ThyssenKrupp FördertechnikExcellence in Technology

Gyratory Crusher

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ThyssenKrupp Fördertechnik isone of the world’s leading manufacturers of machines and plants for the processing industry.

Based on decades of experience, our engineers are engaged in research and development. The results have become an integral part of processing technology.Customers worldwide benefit from our innovations. Whether standard or customized designs – ThyssenKrupp Fördertechnik always offer complete solutions often found in cooperation with the customer.

Reliable, safe, profitable, innovative… ThyssenKrupp Fördertechnik.

Gyratory Crushers by ThyssenKrupp Fördertechnik:because it’s the perfected design that does the job

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1KB 63-89 in Iron Ore.Capacity: 6,200 t/h

2KB 63-75 in AggregatesCapacity: 2,600 t/h

Fields of Application and Design Characteristics3

The design of the gyratory crushers and jaw gyratory crushers is based on more than one hundred years of experience of ThyssenKrupp Fördertechnik in the manufacture of these machines.

Changing mining and processing methods demand (besides new materials and design methods) a continual development of the products. ThyssenKrupp gyratory crushers represent today’s leading crushing technology. They aredesigned for high performances at low operating and maintenance costs.

Fields of application

•Large scale hard rock ore mines

•Lime and cement works

•Open pit and underground operations

•Aggregates industry

Design characteristics

•Spiral bevel gear toothing

•Drive motors with heavy duty ratings

•Heavy duty design

•Optimized crushing chambers for direct feed

•High throughput rates

•Optimum crushing ratio

•Change of stroke through adjustment of eccentricity

•Direct drive for high starting torque facilitates start in case of emergency

•Hydraulic main shaft adjustment for wear compensation and overload protection

•Low operating and maintenance costs

•Includes Gyramatic PLC

3ThyssenKrupp Gyratory Crusher Product Range

4KB 54-75 in Iron Ore

KB 54-67

BK 54-67

KB 54-75BK 63-75 KB 63-75

KB 63-89

KB 63-114

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Working principle

The main shaft (B) of the crusheris radially guided in the spiderbushing (A) and in the inner eccen-tric bushing (G). The thrust bearing assembly (J) arranged on the piston of the hydraulic cylinder (K) ensures the axial support of the main shaft.

The rotation of the drive motor is transmitted via the transmission gear (H) to the eccentric bushing (G). This rotating eccentric bushing is generating the gyrating motionof the main shaft (B) – which is characteristic of gyratory crushers.

Consequently, the crushing gap between the stationary concaves in the crusher housing and the gyrating crushing mantle changes continuously.

The feed material that enters the crushing chamber from the top is continuously crushed between the crushing tools (C) as it falls by gravitation until it exits the crushing chamber at the bottom (F).

Gyratory Crusher

Gap increase caused by wear is compensated by hydraulic liftingof the main shaft.

It also serves as overloadprotection when tramp iron finds its way into the crushing chamber.

Restart under load in an emergen-cy is supported by a heavy duty drive train using a bevel gear set with cyclo-palloid toothing. The spi-ral bevel gear allows the installation of drive motors with high ratings.

Main shaft “jumping” under ad-verse crushing conditions isavoided by a pressurizedhydraulic system ensuringpermanent contact of the individual thrust bearing discs.

6Bevel gear for KB 63-89 withcyclo-palloid toothing

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5Design

A Upper main shaft bearing assembly with two-armed spider ensures a spacious feed opening, equipped with automatic grease lubrication with electronic and visual level control

B Main shaft

C Crushing tools made of high wear-resistant material

D Cast-steel shell sections, weight-optimized by means of FEA calculations

E Highly efficient dust seal

F Large discharge openings owing to three-armed bottom shell

G Eccentric bearing assembly with replaceable inner eccentric bushing for stroke adjustment, integrated counterweight to minimize unbalanced forces

H Transmission gear including device for setting the tooth clearance, safe lubrication due to hermetically sealed splash lubrication, electronic and visual oil level and temperature control, optionally vibration control

I Bevel gear and -pinion with cyclo-palloid toothing ensures smooth transmission of high torque

J Thrust bearing of the main shaft

K Hydraulic cylinder for main shaft adjustment under load

A

B

CC

D

E

F

H

G IJ

K

Technical Data5

1) Average component weight incl. internal

fittings; safety factors for dimensioning of

lifting equipment have not been

considered

2) including wear cap

3) excluding hydraulic cylinder

4) with oversized mantle incl. crushing tools

5) Min: typical throughput at minimum

eccentricity and F80=680mm

Max: typical throughput at maximum

eccentricity and F80=230mm

Bulk density: 1,600kg/m³

The stated values are for information only

and not warrantied.

They depend on material characteristics and

crusher configuration.

The maximum feed size should not exceed 80 % of the feed opening width. Installation drawing with mating dimensions and loads on request.

Drawn displaced by 120°

End of motor shaft

Supporting surfaces

Discharge opening

A

[mm]

B

[mm]

C

[mm]

D

[mm]

E

[mm]

F

[mm]

G

[mm]

H

[mm]

I

[mm]

J 1

[mm]

J 2

[mm]

KB 54 - 67 4,475 4,430 1,535 1,642 4,352 6,026 200 3,200 2,800 3,660 3,660

KB 54 - 75 4,475 4,600 1,630 1,745 4,484 6,295 200 3,400 3,000 3,900 3,900

KB 63 - 75 4,950 5,750 1,955 1,745 4,497 6,930 200 3,400 3,000 3,900 3,900

KB 63 - 89 4,950 6,020 2,120 1,808 4,900 7,024 200 3,720 3,300 4,290 4,290

KB 63 - 114 6,250 6,450 2,273 2,270 5,800 8,725 200 5,000 4,500 5,500 5,500

Gyratory Crusher type

[inch]

130

Min. Max.

150

Min. Max.

170

Min. Max.

185

Min. Max.

200

Min. Max.

215

Min. Max.

240

Min. Max.

KB 54 - 67 1,226 2,284 1,479 2,853 1,762 3,674 2,017 4,317

KB 54 - 75 1,292 2,408 1,480 3,239 1,851 4,177 2,066 4,787 2,216 5,277

KB 63 - 75 1,790 3,304 2,092 4,483 2,219 5,058 2,868 5,613 2,925 6,014

KB 63 - 89 2,501 4,518 2,784 5,116 3,024 5,888 3,407 6,700 3,638 7,489 3,829 8,503

KB 63 - 114 2,964 5,514 3,362 6,368 3,829 7,317 3,959 8,036 4,722 10,274

Throughput [t/h] at open side setting OSS [mm] 5)

Gyratory Crusher

type

[inch]

Feed

Opening

[mm] / [inch]

Mantle

Diameter

(oversized)

[mm] / [inch]

Speed of

Eccentric

Bushing

[rpm]

Max.

Motor

power

[kW]

Total weight

of Crusher

[kg]

Spider 2)

[kg]

Heaviest

Shell 4)

[kg]

Bottom

Shell 3)

[kg]

Main

Shaft

Assembly 4)

[kg]

Eccentric

Bushing with

Bottom

[kg]

Hydraulic

Cylinder

[kg]

KB 54 - 67 1,370 / 54 1,700 / 67(1,750 / 69)

137 450 180,000 29,000 30,500 37,100 32,500 7,100 8,100

KB 54 - 75 1,370 / 54 1,900 / 75(1,965 / 77)

137 650 215,000 32,000 33,000 43,500 43,000 8,500 9,500

KB 63 - 75 1,600 / 63 2,030 / 80(2,100 / 83)

137 650 270,000 37,800 66,000 43,500 50,000 9,500 9,500

KB 63 - 89 1,600 / 63 2,260 / 89(2,370 / 93)

130 1,000 332,000 46,500 71,000 53,000 69,500 13,000 14,000

KB 63 - 114 1,600 / 63 2,900 / 114(2,985 / 118)

127 1,200 530,000 65,500 73,000 124,000 124,000 16,000 19,000

Gyratory Crusher

type

Weights1)

Clearance for mainshaft removal

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Jaw Gyratory Crusher

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Jaw gyratory crusher with specially designed feed opening

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Jaw gyratory crusher for iron ore in an underground

application

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Feed opening of BK 63-75 in a stationary copper ore plant

Working principle

Special feature of the jaw gyratory crusher is the specific shape of the feed opening, which is extended to one side. The feed opening is nor-mally toothed, and together with the upper mantle it forms the primary crushing zone. Further crushing of the roughly pre-crushed material takes place in the lower part of the crushing chamber, where the speci-fied final grain size is produced.Jaw gyratory crushers are designed to handle substantially bigger feed lumps than the comparable size of the gyratory crusher with the same mantle diameter.Jaw gyratory crushers have higher crushing ratios and a low tendency to get clogged in the feed area as a result of bridging.

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Large Feed opening

3080 x1675mm

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Fields of Application:

• Coarse feed material

• Block cave mining

• Underground mines

130

Min. Max.

150

Min. Max.

170

Min. Max.

185

Min. Max.

200

Min. Max.

BK 54 - 67 944 2,133 1,186 2,542 1,570 3,376 1,738 3,872 1,833 4,017

BK 63 - 75 1,057 2,398 1,328 3,036 1,757 3,973 1,946 4,555 2,052 4,871

Technical Data7

The maximum feed size should not exceed 80 % of the feed opening width.

Installation drawing with mating dimensions and loads on request.

A

[mm]

B

[mm]

C

[mm]

D

[mm]

E

[mm]

F

[mm]

G

[mm]

H

[mm]

I

[mm]

J 1

[mm]

J 2

[mm]

K

[mm]

L

[mm]

M

[mm]

BK 54 - 67 4,252 3,400 2,010 1,642 4,352 6,500 200 3,200 2,800 3,660 3.660 2.150 1.350 2.640

BK 63 - 75 4,252 4,400 2,400 1,745 4,484 7,200 200 3,400 3,000 3,900 3,900 2,640 1,675 3,080

Jaw Gyratory Crusher

type

[inch]

Drawn displaced by 120°

Feed

Opening

[mm] / [inch]

Mantle

Diameter

(oversized)

[mm] / [inch]

Speed of

Eccentric

Bushing

[rpm]

Max.

Motor

power

[kW]

Total

Crusher

weight

[kg]

Spider 2)

[kg]

Heaviest

Shell 4)

[kg]

Bottom

Shell 3)

[kg]

Main

Shaft

Assembly 4)

[kg]

Eccentric

Bushing with

Bottom

[kg]

Hydraulic

Cylinder

[kg]

BK 54 - 67 2,640 x 1,350 /104 x 54

1,700 / 67(1,750 / 69)

137 450 175,000 46,000 42,000 36,800 34,000 7,100 8,100

BK 63 - 75 3,080 x 1,680 /121 x 66

1,900 / 75(1,955 / 77)

137 650 209,000 50,400 45,500 43,500 45,000 8,500 9,500

Jaw Gyratory Crusher

type

Weights1)

Discharge opening Supporting surfaces

End of motor shaft

Throughput [t/h] at open side setting OSS [mm] 5)

Jaw Gyratory Crusher

type

[inch]

Clearance formainshaft removal

1) Average component weight incl. internal

fittings; safety factors for dimensioning of

lifting equipment have not been

considered

2) including wear cap

3) excluding hydraulic cylinder

4) with oversized mantle incl. crushing tools

5) Min: typical throughput at minimum

eccentricity and F80=680mm

Max: typical throughput at maximum

eccentricity and F80=230mm

Bulk density: 1,600kg/m³

The stated values are for information only

and not warrantied.

They depend on material characteristics and

crusher configuration.

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Crusher Drives

ThyssenKrupp gyratory crushers are driven directly by a multiple-disc steel clutch with intermediate shaft and a safety coupling. The multiple-disc steel clutch compen-sates geometric deviationsbetween motor- and transmission gear shaft, while the hydraulicsafety coupling protects thecrusher motor against overload when uncrushable foreign matteris fed to the crusher. The intermediate shaft allowsthe disassembly of the transmission gear without dismantling the motor.

The monitoring and controlsystem “Gyramatic” ofThyssenKrupp Fördertechnikgyratory crushers ensures aneasy and safe operation of these crushers in different applications. This compact and solid unitconsists of a control cabinet witha touch screen terminal and willbe integrated into the localelectrical equipment. The input values are important operation parameters being measured onthe crusher, on relating units and the environment. The touchscreen terminal will acceptinteractive input to set parameters and display the operating data.

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10

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Gyratory crusher with multiple-disc steel

clutch with intermediate shaft and safety

coupling

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Direct drive of the gyratory crusher

A Crusher side

B Fully enclosed cartridge

C Multiple-disc steel clutch

D Safety coupling

E Intermediate shaft

F Motor side

A B C D E CF

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Monitoring and control system

of the gyratory crusher

“Gyramatic”

Customized Crusher Solutions9

Split shellHydraulic nut for quickshell release

For individual applicationsindividual designed spidersare available

1: Standard ring spider2: Split ring spider for applications with dimension and/or weight restrictions3: “Bone” type spider for quick release and larger feed opening4: “Jaw type” spider for extreme large feed opening

ThyssenKrupp Fördertechnikpays large attention to provide crusher solutions adapted to clients’ needs. For varying crusher demands dependent on feedmaterial properties and productrequirements ThyssenKruppprovides individual solutions.There are different spiderdesigns, wear part shapes andcrushing tools available oreven tailor-made solutionsfor specific needs.

1: Ring spider 2: Split ring spider

3: “Bone” type spider 4: “Jaw type” spiderScissor lift for dismantling of eccentric

Chamber covers and Concave racks for safe & quick maintenance

Wear parts in Rock-Box design

Hydraulic spider lock(Patent pending)

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Examples of Crushing Plants with Gyratory Crushers

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Primary crushing plant with gyratory

crusher KB 63-75 for iron ore / overburden.

The crusher is directly fed from two sides

by means of dump trucks.

Capacity: Ore 3,650 t/h

Overburden 4,500 t/h

Product P99: Ore ≤ 280 mm

Overburden ≤ 350 mm

Feed size: max. 1,400 mm

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Jaw gyratory crusher BK 63-75

installed underground in a crushing plant

for copper ore.

Capacity: 2,000 t/h

Product: P80 ≤ 150 mm

Feed size in block

caving: max. 2,000 x 1,500 x 1,000 mm

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Relocation of semi-mobile crushing plant

equipped with KB 63-114 for copper ore.

Proven capacity >10,000t/h

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Dependent on the crushing duty, the performance and availability of gyratory crushers are optimised due to specific design andarrangement of feeding and discharging devices.

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Research, Development and Services11

ThyssenKrupp Fördertechnikis dedicated to continuous,innovative research and deve-lopment. For us, innovationsand technical progress are key factors in managing globalgrowth and using finite resour-ces in a sustainable way. Withour engineering expertise weenable our customers to meetthe rising demand for “more” ina better way, gain an edge inthe global market and manu-facture innovative products in a cost- and resource-efficient way.

This ranges from basic analyses to measurements on new andold crushers.

At first analyses of the depositsor the feed material are carriedout by means of up-to-datemethods allowing a materialcharacterization and based hereon the right choice of asuitable crusher.

Furthermore, by these basicanalyses the best possibleadaptation of the crusher canbe ascertained, like e.g. thecorrect sizing of individualcomponents by means of thefinite element analysis.The computed values will thenbe field-tested using a newlydeveloped control- anddiagnosis system which allowsthe control of the mostimportant operating data.

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Teleservice

- Collecting, archiving and evaluating

machine / process data

- Worldwide access via GSM

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Spare Parts Service

Easy access of crusher components via

electronic spare parts catalogue

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Scan service

- Crushing Tools evaluation by on-site 3D

scanning

- Wear analyses and optimization of

crushing tools

Our services include projectresearch, damage analyses,planning and modification aimedat a modernization and anincrease of the output ofmachines and plants in conjunction with a worldwideafter-sales service which alsocovers the equipment of other manufacturers.

Maintenance and repair services offered by ThyssenKruppFördertechnik include expert on-site consultancy. Repairs are carried out by highly qualifiedstaff using high-quality andtested spare parts. Increase theproductivity of your machineryand equipment.

Get in touch with ThyssenKrupp Fördertechnik – wherever you are.

• Inspection services

• Stand-by emergency services

• Repair services – on site – in the workshop of the service centre

• Diagnosis systems

• Maintenance contracts

• Spare parts services

• ImProMa - Program (Improvement of Process and Machines)

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ThyssenKrupp FördertechnikPartners of the mineral processing industry

Product range

Crushing technology

•Stationary, semi-mobile and mobile crushing plants

•Gyratory crushers

•KUBRIA® cone crushers

•Double-toggle jaw crushers

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•TITAN® double-shaft hammer crushers

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Screening technology

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EngineeringModernization, RefurbishmentAfter-sales serviceTraining

ThyssenKrupp Fördertechnik GmbH

Processing

Schleebergstraße 12, D-59320 Ennigerloh (Germany), Tel.: +49(2524)30-0, Fax: +49(2524)2252

E-mail: info.tkfen@thyssenkrupp.com, http://www.tk-processing.com

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