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TSUV Gyratory Crushers
TSUV Gyratory Crushers
Top service
TSUV Gyratory Crushers
Safer, smarter and
more powerful crushing
WE DISCOVER POTENTIAL
The lowest cost per tonne It’s a hard rock life
of product processed With mining companies increasingly turning to
low-grade deposits to meet market demand, the pressure
on crushing operations is greater than ever.
Crushing just got harder. With low grade ore deposits requiring higher Are you doing more work for the same yield? ■ More power without a significant increase in crusher footprint
power and higher throughputs than ever before, you need a crusher Your energy bill is higher. Your maintenance costs are higher. Your ■ Greater capacity without compromising on performance
that can take the impact – without compromising on efficiency. health and safety risks are higher. That’s the reality of crushing ■ Optimised speed to balance throughput and wear rates
With more power and greater capacity, the digitally-enabled TSUV low-grade ore. ■ Enlarged feed opening for greater flexibility
is the world’s most OPEX and CAPEX-efficient gyratory crusher. ■ Service through the top, significantly reducing safety risks
At the same time there is pressure to reduce the environmental ■ Integrated, smart controls, including wear compensation and
impact of your operation. Bring down energy consumption. Increase automatic mantle adjustment to maximise crushing efficiency
efficiency. And of course, always, protect your personnel from harm. ■ Potential to connect to your mobile device for real time status
and alerts, wherever you are
It’s time for next-generation crushing ■ Liner optimisation for the lowest wear cost per tonne
We can’t change the nature of your deposit. But we can change
the way you crush it. Our Mark V Top Service Gyratory Crusher It’s the most efficient gyratory crusher on the market, designed
– the TSUV – brings you: to help your mining operation reach its full potential.
1.2
240
% Copper
1
200
0.8
160
0.6
120
80 0.4
■ ■ ■ ■ ■ 0 0
1990 1995 2000 2005 2010 2015 2020 2025
Ultra-heavy duty Lowest cost per tonne Lowest total cost Safer, simpler Digitally enabled for
design in operation of ownership (TCO) maintenance optimal productivity
Unlike other gyratory crushers, which require workers to get in It’s also safer than ever before. The all-new self-aligning main-shaft 1905 1950 1990 2006 2020
underneath the crusher to perform maintenance tasks – a high-risk negates the need for service personnel to be working underneath Bulldog MK I TC MK II NT MK III TS MK IV TSUV MK V
operation – the TS range allows service and maintenance to be a heavy suspended load. Previously the 100+ tonne fully-dressed
carried out from above. The eccentric assembly, bushings and main-shaft had to be guided into the eccentric assembly by hand.
hydraulic piston are easily accessible and removed through the top With this new development the shaft aligns automatically,
of the crusher, hence the name ‘Top Service’. Not only is this much dramatically reducing risk. Strip
Feed Power Down
safer than the bottom service crusher design, it also increases the
Crusher First Desig Opening Capacity Power to Weight Reduction Time
speed and simplicity of maintenance work, reducing costs and To offer even greater potential to optimise performance, the model built nation (in) (mtph) (kW) Ratio Ratio (hrs) Notes
boosting availability. TSUV is digitally enabled – giving you more control over operations
and availability. This is a game-changer. The ability to make fine Bulldog 1905 Mk I 18 200 150 1:1 2.5 : 1 48 Side discharge - belt driven (flat, later V-type)
In addition to safety and the reduced maintenance burden, the adjustments to wear compensation, track equipment trends and
1910 Mk I 48 1.200 225 1:1 2.5 : 1 48 Maintenance intense (multi-daily)
TS gyratory crushers are built for strength, durability and the ability instantly detect crusher obstructions will enable increased uptime,
to adapt to the various requirements of mine operators. optimum equipment life and a significantly reduced risk of un- Grew over 50 years.
1919 Mk I 60 2.000 330 1:1 2.5 : 1 48
planned downtime. Additionally, our integrated control system Became basis for all other designs
incorporates all the required safety and interlock features to 1950 Superseded Eventually, over 2,400 sold
keep your operators safe.
TC Circular discharge
1950 Mk II 60 3.000 375 1 : 1.5 3.5 : 1 30
- belt driven (flat, later V-type)
1969 Mk II 72 3.400 525 1 : 1.5 3.5 : 1 30 Hydraulic adjustment introduced in early 60's
1990 Superseded
Capacity increase (mtph) Power increase (kW)
NT 1990 Mk III 60 x 113 4.500 750 1 : 1.7 4.0 : 1 17 Circular discharge - shaft driven
15000 1500
1500 2005 Mk III 60 x 113 6.000 1.000 1 : 2.0 4.0 : 1 17 Incorporation of FEA and modern controls
12000 1200 2013 Still current Modularised and simplified components
1200
9000 900 TSU 2006 Mk IV 63 x 114 8.000 750 1 : 1.7 4.5 : 1 5 Circular discharge - shaft driven
900
6000 600 2009 Mk IV 63 x 118 10.000 1.200 1 : 2.3 4.5 : 1 5 Incorporation of FEA and modern controls
600
2013 Still current Eccentric serviced from top
3000 300
300
TSUV As TSU but more enhancements.
2020 Mk V 72 x 130 15.000 1.500 1 : 2.7 4.5 : 1 4
0
0
0 Rotable shells, self-aligning main-shaft
Low High Low High
Low High Our next generation model 1,500 kW and capacities up to 15,000 mtph
MK I MK II MK III MK IV MK V MK I MK II MK III MK IV MK V
MK I MK II MK III MK IV MK V
We understand that to cope with new challenges, you need new Enlarged feed opening – For those customers with ‘slabby’ or
technology. It’s why we re-engineered the entire TSUV, rather than ‘blocky’ materials, we have introduced extended topshells to give
adding features to the previous model. Every part of the Mark V has you larger feed openings. These are optional for all machines in the
been strengthened and improved to give you greater crushing TSUV range.
efficiency and a low total cost of ownership (TCO). We’ve instilled all
our knowhow and process experience into the design to bring you: Liner optimisation service – This service ensures wear maintains
the desired nip angle, which keeps power at a constant range and
Higher power – Improved power handling capabilities allow you to thus optimises throughput.
process more material as ore yields decline, enabling you to remain
competitive. The crusher footprint has only nominally increased but Easier maintenance – Up to 74% reduction in planned
maximum power handling is now up to 1500 kW. maintenance time means more time in production, increasing
productivity and boosting your bottom line.
Higher capacity – Improved capacity throughputs make use of the
additional power available without compromising on setting or Integrated controls – Our advanced control system includes KPI
product size. You get the same product – but more of it. dashboards, built-in trending, power and PSD wear compensation,
automatic lowering of the mantle and camera/laser detection of
Optimised speed – We’ve optimised eccentric speeds to ensure oversize boulders and bridging. These are significant developments
maximum throughput without incurring excessive wear rates. This is that will enable you to increase reliability and reduce the risk of an
a finely balanced equation, based on extensive R&D work, which unscheduled stop.
together with the new service and operational features, gives you
the lowest possible cost per tonne of material processed.
In this latest generation, speed is increased by a further 7%. ■ Higher power handling – maximum power now up to 1500 kW
This, in conjunction with the larger mantle diameter, equates to ■ Rotable top and middle shells as standard
approximately a 10% capacity increase – and not at the expense ■ Self-aligning main-shaft as standard on all TSUV models 10
of setting. (a significant advantage to health, safety and availability)
■ Digitally enabled controls and condition monitoring
■ Designed to crush even the hardest ore
Features 4
1.
The bar-type spider’s four-bolt design reduces 7. Integral main-shaft lifting eye ensures that 11
the amount of time required for removal. Further, it is stronger and never misplaced.
12
its rectangular design reduces the overall amount
of space necessary during maintenance. 8.
Grease spider lubrication is simpler than
oil lubrication and easier to maintain.
2.
Spiral bevel gearing allows for larger installed
power on the crushers. 9.
Bronze spider bushing provides improved life
and better impact resistance than a cast iron spider
3.
The countershaft assembly is designed to allow bushing.
3
2
for fine adjustment of gear mesh during installation.
It includes self-adjusting bearings that require no 10. Top shell wear plates are designed to be easily
maintenance or pre-load. replaceable, better fitting and leading to faster
dump pocket clean-out.
13
4.
Eccentric and hydraulic piston now accessed from
the top, are serviced faster, more efficiently, and safer 11.
Pressurised dust seal minimises particle ingress
than a traditional bottom service gyratory crusher. and ensures that oil stays clean of contaminants.
5.
Threadless main-shaft design improves strength 12. Bottom shell view ports allow maintenance personnel
by minimising peak stresses during demanding to view crusher shell liners and check for wear. 1.
Bar-type spider 5. Threadless main-shaft design 10. Top shell wear plates
2.
Spiral bevel gearing 6. One-piece integral main-shaft 11. Dust seal pressurised chamber
crushing operations.
3.
Countershaft assembly 7. Integral main-shaft lifting eye 12. Bottom shell view ports
13. We utilise identical oil in both the hydraulic and 4.
Top serviceable eccentric 8. Grease spider lubrication 13. Identical lube and hydraulic oil
6.
One-piece integral main-shaft standard on all sizes lubrication systems, ensuring that if cross-contamination and hydraulic piston 9. Bronze spider bushing
eliminates core shrink fit and reduces any loose occurs there is no need to flush out the system.
core downtime.
SiteConnect
Want to know what’s going on when you’re not on site?
Stay connected with our mobile SiteConnect app for
iOS and Android. View your asset performance and
health data, no matter where you are, so that you can
make the best decisions for your plant and equipment,
promptly and with confidence.
Capacity (mtph)
W
OSS 4 in 5 in 6 in 7 in 8 in 9 in 10 in 11 in
Model 102 mm 127 mm 152 mm 178 mm 203 mm 229 mm 254 mm 279 mm
900 x 1500
680-1,058 1,199-1,823 1,536-2,259 1,915-2,749 – – – –
1100 x 1500
1100 x 1900
F D T – 1,474-2,272 2,254-3,383 2,800-4,058 3,396-4,766 – – –
1300 x 1900
H 1400 x 2200
– – 2,351-3,791 2,886-4,519 3,472-5,300 – – –
1600 x 2200
1600 x 2600
– – 2,926-4,842 4,142-6,733 4,913-7,821 5,436-8,494 – –
1800 x 2600
1600 x 3000
E – – – 4,800-6,050 5,550-7,450 6,700-8,750 7,500-9,650 8,250-10,750
1800 x 3000
Clearance B 1600 x 3300
X
to remove – – – 5,000-6,100 7,250-8,750 8,600-10,100 10,500-12,550 12,400-14,400
main-shaft 1800 x 3300
assembly
Notes: All capacities based on material with 1.65 t/m3 bulk density and Bond Crushing Work Index of 13 kWhr/mt.
Minimum and maximum numbers based on Fine and Coarse feed gradations. Fine: F80 = 450 mm. Coarse: F80 = 700 mm.
S
Discharge L C Centres
diameter
Clearance
to remove Product gradation
countershaft Percent passing
assembly
100
90
Motor (kW) Weight
Model (Low – Standard) (mt) B C D E F H L M S T U W X 80
900 x 1500 375 - 450 90 2,507 2,186 4,245 150 3,923 2,687 2,770 3,451 2,300 805 3,259 820 1,334 4.0 in
70
1100 x 1500 375 - 450 108 2,507 2,186 4,453 150 4,136 2,898 2,770 3,650 2,300 805 3,457 705 1,334 5.0 in
1100 x 1900 450 - 600 147 3,343 2,843 5,717 150 5,136 3,376 3,645 4,470 3,080 1,139 3,966 1,228 2,068 60 6.0 in
1300 x 1900 450 - 600 175 3,343 2,843 5,998 150 5,414 3,641 3,645 4,728 3,080 1,139 4,207 1,056 2,068
50 7.0 in
1400 x 2200 600 - 750 250 3,900 3,400 6,716 150 6,102 4,177 3,850 5,568 3,599 1,250 4,836 1,275 1,973
1600 x 2200 600 - 750 298 3,900 3,400 7,046 150 6,433 4,505 3,850 5,889 3,599 1,250 5,130 1,096 1,973 8.0 in
40
1600 x 2600 750 - 1,000 391 4,850 4,250 8,029 150 7,139 4,877 4,975 6,770 4,171 1,500 6,325 2,635 2,981 9.0 in
1800 x 2600 750 - 1,000 474 4,850 4,250 8,423 150 7,526 5,260 4,975 7,160 4,171 1,500 6,710 2,266 2,981 30
10.0 in
1600 x 3000 1,000 - 1,200 522 5,450 4,850 8,770 150 7,929 5,408 5,215 6,574 4,775 1,670 6,320 2,468 2,780
20
1800 x 3000 1,000 - 1,200 608 5,450 4,850 9,200 150 8,318 5,833 5,215 6,953 4,775 1,670 6,705 2,122 2,780
1600 x 3300 1,200 - 1,500 554 5,450 4,850 8,631 150 7,539 5,001 5,350 6,900 4,780 1,670 6,416 2,538 3,060 10
1800 x 3300 1,200 - 1,500 654 5,450 4,850 9,055 150 7,948 5,394 5,350 7,297 4,780 1,670 6,807 2,183 3,060
0
10 mm 100 mm Product size [@ OSS setting]
EQUIPMENT
MONITORING Key benefits of a connected crusher
Get easy and direct access
to information on your crusher ■ On demand information in the ■ Real-time insights available ■ Maximise productivity and reliability
health and performance with control room or on your mobile to top management ■ Reduce environmental impact
our intuitive HMIs or on your
mobile device.
■ Expedite remote support ■ Increase uptime and availability ■ Cut operating costs
■ Enable faster decisions and actions by decreasing unplanned breakdowns ■ Control and optimise operations
Expert review
14 15
Service package level
General category Monitoring point Benefit Level I Level II 20
Overload General overload warning Yes Yes
monitoring High specific power Yes Yes
Liner wear All these features are monitored by the Yes Yes
smart control system. The aim is to avoid long-term
Excessive tramp cumulative overload damage to bearings, frame, Yes Yes
eccentric main-shaft , gears and drive 18 4
Excessive reduction No Yes
2
Excessive fines No Yes
High ore work index No Yes
3
Crusher Overall bearing condition Yes Yes
13
bearings 1 Countershaft bearings Yes Yes
Ensures component replacement
2 Outer eccentric bushing at next planned shutdown before Yes Yes
unexpected catastrophic failure
3 Inner eccentric bushing No Yes
4 Main-shaft wear rings No Yes
Grease lube 14 Grease level monitoring Avoids nuisance trips from low grease level. Yes Yes
system 15 Grease flow rate monitoring Ensures adequte grease flow to spider bushing Yes Yes 8
Hydraulic 7 Pump wear Yes Yes
Proactive lube system maintenance to avoid
system 16 Filter condiiton Yes Yes
interrupted OSS crusher adjustment 16
17 Reservoir level monitoring Yes Yes
Leakage monitoring Prevent main-shaft drift and oversize product Yes Yes
12
18 Piston seal damage Allows proactive oil replacement thereby extending Yes Yes
hydraulic system component life 19 19
19 Oil contamination monitoring No Yes
Liners 20 Wear monitoring Optimises liner procurement and changeout planning Yes Yes
compensation calculated with power targets and tonnage. uses cameras to analyse the particle size of each truck load prior ■ Power draw
■
PSD Wear Compensation: Fine adjustments for wear to it entering the crusher. The system interlocks with the tipping
compensation calculated with PSD targets with feedback signal light to prevent tipping of oversize rock into the crusher. The end result? A productivity and profitability boost thanks
from camera/laser scanner. ■ The Gyratory Crusher Bridging Particle Size System to improvements in product quality, wear part utilisation and
■
Feed Camera/Laser Option: Detection of oversize boulders monitors the crusher feed opening using camera equipment equipment availability.
and bridging will alert you to take early/fast decisions. and a particle size analyser to detect bridging/blocking.
If a blockage is detected, an alert is sent to the operator and
Plus, intelligent controls automatically adjust the mantle position the tipping signal is triggered to prevent further feed entering
setpoint, raising it to compensate for liner wear and lowering it in the crusher.
response to over-pressure or over-power events. ■ The Gyratory Crusher Particle Size – Product Belt Camera
System analyses the output of the crusher to check the reduction Imbalanced
ratio is as expected. If output is oversized, the crusher gap is crusher loading
automatically adjusted. resulting in
poor production 100%
65%
Properly
balanced crusher
loading resulting
in maximum 90% 90%
production
From fixed stations to traditional truck-fed semi-mobile stations to Our complete range of TSUV Gyratory Crushers can be mounted
low profile semi-mobile stations, we have the solution you need. on fixed and semi-mobile steel plants, giving you the freedom and
flexibility to design your plant the way you want to.
The TSUV crushers offer benefits that no other crushers can offer
when you consider the following: Not enough height to go direct dump? Opt for the “Low-Profile”
configuration, which can accommodate your civil constraints.
Despite their higher power handling capabilities, TSUV crushers
offer the lowest dynamic loadings in their class. This leads to less
steelwork, less civils and therefore no need to compromise on the
crusher you really need for the job at hand.
Rockbreaker
BY CLIENT Gyratory Crusher
Dump Hopper Apron Feeder AFD9 1300 x 1800 TSU
Control Cabin
EL.+12.100
BY FLSmidth
EL.+7.250
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0 (Pu
2200
EL.+4.700
Belt Conveyor
15Ā
3072
Conveyor
Hood EL.+2.500
4060
EL.+0.000
The team at FLSmidth has been working with a number of “Hydroset replacements are planned/recommended anywhere
customers recently to eliminate unexpected crusher shutdowns between one and five years, again depending on site-related
and to optimise equipment reliability. Manager of Life Cycle variations. General maintenance is hard to time, but an educated
Services Charlie Madsen was happy to share this knowledge. estimate would be something along the lines of three to four days
“Planned major maintenance predominantly means liner every half year. Maintenance schedules are planned through
changeouts,” he said. “But generally, the crusher will be shut information, data, and trending of wear and components.” Rate
down for two mantle changes and one concave change per year. of wear and wear characteristics are typically determined by
Mantle changes can be done in approximately 24 hours and the orebody type, work index, abrasiveness and fracture rate,
a concave with a mantle change in four to seven days as well as throughput.
depending on factors such as mine location and site specifics.
“These are characteristics that can change over the lifespan of Maintaining the open side setting (OSS) is typically done by
a pit or orebody, requiring constant attention to liner material choice operators with a control system that shows the main shaft position
and profiles. This ensures wear patterns and wear loss are kept at all times. FLSmidth’s automation team has designed new software
at the optimum level and secures lowest cost per metric ton in that can carry out optimisation of the main shaft position based
operation,” Madsen said. “FLSmidth mitigates wear rates by using upon a number of instruments that maximise throughput, power/
different types of manganese in its liners, upgrading to chrome- wear and final product. “Calibration of the main shaft is an infield
moly where necessary. White iron can also be advantageous.” exercise, as manual verification and measurements have to be
conducted in order to calibrate and scale the electronic equipment,”
Combining this with the optimisation of liner profiles, throat/chamber said Madsen. “By optimising the main shaft position, we create
design and operations on-site for feed characteristics tends to give a more effective and constant wear profile, which allows the end
the most successful result, and changes in the above can extend user to get full wear out of liners.”
liner profiles and throughput over a lifetime by up to 500,000 mt
in some cases. This is obviously welcomed by the customer FLSmidth is developing a comprehensive maintenance
as downtime is cut and maintenance costs reduced. Madsen management system for its Excel-Raptor cone and gyratory
explained: “There are an abundance of checks that should be crusher lines. “We also we have a self-aligning main shaft, which
carried out fully and thoroughly in preventative maintenance improves on installation times, and more importantly, safety and
inspections and with a computerised maintenance management suspended loads,” Madsen added. “We are also the only OEM
system (CMMS). These, in combination with customer training, with a fully top service gyratory, which improves on maintenance
can reduce maintenance times and cut unplanned failures. downtime and saves on building and construction designs and
It also enables more consistent scheduling of work activities, sizes.” The team has designed rotable shell segments to reduce
planned shutdowns and parts supply.” concave liner changeout times, and the spider removal jacks are
threaded into the shell rather than being free standing to reduce
manual handling requirements and improve ergonomic positioning
for staff.
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M 10-20 0000-11-ENG
FLSmidth A/S
Vigerslev Allé 77 Tel. +45 36 18 10 00
2500 Valby Fax +45 36 30 18 20 Copyright © 2020 FLSmidth. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth.
This brochure makes no offers, representations or warranties (express or implied), and information and
Denmark [email protected] data contained in this brochure are for general reference only and may change at any time.