Optimizing Your Crushing

Equipment
Vietnam - Hanoi, 25th March 2019
thyssenkrupp Industrial Solutions | Wong Loong Wei
Agenda

Optimizing your Crushing Equipment

• Hammer Crusher
• Impact Crusher
• Double Roller Crusher/Sizer
• Apron Feeder
• Crusher Revamp References

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Different Quarries means
Different Materials.

Pakistan Spain Malaysia Philippines

Saudi Arabia Columbia Germany Algeria

Therefore, different crushing solutions are needed

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Different Materials will require
Different Crushers.
Product Range of thyssenkrupp Industrial Solutions

Selection Criteria for the most suitable crusher

Max. Crushing Ratio Compressive Strength Silica Content Moisture

Type of crusher
[-] [ Mpa ] [%] [%]
Single shaft hammer
1 : 100 < 150 ∼8 < 10
crusher
Double shaft hammer
1 : 100 < 150 ∼8 < 15 - 20
crusher
1 : 20 l 1 : 60
Impact crusher < 175 ∼ 12 <8
Grinding Path

Double roll crusher 1:5 < 150 > 15 > 20

1 : 6 [Primary] > 15 [Primary]

RollSizer 1 : 5 [Secondary] < 150 > 15 < 15 [Secondary]
1 : 4 [Side Sizer] < 15 [Side Sizer]

Jaw crusher 1:5 > 150 - 400 > 15 <5

Gyratory crusher 1:5 >150-400 > 15 <5

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Agenda

Optimizing your Crushing Equipment

• Hammer Crusher
• Impact Crusher
• Double Roller Crusher/Sizer
• Apron Feeder
• Crusher Revamp References

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The Titan Double Shaft.
A Hammer Crusher with Modern Design.

Hydraulic Devices Drive

Rotors Baskets

Casing

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The Titan Double Shaft.
A Hammer Crusher with Modern Design.

Feed Raw Material

Rotation Direction Rotation Direction

Hammers
[Forged, Casted, Bi-metal Type]

Rotor

Anvil

Basket 2 x 125 deg.

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Choosing the right Hammer
for your Crusher.

Hardness at the mounting hole Hardness at the impact area

Type Material Size/ Weight Price Level/ Lifetime
HB N/mm2 HB N/mm2
420
Cr-Steel with Titanium 1450
TK-DUR-C up to 160kg 350-400 1100-1360 Inlay: 1100-
Carbide Inlay (Steel Matrix)

Price/Lifetime
1800HV
TK520 Forged up to 160kg 350-400 1250-1350 480-530 1600-1800
TK50 Rolled Steel up to 160kg 270-320 900-1100 430-520 1500-1800
200 200
GX120MNCr18.2 Marganese Steel up to 160kg 800 (1630) 800 (1630)
(up tp 500 HB) (up tp 500 HB)

A correct hammer selection is a critical to balance your hammer lifetime, maintenance

activities, overall cost, and operation availability.
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Grate Basket.

Basket Setup Shape of Grate Basket

One-part (old design) Split design (new design) Progressive Conservative

(Gap increase in discharge direction)

Choose a split basket design, where you can change your grate bar easily while reuse the main
frame. A different grate bar setting can be exchange quickly for change in product size or sticky
material.
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Hammer Crusher Rotor
Hard Steel Bushings

Hard facing on Tungston

4 or 5 piece Hammer Axle Design
Carbide basis

Rotor Discs fitted by shrinking Rotor Discs are connected at

onto the Shaft the outer Damper

More robust rotor design, our experience shows TKIS hammer crusher having generally twice
the lifetime compare to other competitor, with lifetime overall > 5 years with very low
maintenance activities involved.
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Anvil.

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Anvil.

MCC Inlays

Up to 3 times longer lifetime compare to all other existing solution

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Agenda

Optimizing your Crushing Equipment

• Hammer Crusher
• Impact Crusher
• Double Roller Crusher/Sizer
• Apron Feeder
• Crusher Revamp References

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Impact Crusher.

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Impact Crusher.

Hydraulic Wedges Claiming

New cast Rotor design

tkIS Automatic Gap

System
Tk-Dur Blow Bar

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The CR Discs Rotor.
Most Advanced State of the Art.

Characteristics

• Package of discs
• Form-closed connection between the discs, secured
tensioning bolts
• Taper lock ring element for each disc
• Changeable side discs
• No welding connections
• Hydraulically fixed blow bars
• Wear volume of blow bar 50%
• Maximised rotating energy

TKIS new impact crusher rotor are able to retrofit into most 3rd party machine, with the
advantage of higher rotor lifetime, maintenance friendly for blow bar replacement, and high
wear volume of the blow bar up to 50%.
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thyssenkrupp Industrial Solutions proprietary technology.
The Automatic Gap System.
Advantages

• Maintenance and operations friendly

• Gap can be adjusted during operation
• No crusher shutdown necessary
• No manual adjustment and measurement necessary
• Automatic recalibration
• Integrated into the existing plant PLC system
• Wear detection
• …

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 IMPACT CRUSHER
Blow Bar: Choose the right blow bar for your crusher
Different qualities for each application

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 IMPACT CRUSHER
Blow Bar: Choose the right blow bar for your crusher

A correct blow bar selection is a critical to balance your hammer lifetime, maintenance
activities, overall cost, and operation availability.
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Agenda

Optimizing your Crushing Equipment

• Hammer Crusher
• Impact Crusher
• Double Roller Crusher/Sizer
• Apron Feeder
• Crusher Revamp References

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Double Roller Crusher & Sizer.

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Double Roll Crusher & Sizer

- 1 fixed roller, 1 floating roller - Both fixed roller

- Roller diameter bigger - Roller diameter smaller
- Roller speed can be change/ different - Roller speed is fixed
- Gap adjustment possible - roller gap cannot be adjusted
- product size can be kept constant in - wear results in an increased product size
case of wear

Double Roller Crusher & Sizer are always the choice when comes to crushing of clay material, due
to ability to handle high silica and high moisture material, but normally comes in two stage of
crushing due to limit in size reduction ratio.

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Double Roller Crusher.

Replaceable Segments

Replaceable Teeth

Replaceable segment unable quick segment exchange without remove the rotor, reduce
maintenance activities, and maximize the wear parts lifetime.
Replaceable teeth with different material in order to achieve the optimum wear life
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thyssenkrupp eXide wear Solution.
Made with Titanium Carbide Inlay.

Characteristics
• Medium + high investment costs
• Casted manganese or chrome base plates possible
• Increased to high wear resistance
• Increased to long service life in abrasive materials
• Possibility of re-welding (pre-heating)

Manganese Steel High Chrome Steel WC Overlay Welding TiC Inserts thyssenkrupp eXide

Key Features • Monometallic • Monometallic • More than 50% tungsten carbide • Titanium Carbide columns • Metal Matrix Composite
• Hardening through • High Chrome content for content for higher wear resistance embedded within the high wear technology
impact increased wear resistance • Up to 6 mm of tungsten carbide zone • Titanium Carbides are generated
• Optional Bi-Metallic overlay welding • Columns are shrink fitted into the during the casting process with an
Version available with hard hammer head exothermic reaction and are
impact zone and softer surrounded by a steel matrix
bonding area
Wear Resistance Low High Medium High Very High

Impact Resistance Very High Medium-Low Medium-Low Medium Very High

Failure Risk Low risk due to ductile Higher risk due to brittleness Medium risk due to brittle overlay Medium risk due to weak bonding Low risk due to ductile steel matrix
material of hard material between TiC columns and steel body
Wear Resistance
Rate (/ tons ratio) 1 - 1.5 1.5 - 2 1.5 1.5 – 2 3-4

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Agenda

Optimizing your Crushing Equipment

• Hammer Crusher
• Impact Crusher
• Double Roller Crusher/Sizer
• Apron Feeder
• Crusher Revamp References

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Main modules and Spare Parts
of the Apron Feeder Machine.
Pans Tractor chain Drive sprockets

Apron feeder frame Drive and tail-end shaft Sliding rails

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Main modules and Spare Parts
of the Apron Feeder Machine.

Speed Adjustable Drives

Heavy-duty Welded or Cast Pans

Apron Feeder with lifetime Self-lubricated Slide Rail

Lubricated Tractor Chain
Type D4 up to D11

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Agenda

Optimizing your Crushing Equipment

• Hammer Crusher
• Impact Crusher
• Double Roller Crusher/Sizer
• Apron Feeder
• Crusher Revamp References

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Typical Modernization and
Refurbishment Projects – Apron Feeder.

Oman, Oman Cement

Installation of frequency converter controlled apron feeder drive
instead of hydraulically drives

Advantages:
• Increasing output capacity;

• Less and easy maintenance

• Replacement of drive system to motor drive is cheaper

compare to hydraulic drive

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Typical Modernization and
Refurbishment Projects – Apron Feeder.

Lafarge Cement Plant ASHAKA, Nigeria

Conversion and rehabilitation of an old apron feeder

• Apron feeder to RKF 2000 x 13000-D7

• Chain scraper type KK2100 x 12700

• Reusing of existing main support structure

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Typical Modernization and
Refurbishment Projects – Apron Feeder.

Old execution New execution

Schwenk Zement Plant Karlstadt, Germany

Rehabilitation of a apron feeder RKF 2,200x17,900mm-D8;

Execution on “Turn Key basis”, Project handling, engineering , delivery, disassembly and assembly
was done by thyssenkrupp;

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Revamp of “Competitor”
Double Hammer Crusher– Rotor Replacement.
National Cement Company, Egypt
Delivery and installation of 2 thyssenkrupp rotors,
baskets, anvil into a KHD double shaft hammer
crusher, type: HDS 2000/2520 incl. revamping of the
apron feeder 2,200x16,100, 1.400tph.
Advantages:

• Reusing the existing structure;

• Less invest cost compare to complete new
crushing plants;
• Improvement of the performance;

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Revamp of “Competitor”
Double Hammer Crusher– Rotor Replacement.

Chinese Execution New tkIS Execution

Vietnam
Replacement of rotors on SINOMA double shaft hammer crusher for limestone.

• Number of hammer axles reduced from 6 to 5 pcs. for better material penetration
• Hammer weight increased from 150 to 160 kg casted hammers
• Pentagonal rotor shaft for improved impact forces.

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Revamp of “Competitor”
Double Hammer Crusher– Rotor Replacement.
Old Execution DHB1617 New Execution Titan design

Holcim Plant Hoever, Germany

Rotors for KRUPP, DHB and HAPRA crusher
Modified rotor for a KRUPP DHB double shaft hammer crusher for limestone.

- Improved casting quality;

- Rotor discs fitted by shrinking onto the shaft;
- All rotor discs are connected at the outer diameter each other;
- Hard steel bushings are shrunken into the hammer axle bores;
- Improved rotor disc construction; Hardfacing on tungsten carbide basis.

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Revamp of “Competitor”
Double Hammer Crusher– Rotor Replacement.

Old execution New execution

Spain
Modified rotor for a double shaft hammer crusher for limestone.

• Number of hammers reduced from 51 to 48 pcs

• Hammer weight increased from150 to 172 kg. Forged hammers type TK 550
• Circumference speed of rotor. increased from 29 to 34 m/s
• Throughput capacity increased from 1,000 t/h to 1,500 t/h
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Revamp of “Competitor”
Impact Crusher – Rotor Replacement.
Old execution New execution

Vietnam
New rotor for Impact Crusher type APS 1430/Q
• Modification of fixing elements from screw wedges to clamping wedges
• New forged steel blow bars

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Revamp of “Competitor”
Impact Crusher – Rotor Replacement.

Existing Rotor New tkIS Rotor

Cementos Apasco, Mexico

New rotor for Impact Crusher type APK 70Br
• Reverse Engineering

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Revamp of “Competitor”
Impact Crusher – Rotor Replacement.
Existing Rotor New tkIS Rotor

Siam Cement Group, Plant: Lampang: Thailand

Delivery of an new rotor type: PB200x330 for KHD Impact Crusher.
Reverse engineering project
• Upgraded design with hydraulic blow bars fixing system
• Including our extreme wear resistant blows tk-DUR
• Positioning equipment for maintenance
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Revamp of “Competitor”
Impact Crusher – Rotor Replacement.
Old execution New execution

PT Semen Tonasa Plant: Pankep, Indonesia

Conversation of Kawasaki rotor KSB-2237 to thyssenkrupp casting disc design CR220/370

• Improved casting quality

• Rotor discs fitted by tensioning rings onto the shaft

• Including hydraulic fixing system for blow bars

• Improved rotor disc construction

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Typical Modernization and
Refurbishment Projects – Roller Crusher Rolls.
Bedeschi design thyssenkrupp design

Modernization of a Bedeschi clay crusher type RV 6,5/28 to segment type crushing roll

• Exchangeable segments;
• Improved intake behavior;
• Short maintenance downtime;

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Typical Modernization and
Refurbishment Projects – Roller Crusher Rolls.

tk Pipe design tk Segment Ring design

PT Indocement, Citeureup Plant

Primary tk Sizer 800x2000
• Replacement of existing rotor
• Modification from pipe design with picks to ring design with hard-facing

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Reference list for
Crushing Plant Revamps.

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Wrap Up Summary

When comes to Crusher and Material Handling technologies, TKIS with

more than 150 years of experience, we are not just equipment supplier,
but SOLUTION provider.
Optimization is not only about capacity, but also about making the
machine more maintenance friendly, better operation availability, and
cost effective.
We are always the your chosen partner for cooperative.

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 www.thyssenkrupp-industrial-solutions.com

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