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...