ball Mills

Ball mills accept feed that ranges in size from 80% passing 70mm (ROM Ball Mills) through 15 mm (post a tertiary crusher circuit) to fine feeds of less than 1mm in regrind operations. Products may be as coarse as 0.5 mm or as fine as 40 microns and below. In a ball mill the length may be less than, equal to, or greater than its diameter. A short length mill has a lower retention time and produces a coarser product. Longer mills have a longer retention time and therefore produce a finer grind.

Grate Discharge:
This mill type embodies the principle of steep pulp gradient, quick discharge operation. A grate and pulp lifter assembly at the discharge end of the mill enables a ball charge of 35-40%. The quick removal of ground material reduces overgrinding, especially when operated in closed circuit with a classifier.

Overflow:
As the name implies, material is discharged from an overflow mill by overflowing the discharge opening. The overflow mill is simple to operate and maintain and is ideal for producing fine products such as in regrind operations.

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KPI-JCI SuperStackers

The KPI-JCI SuperStacker™ is designed to help customers meet increasingly demanding material specifications. Available in various sizes, the SuperStacker gives producers the ability to stockpile “in-spec” aggregate in larger piles with smaller footprints using fully automated PLC technology.

  • Portable Radial Stackers
  • Extendable SuperStackers™
  • Transfer Conveyors
  • Feed Systems
  • Complete Systems

Capable of creating custom-shaped, partially or fully desegregated stockpiles to fit maximum material in minimum space, the SuperStacker™ certainly lives up to its name. The standard Cam-Arm linkage maintains a constant radius from the pivot plate to the axle ensuring a true radial movement and uninterrupted stockpiling. Enhance your SuperStacker’s™ performance with the optional Wizard Touch Automated Control System. Offering preprogrammed performance to meet any job’s daily demand.

Superstacker Series 33

The Series 33 consists of a “stinger” conveyor mounted inside an outer conveyor. The stinger conveyor moves linearly along the length of the outer conveyor, varying the location of the discharge pulley.

The height of the discharge pulley is variable, as well as the radial position of the conveyor. The three axis variation is essential in making the layered pile that overcomes segregation.

Features & Benefits

  • Built in counterweights at the tail end of the main conveyor.
  • Standard Gull Wing Axle allows for quick set-up and transport, eliminating the time, expense and manpower associated with manual configurations.
  • Hydraulic planetary power travel is provided on the radial travel wheels, eliminating the disassembly of chain drives.
  • Cam Arm Undercarriage is standard on all KPI-JCI Superstacker models. This maintains a constant wheel radius when raising / lowering the conveyor without having to skid the tires or interrupt stockpiling. A smaller width runway is required due to constant travel radius.

Transfer Conveyors

We offer transfer conveyors ideal for all types of operations. For semi-mobile or in-pit portability, KPI-JCI Transflite™ Transfer Conveyors are the ideal solutions and available in skid mount or dolly axle configurations. Channel or lattice frame overland conveyors are available to cover longer distances, eliminating the need for haul trucks.

Our stackable conveyors can pack up to 480 feet of conveying power in a single truckload, perfect for portable operations always on the move. For additional on-site portability, 3-pack conveyors are configured to be towed away in loads containing up to three, 70-foot long, wheel-mounted conveyors.

Feed Systems

Maximize the effectiveness of your entire operation with the seamless compatibility of material feed products. Our entire line of feed solutions has been designed using several decades of experience in building aggregate processing and recycling equipment. Couple this experience with versatile and innovative engineering capabilities and you receive the flawless compatibility only KPI-JCI Feeding Equipment can deliver — enabling you to run at peak performance and keep material moving at the rate your operation requires.

COMPLETE SYSTEMS

Providing material to and taking material away from your processing equipment at a productive rate is vital to your profitability. We offer a streamlined design of highly productive material handling systems. Load and unload railcars, trucks or ships and move massive loads of material throughout your operation in no time. From tripper systems to loading or unloading, we have the right design, components, installation and support for your application.

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Scrubbers

Osborn Telsmith Super Scrubber is offered under license to Telsmith of the USA. These scrubbers are suited to the most arduous conditions encountered in the South African Mining and Quarrying Industries.

With one of the largest and most modern facilities in South Africa, Osborn also offers installation, commissioning, spares, reconditioning and after sales service, plus the capability to supply the right unit for any type of enquiry.

Applications for Rotary Scrubbers

  • Cleans ores, stone, gravel and sandstone.
  • Mill type cascading action disintegrates a large amount of clay and dirt, which is carried away by the water flow.
  • Helps meet the requirements of many specifications that need crushed stone to be scrubbed before screening to eliminate or reduce soft stone, clay and dirt.

In addition, Osborn Telsmith Super Scrubbers compliment Osborn's wide range of mills, screens, crushers, vibrating feeders, apron feeders and idlers. Turnkey plant capability is also available.

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