Osborn offers a one-stop shop for coal handling

SingleToggle Jaw Crusher

With coal use worldwide continuing to grow – led by China and India - the future looks bright for equipment suppliers who can contribute to meeting the burgeoning demand for coal-fired energy.

Elandsfontein-based Osborn is one such supplier, and with the addition of a new mineral sizer to its product range, offers a virtual one-stop shop for the coal industry.

Commercial Director Stephen Ireland elaborates: “Osborn has been supplying the coal industry with robust, high quality equipment for more than five decades, and we are exceptionally well positioned to meet current and future demand. Osborn's machines have gained popularity as far afield as Australia and Turkey and closer to home with our neighbours Zambia and Zimbabwe,” he adds.

Referring to the typical process flow for a 1 000 to 2 500 tph coal mine, Ireland says that the coal is generally drawn from a primary tip hopper onto an apron feeder, which then discharges onto a vibrating grizzly. The undersize material is fed directly onto a conveyor, with the oversize being fed into a primary jaw crusher or rotary breaker from a second apron feeder.

The jaw crusher employed is often Osborn’s biggest - the Osborn Hadfields 80 x 60 Single Toggle Jaw Crusher. This immense machine, which weighs 140 000 kg and stands as tall as a double-decker bus, is one of the largest manufactured in the world. “It has found its niche in primary opencast mining operations throughout Southern Africa,” Ireland says.

“It is also firmly positioned as the primary crusher of choice in the African coal industry, handling up to 2 m x 1.5 m feed size with throughput in excess of 1 600 tph.” The undersize and crushed material is conveyed to a scalping screen, with the oversize being further reduced in a rotary breaker.

Osborn's rotary breaker is a product that in recent years has come back into favour in the coal industry, because, he states, customers are once again recognizing its value, and the fact that its simplicity makes it the machine of choice for this application. Osborn has seen rotary breaker orders increasing in the last year, with a number of machines sold in the past 12 months, Ireland says.

“The rotary breaker has proved to be the most efficient machine for use in 'dirty' coal mining environments,” he adds. “All of the equipment in the coal handling process is offered by Osborn – from the largest jaw crusher and rotary breaker, as well as mineral sizers, double roll crushers and rolling ring crushers, right down to the smallest components, the conveyor idlers. The Hadfields range of Double Roll Crushers is designed and manufactured by Osborn primarily for use in the coal industry and similar related soft rock applications. Osborn’s American Pulverizer Rolling Ring Crushers are also increasingly sought by the coal industry.”

The most recent addition to Osborn's coal industry equipment offering is its new range of mineral sizers.

“Our design can be configured to a range of single shaft and twin shaft sizers,” Ireland states. “We've maintained a heavy duty low profile design capable of handling high tonnages while using minimal installed primary power. The low profile and small footprint of these machines makes them ideal for primary tips where the mine doesn't want a huge installation as is required by a big gyratory or jaw crusher.” One of the biggest advantages of a mineral sizer is that it keeps most of the dynamic loads within the framework of the machine, which means much lighter foundations and much lower installation costs compared to a conventional crusher system.

The Osborn Mineral Sizer can be configured to operate in two ways, depending on the material output size required. Explains Ireland :

“As a primary crusher, for example, rotation of the breaker shafts will be towards the centre of the machine, but by reversing the rotation of the breaker shafts towards the sides of the machine and changing the tooth or segment configuration, it can be used as a secondary or tertiary crusher.” Backing up Osborn’s range of robust, high quality machines for the coal industry is a 24/7 service department and spare parts division