a new Hydrocone® crusher with hi-tech strength

H7800
a new Hydrocone® crusher with hi-tech strength
SANDVIK ROCK PROCESSING
Increasing
A BIG DECISION
Investing in a new crusher is always a big decision.
Since your crusher does not operate as an independent
unit, but is often part of a production chain containing
many different links, buying a new piece of equipment
requires careful consideration – not least regarding its
efficiency and economy. That’s why we at Sandvik Rock
Processing have gone right back to the drawing board
to design a new Hydrocone ® crusher, to produce a
machine which delivers really significant benefits over
and above those of your existing equipment. H7800 is
the first of a new generation of crushers with what we call
‘hi-tech strength’.
SIZE ISN’T EVERYTHING
In the past it was assumed that the performance of a
crusher could be measured in relation to its weight.
A heavy crusher was synonymous with a heavy-duty
crusher. However, the arrival of H7800 challenges this
assumption, so mine and plant owners and operators
can afford to think differently. H7800 gives enhanced
performance in relation to size and weight. It looks like
a medium-sized crusher, yet it has all the strength and
power of a much larger crusher. So, it’s time to accept
that size isn’t everything after all.
2
PRODUCTIVITY
When your goal is to increase productivity
at an existing site, there are several
important factors to take into consideration:
the cost of new equipment and how to
install it, versus the increase in productivity
it will deliver. Being a neat, compact
crusher, H7800 fits in nicely where space
is limited, and it gives you a high level
of performance in relation to its size. It
therefore provides a cost-effective boost
to production at your existing operation,
enabling you to utilize existing infrastructure
such as foundations, buildings and material
handling arrangements.
THE RIGHT LEVEL OF PRODUCTION
Whilst a modern crusher enables you to boost
production, it obviously needs to be synchronised
with the rest of your plant or line. In terms of
production volume, H7800 lies between H8800 and
H6800 (Sandvik Hydrocone models or similar), giving
you levels of production that are highly efficient, with
excellent space/weight/performance ratios, yet not
overproducing in such a way as to create bottlenecks
in your downstream processes.
BETTER REDUCTION
In H7800, two important factors combine to give
greater reduction - new crushing chambers and the
automation system ASRi™. Power is used to improve
reduction rather than just increase capacity, so you
get a better quality product in relation to the energy
consumed. The product is simply more efficiently
reduced. Working in combination with the ASRi
crusher control system, circulating load is kept to
a minimum. Your crusher is always working at its
upper limit, giving you optimum performance whilst
preventing overloading.
3
DESIGNING
WHAT CAN H7800
H7800 from scratch
do for you?
Why does H7800 look different from other
members of the Hydrocone® family and what
are the advantages of this new design?
The fact is that in addition to having all
the know-how and experience needed to
refine our Hydrocone crushers’ design, we
also use the latest advanced engineering
tools. So in creating H7800 our designers
were able to rethink the basic principles of
crusher design from scratch, developing a
different shape, applying new materials and
finishes, and strengthening the crusher’s
important points.
4
THE RESULT IS that in H7800 you get a lighter
weight crusher with hi-tech strength, i.e. strength in
all the right places. We put in 520 kW (700 hp) of
power and this fact, in combination with a greater
shaft travelling height (to facilitate the elimination of
tramp metal) accounts for its weighty bottom shell.
THE TOP MOUNTING of the hydraulic components in the oil tanks also represents a new approach.
It makes servicing far more tidy as oil doesn’t spill.
In addition, the lubrication tank and the Hydroset
tank are divided into two separate units. This means
they can be placed in different locations, optimising
available space. A plexi-glass window has been fitted
in the oil tank making it easy to see oil flow and condition
and notice at a glance if the oil levels are low.
Sandvik as a leading innovator
For over 100 years we have been making crushers,
and for 30 of those, we have also been developing
crusher control systems to optimise the performance
of our crushers. With H7800, we demonstrate once
again that Sandvik is the leading innovator in the
field of rock processing, taking crusher design technology combined with advanced crusher control
to new heights. H7800 is a genuine innovation in
rock processing equipment from Sandvik, building
on the strength and robustness of our proven
Hydrocone® crushers.
• It can improve your production capacity. Thanks to
the new design described above, even if H7800 is not
a large crusher, it has strength in all the right places.
• It can handle the toughest minerals processing
applications in mines and processing plants. H7800
was specifically designed to operate 24 hours a day
in mining and aggregate applications, the toughest
job in the business. This is the best guarantee of the
crusher’s ability to handle heavy-duty applications.
• In designing this new crusher, operators’ feedback
has been taken into consideration. Easy maintenance
is an issue we take particularly seriously, hence the
positioning of the dump valve at the side of the
machine and the design of the oil tank, which is
made for easy servicing.
• Change wear and spare parts with minimum downtime.
For example, the liners of H7800 do not require any
backing material like plastic epoxy or zinc. This saves
the time usually spent mixing, pouring and waiting for
the curing to take place, whilst also increasing safety
for your maintenance staff.
• H7800 generates downstream process savings
in cost and efficiency, thanks to better reduction,
promoted by a new chamber design and by the use
of ASRi crusher control system.
• It handles tramp metal more effectively. H7800 is
designed for a greater shaft travelling height and
this facilitates the relieving of incidental tramp metal.
ASRi ensures that the shaft is returned at the right
moment to its former position.
• Gives you enhanced control and protects your
capital investments. H7800 comes with a built-in
TIMS™ (Tank Instrumentation Monitoring System) a small control unit designed to check lubrication,
temperature and oil flow. TIMS automatically
watches all functions like switching on cooling fans
and heaters when necessary. It also eliminates most
of the local installation work and provides enhanced
control with a full factory guarantee.
• Enhanced performance through compatibility
with our ASRi crusher control system. Used
in combination with H7800, ASRi gives you a
continual flow of information and constantly makes
adjustments leading to more efficient production. For
example, it adjusts crusher settings automatically in
order to compensate for the liner wear; it ensures the
highest possible crusher performance. Pressure and
power in relation to load are automatically adjusted
to suit rock properties, moisture etc. All influencing
conditions are taken into consideration, 24 hours per
day, keeping your crusher pushed up to its 100%
performance, automatically.
5
ø2507
Inlet ø2200
TECHNICAL FEATURES
Approximate weights H7800
of H7800
Heaviest lift during maintenance:
13000 kg
Weight (excl. motor):
50 Tonnes
Total weight (incl motor & subframe):
58 Tonnes
8
H7800-EC
10
13
16
19
22
300
H7800-C
240
H7800-MC
195
H7800-M
155
H7800-MF
100
H7800-F
90
H7800-EF
80
520
550
25
29
32
38
44
51
57
64
70
980
1060
1120
1240
1350
1490
1610
1740
1860
1030
1110
1180
1300
1420
1570
1690
1830
1960
990
1060
1140
1200
1330
1460
1610
1730
1880
2010
1330
1470
1580
1720
850
910
970
1040
1100
1220
770
830
880
940
1020
1070
1180
700
760
810
870
920
1000
1050
1160
600
650
690
740
790
850
900
990
378
C.S.S. (mm)
638
(mm)
(Without splitter)
3711
Nominal capacity (t/h)
Crusher
752
Max feed size
(With splitter)
3995
Nominal capacities for Hydrocone H7800
4084
1600
4226
Nom 6354
Max. motor size: 500 kW/700 Hp
Crushing chambers
H-crushers:
Several standard crushing chambers are available:
EF = Extra fine
F = Fine
MF = Medium fine
M = Medium
MC = Medium coarse
C = Coarse
EC = Extra coarse
3095
MIN 4400
Capacity, MTPH
Performance figures are approximate and give an indication of what the
crusher can produce.
They apply for open circuit crushing of dry material with a bulk density of
1600 kg/m3. It is assumed that material much finer than the crusher’s closed
side setting (CSS) is removed from the feed.
Consult us regarding the application of the crusher since the chosen
eccentric throw, degree of reduction, the material’s crushability (Wi) the size
analysis of the feed, the design of any recrushing circuit and the moisture
content in the feed all affect performance of the crusher.
1228
ø625
Product curves
The product curve and the percentage of the crusher product that is smaller than the closed side setting (square hole, mm) is dependant on the
crushability (Wi), of the material, the size distribution of the feed and other factors.
Hydrocone H7800
MIN 1720
1202
100
90
1433
MIN 2850
CSS
8
10
13
16
22
25 32 38 44
51
70
1600
4226
1224
0
2671
31
60
2680
40
750
1340
50
3200
2489
30
1584
20
10
220
Weight Fraction Passing Through (%)
80
ø80(4x)
ø180(4x)
2489
0
1
6
10
Particle Size [mm]
100
7
1. A taller piston that improves the travelling
height of the main shaft, thus increasing the
ability to handle tramp metal.
7. The two top shell arms are protected against
wear by robust liners made out of special
steel alloy.
8. The main shaft is protected by replaceable
sleeve and inner head nut.
9. CLP (constant liner performance) crushing
chamber is standard. The CLP-chamber
design maintains feed opening throughout
the entire life of the liners. One top shell is
used for all crushing chambers.
10. Inspection doors are provided in the
bottom shell.
11. Operates at low noise level and has a long
life thanks to bevel gears with hardened,
spiral cut gears.
2. A new shell liner design that does not
require the use of plastic backing and
makes the changing of wear and spare
parts quicker and simpler.
1. Separate lubrication and hydroset tanks. The oil tank unit
automatically maintains oil flow to the various bearings.
The pump is independent of the crusher and permits
full lubrication even before the crusher itself has been
started up. The oil is filtered and cooled automatically.
2. All components in the tank are easily accessed through
inspection doors.
3. TIMSTM (Tank Instrumentation Monitoring System) to
check lubrication, temperature and oil flow.
4. The condition of the oil can visually be checked through
the plexiglass window.
3. The interior of the crusher is protected from
dust by a self-lubricating seal ring.
5. Duplex filters can be changed during operation.
6. The function of the Hydroset tank is to control the
movement of the main shaft. Motors and pumps are
easily accessed.
4. Product curve and capacity can be
optimised by adjusting the eccentric bushing
supplied with the crusher.
6
1
2
5. H7800 is compatible with the widely
recognised ASRiTM (Automatic Setting
Regulation System) – implying further
opportunities for enhancing performance.
5
3
6. A dump valve is positioned at the side of the
crusher for ease of maintenance.
4
9
idéfolket 2004
JAWMASTER™: Characterized by attention to detail in design and manufacture.
The ideal crusher to choose when high production and low total cost are in focus.
HYDROCONE®: Ideal for secondary and tertiary crushing, this crusher is
characterized by its robust design, reliability and high performance. Hydrocone can
also be equipped with an automatic crusher control system.
IMPACTMASTER™: An impact crusher best suited to primary, secondary
and recycling applications. Allows high product reduction and provides quality
products (cubicity).
MERLIN-VSI®: An advanced vertical shaft impact crusher, designed mainly, but
not exclusively, for crushing abrasive and hard materials: such as in sand and gravel
plants, industrial minerals, mining and recycling.
Sandvik is a high-technology engineering Group with advanced
products and a world-leading position within selected niches;
tools for metalworking, machinery, tools for rock-excavation,
products in stainless steel, special alloys, high-temperature
materials and process systems. Sandvik Rock Processing is a
business sector within Sandvik Mining and Construction and
manufactures products for the mining and construction industry;
crushers, screens, feeders, mobile crushers and screening
stations. Worldwide business activities are conducted through
300 companies and representation in 130 countries.
B 223.109 EN – © Sandvik Rock Processing 2004. Subject to alteration without prior notice.
Sandvik Rock Processing, SE-233 81 Svedala, Sweden. Tel. +46 40 40 68 00. Fax +46 40 40 68 98.
www.rockprocessing.sandvik.com e-mail: [email protected]