A typical crusher plant installation
The Jaques cone crusher at the Ormeau Crushing and Screening plant crushes primary crushed material from the jaw crusher , of feed size of approximately 100mm to 50mm, through the use of an eccentric rotation. The rotation occurs only at the bottom of the main shaft. An 110KW electric motor creates the drive to the eccentric assembly through multiple drive V belts. The eccentric assembly turns at a constant speed, causing the lower end of the main shaft to gyrate. The main shaft is pivoted at the top of the main shaft by the spider bearing. The process is continuous.
Jaques cone crusher crushing process
gyratory crusher
After material has passed through the jaw crusher it is feed into the Jaques gyratory cone crusher, which in the system is called a secondary crusher. Crushing occurs when pressure is applied to material which falls in between the eccentrically rotating main shaft wear liner called the mantle against the fixed wear liners called the concave ring and concaves. Due to the eccentric rotation there is a close side between the mantle wear liner and the concave wear liner, and also an open side.
Therefore feed material falls into the crushing chamber and is crushed at the nip points, close side, as the mantle eccentrically rotates around the concave. Some material may fall through the cycle without being crushed on the open side. Material that has passed through the crusher on the open side will be crushed on other cycles. After material, which is now called secondary crushed, falls onto a discharge conveyor and travels to the next stage of the process.
Close Side Setting
The close side distance of the crushing chamber is called the Close Side Setting (CSS). The CSS is the distance from the mantle to the concave at the point where nipping occurs. The larger the CSS, the larger the output rock will be. The CSS can be adjusted and is accomplished by raising or lowering the main shaft assembly. By raising the main shaft assembly, the CSS would decrease.
The open side measurement, on the opposite side of the mantle is called the open side setting (OSS). The OSS is equal to the eccentricity plus the CSS. The adjustment is achieved mechanically. The top of the main shaft assembly is threaded, and so by way of turning the suspension nut the height of the main shaft assembly and subsequently the CSS is adjusted.
As a secondary crusher, it uses a superior mantle and concave, this refers to the shape of these two components. The shape allows for a larger input size of material, while still outputting a well reduced size of rock. This is referred to as the Percentage Reduction. Therefore the percentage reduction of the 900mm Jaques Gyratory Cone Crusher is higher than the tertiary crushing configuration.
Jaques cone crusher oil system
This particular crusher at Ormeau has been modified from the Original Manufacturers specifications. The crusher is lubricated through one simple system. Oil is transferred from the reservoir by the oil pump. The pump is driven by a speed reducing gearbox which is connected to a 5KW electric motor, instead of being driven directly from the main shaft. Oil then enters a filter, and then through an oil cooler. Oil then enters the crusher through the pinion housing. Oil flows through the pinion housing to the crown wheel and through the eccentric assembly. Oil is then gravity feed through a port in the bottom of the pinion housing back to the reservoir.
CRUSHER PROTECTION SYSTEM
The crusher is fitted with protection systems. The crusher motor is electrically interlocked, therefore the crusher drive motor will not start until the oil pump has been started and the low oil flow sensor is not reading low oil flow. The low oil flow sensor is located on the return side of the lube system, and so oil circulates the entire system and is returned back to the tank, before the low oil flow sensor does not read. This means that the crusher has sufficient lubrication and can be started. The interlock now allows for the crusher motor to be started. This interlock also works when operating the crusher; if the low oil flow sensor reads low oil flow the crusher motor will stop, as there is a problem.
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