Crushing

Systems

Crushing, screening, feeding and plant solutions

FLSmidth crushing
system capabilities

FLSmidth is more than just an equipment

supplier, we are a solutions provider. We
offer extensive global leading equipment
lines for complete flowsheets.
FLSmidth has created an unmatched
portfolio of accomplishments by
combining the proven reliability and
quality of the industrys leading brands:
ABON, Buffalo, CEntry, Conveyor
Engineering, Dawson Metallurgical
Laboratories, Decanter Machine, DorrOliver, EIMCO, Essa, FFE, Fuller-Traylor,
KOCH, Knelson, Krebs, Ludowici, MAAG
Gear, Mayer Bulk, M.I.E. Enterprises,
Mller, MVT, PERI, Phillips Kiln Services,
Pneumapress, RAHCO, Raptor, Roymec,
Shriver, Summit Valley, Technequip,
WEMCO, Vecor, and Ventomatic.
FLSmidth integrates testing, detailed
design engineering, global procurement,
expert process control and localized
services to ensure fully customized
solutions for our clients. Along with
equipment, FLSmidth provides the support
you need to be sure that your plant gets
up and running quickly and stays
maintained for maximum performance.

FLSmidth equipment, whether it is our gyratory or cone

crushers, Ludowici screens or feeders, has continuously
withstood the harshest requirements found in the worlds mines
and rock quarries for over a century. Our equipment delivers the
rugged dependability needed to keep your plant running while
delivering the results youre looking for.
With improved safety, maintenance and performance features,
FLSmidth allows you to get more out of your operations with
higher reliabilities and safer maintenance.

FLSmidths Minerals division combines heritage equipment

with successful track records under one roof, enabling our
customers to access the best technology and processes for
their projects. The crushing & screening products within the
mineral processing portfolio provide our customers with the
a variety of options in developing a best-in-class solution to
their process, whether is it for a mine, quarry, or
construction site.
FLSmidths expertise can help to develop the best solution
for your project. We are capable of going from raw
material testing, to installation and commissioning for a
project of any size anywhere on the globe. Although
FLSmidth prides itself on large minerals processing plants, it
has also used this expertise to develop smaller flowsheets
and equipment for all crushing and screening applications.
FLSmidths capabilities currently extend from large fixed
plants to mobile / semi-mobile and also portable plants for
our smaller sized equipment. All supplied equipment is
available as a standard design or customized for a specific
application and location.
Once the equipment has been installed and commissioned,
FLSmidths Operations and Maintenance group can assist
with all of our a customers needs. We have the capabilities
of operating and servicing a plant, providing training to
personnel, process optimization, or simply provide support
for our customer on as as-needed basis.

Available Configurations
Products
Portable
Gyratory crushers
Jaw crushers

ABON sizers
Cone crushers
Impact crushers
Screens

Mobile &
Semi-Mobile

Fixed

Gyratory crushers

FLSmidths legacy of quality crushers dates back to the

Traylor and Fuller-Traylor gyratory crushers of the early
1900s. FLSmidth crushers have continuously withstood the
harshest requirements found in the worlds mines and rock
quarries. Through constant and continual improvements in
engineering to meet customer needs, FLSmidth is a proven
and preferred crusher supplier throughout the industry.
Design
Both the bottom service (NT) and top service (TS) crushers are
available from FLSmidth to meet any process requirement.
Machines are available for surface or underground
installations (in standard or split-shell configurations), for
stationary, mobile or semi-mobile operations, and for
applications in climates that range from tropical to arctic.

Performance
The TSU, top service, ultra-duty model, with its larger motor
and heavier components can allow for process optimization
(greater throughput/higher reduction) after installation.
Maintenance
The TS gyratory crusher is distinguished from other gyratory
crushers by its revolutionary design which allows major
service and maintenance functions to be safely performed.
The top service feature greatly simplifies safety procedures,
reduces costs and helps to increase availability for the
equipment over more traditional bottom service crushers.

3
2
4
1
5
6
7

12
9

8
15

13

16

10

1. Spider

15. Concave

2. Spider Arm Shield

16. Dust Seal Bonnet

3. Spider Cap

17. Dust Seal Assembly

4. Spider Bushing

18. Eccentric Assembly

5. Spider Grease Seal

19. Gear Cover Assembly

6. Threaded Mainshaft

20. Countershaft

Sleeve

21. Countershaft Taconite

7. Headnut

17

Seals

8. Mainshaft

19

9. Mantle

11

Assembly

10. Mantle Core

23. Hydraulic Piston

11. Split Contact Oil Seal

12. Top Shell
13. Middle Shell

14

22. Hydraulic Cylinder

Assembly
24. Mantle Position
Indicator

14. Bottom Shell

18
20

Available TS Crusher Sizes (mm)

17

900 x 1400
1100 x 1800
23

1300 x 1800
1400 x 2100

22

1600 x 2400
1600 x 2900

24

1600 x 3000

Features

The bar-type spiders 4-bolt design reduces the

amount of time required to remove and its slim

design reduces the overall amount of space
necessary during maintenance.

more efficient, and safer than a traditional bottom service

gyratory crusher.

Threadless mainshaft design improves strength by

minimizing peak stresses during demanding crushing

operations.

The countershaft assembly is rotatable to allow

for fine adjusting of gear mesh during installation

and includes self-adjusting bearings that do not
require maintenance of pre-load.

Top serviceable eccentric and hydraulic piston are faster,

FLSmidth designs custom chamber profiles for each

application and customer requirements.
Integral mainshaft lifting eye ensures that it is never

misplaced.

Jaw crushers

FLSmidths history with the design and manufacture of jaw

crushers dates back more than 100 years with the Traylor
and Fuller-Traylor double toggle jaw crushers. FLSmidth is
proud to add their new line of single toggle jaw crushers,
the TST, to the heritage the double toggle crushers
established.
Design
The TST jaw crushers are engineered for trouble-free
operation, characterized by safe and easy serviceability. The
most modern analysis techniques and features available to
date ensure a strong and reliable crusher design. The TST is
equipped with an efficient crushing motion, modular frame
and a simple, low maintenance design to handle
increasingly hard ores and remote site locations.

Performance
An often overlooked, but very important, characteristic of the
single toggle jaw crusher is its kinematic design. FLSmidths
chamber design enables the TST to efficiently crush hard
material via a combination of shaft eccentricity, toggle angle
and chamber layout. The steep nip angle enables the units to
easily crush the hardest rock at high production rates, while
maintaining the necessary product size.
Maintenance
The TST design utilizes a tramp relief shear pin (FLSmidths
safety pin) which, when un-crushable material is
encountered, shears and protects the crusher. The safety pin
works by removing the flywheels kinetic energy from the
crusher shaft, thus preventing overstressing the crusher. This
feature greatly simplifies safety procedures over more
traditional/breakable toggle jaw crushers.

25
8

9
10

24
7
6
23

21
18
11

5
22

15

14

17

16
13
1

12
20
3

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Front Frame
Mounting Foot
Side Frame
Swing Jaw
Rear Frame
Eccentric Shaft
Roller Bearings
Labyrinth Seal
Bearing Cap
Flywheel
Safety Shear Pin

Available TST
Crusher Sizes

19
2

12.
13.
14.
15.
16.

TST1900

Tension Rod Spring

Jaw Retainer
Replaceable Tip
Backing Plate

FLSmidths bolted and pinned frame assembly

comes together for a very strong and robust
design

21.
22.
23.
24.
25.

Cheek Plate
Jaw Plate
Retaining Wedge
Swing Jaw Wear Plate
V-Ring Seal

Hydraulic cylinder wedge adjustment

takes up wear seen on the jaw plates

Safety shear pin provides faster and

safer maintenance than a typical
breakable toggle plate

Swing jaw & front frame employ replaceable

jaw plate holders in the event of wear.

Rolling toggle design and replaceable abrasion

resistant toggle seats provide long life

TST1400
TST1550

17.
18.
19.
20.

Features

TST1100
TST1200

Replaceable Toggle Seat

Toggle End
Toggle Plate
Adjustment Wedge
Tension Rod

Spherical roller bearings use a multi-pass

labyrinth and grease to minimize dust
and dirt ingress

ABON low speed sizers

FLSmidth ABON has been manufacturing low speed sizers

since the mid-1960s. The sizers are successful in multiple
applications and are often the preferred choice in iron ore,
coal and bauxite applications.
Design
ABON sizers are built using the highest quality components
and highest design standards. This combination results in a
robust design and a dedicated customer base.
Performance
Low Speed Sizing is one of the more unique crushing
technologies in the world today. A combination of high
torque and low roll speeds with a unique tooth profile in
the ABON equipment leads to a specified product with a
minimum of fines creation.

ABON Center Sizing

ABON Side Sizing

Maintenance
The sizer teeth are fully adjustable and maintainable to
allow for accommodating changes in process. The can
easily be taken apart and moved without any specialized
tools.

Features

Simple Infrastructure requirements due to minimal

dynamic loads placed on surrounding supports and
structure

Long wear life of consumable elements due to

positive bite and minimal feed slip

Exceptionally low headroom requirements

Environmental features of low noise, low dust and

minimal fines creation

Largest sizer models supplied and operating on the

market

Ideal for In Pit Crushing & Conveying (IPCC) systems

ROM feed size up to 2,000 mm

Capabilities in excess of 12,000 mtph

Insensitive to clay and sticky materials

Pre-scalping of undersize not required

7
3

8
4

1.
2.
3.
4.
5.
6.
7.
8.

Modular main frame assembly

Single piece forged shafts
Sizing teeth
High torque gearbox
Wear plates
Wheel assemblies
Drive motor
Safety coupling

10

Raptor cone crushers

Raptor cone crushers have been proven in some of the

most demanding applications worldwide. No matter the
application (aggregate, minerals, pebble), the Raptor cone
crushers offer more flexibility in production to meet
customer requirements.
Design
Raptor cone crushers have been designed with input from
plant operations and maintenance people around the
globe. This input has led to many designs and features that
reduce maintenance time and increase production.
Raptor cone crushers critical load bearing components
meet specifications that typically exceed what is commonly
offered in a conventional cone crusher. Our major
components are cast of high grade steel, and our eccentric
material selection provides greater certainty of a reliable

surface finish, even after many years of service.

Performance
FLSmidths Raptor cone crushers are designed to be the
most productive units on the market. The crushers are
equipped with a high pivot point design that allows for
greater crushing force and contributes to improved
throughput and better reduction.
Maintenance
New Raptor cone crushers have been designed to give
better access to the inside of the crusher through features
like Main Frame Inspection Doors, Cartridge Countershaft
Boxes and the new Socket-less design.

11

Features

Integral counter shaft box ensures a stronger design

and decreased dust ingress

Socketless design facilitates eccentric assembly

removal

Fail-safe hydraulic system allows crusher to be

operable after a failed piston

Main frame inspection doors allow operator to view

wear liners without disassembly or crawling
underneath the machine

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Hopper Assembly
Bowl
Adjustment Cap
Drive Ring
Feed Plate Assembly
Head Assembly
Torch Ring
Mantle
Bowl Liner
Socket Liner
Adjustment Ring
Clamping Cylinder
Main Frame
Main Frame Liner

15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

Main Frame Seat Liner

Tramp Release Cylinder
Main Shaft
Eccentric
Counterweight
Gear
Countershaft
Pinion
Wedge
Arm Guard

Raptor cone crushers come in the following models: 200,

300, 400, 500, 600, 900, 1000, 1100, 1300 and 2000

2
4
5

23
7

12

8
11

15

10

18
6
16

17

19
24

20

13
21
14
Raptor 1300 depicted above

22

12

FLSmidth

Strike-Bar crusher

The Strike-Bar crusher is FLSmidths horizontal impact

crusher designed for soft to medium-hard ores, mainly for
primary applications.
Design
The FLSmidth Strike-Bar (SB) crusher is one of the newest
products available through FLSmidth. Our extensive
knowledge of impact and hammer crushers has been
implemented in combination with the industrys most
modern techniques, making this crusher one of the most
cutting-edge designs on the market.

Performance
The SB crusher accommodates clay and sticky materials
better than compression-type crushers. It provides high
reduction ratios and top size control which produce a
cubically shaped product.
Maintenance
Hydraulic cylinders open the rear housing section to provide
complete and easy access to the internal wear parts.
Additionally, the SB crusher has multiple, easy-to-access,
maintenance doors and bolted wear liners for quick
changeouts.

13

Features

Achieves size reduction ratios up to 1:40

The crusher requires little floor space and installation

height

Hydraulic opening of the breaker side provides easy

access to the interior of the crusher of the crusher

The SB crusher is designed to simplify plant layout and

reduce civil cost

The impact bars remain serviceable at >50% of their

initial weight wear

The hydraulic adjustable breaker plates allows

compensating for wear on impact bars

Using a gear unit instead of a V-belt drive facilitates

maintenance

Final grinding plate effectively controls the top size of the

crushed product and maintains a consistent flow to the
conveyor

2
1
3

5
8

1. Breaker plate (primary)

2. Breakers plate
adjustment
3. Maintenance access
doors
4. Breaker plate
(secondary)
5. Breaker plate (tertiary)
6. Wear liners
7. Rotor impact bars
8. Rotor

14

Ludowici BRU linear

motion vibrating screens

The BRU exciter driven linear motion screens have long

life-span providing customers with confidence and maximum operational efficiency.
Design
FLSmidths BRU screens feature full continuous fillet
welding and stress-relieving of all major fabricated parts
and a full quality assurance and quality control system in
line with worlds best practices. These screens come in a
wide range of sizes ranging from 0.9 m to 4.8 m wide and
up to 11.0m long.

Performance
They are available in horizontal, multi-slope and inclined
versions coupled with single, double and triple deck
configurations. These are the largest size screens available
to achieve the maximum possible capacity. FLSmidth
technical experts are on hand to advise on the optimum
screen size and configuration for any application.
Maintenance
All major components are computer generated ensuring
spare parts will fit with ease. Worldwide spare parts
network and service capability.

15

12

1
8

14

14

14

4
2
13

10

1.
2.
3.
4.
5.
6.
7.
8.

11

Drive arrangement
Drive beam
Eccentric mass
Exciter
Side plate
Cross member
Deck panel
Feed box liner

9. Countermass /
isolation frame
10. Steel coil springs
11. Shock absorber
12. Spray bar system
13. Lifting beam
14. Spreader beam

Features

High G-force operation of up to 5.0 for optimum

screening efficiency

Suitable for a large range of screen media including

modular panels, cross tensioned screen cloths and
bolted screen panels

Floor mounted on galvanized steel coil springs to give

up to 98% vibration isolation

Available in single, double and triple deck

configurations

Available in horizontal, multi-slope and inclined

versions

Wide range of sizes with widths - up to 4.8 m wide

and 11 m long

Linear motion provided by the reliable Honert Brute

Force geared exciter

16

Feeders
FLSmidth offers multiple feeders to meet most customers
needs, FLSmidth produces heavy duty apron and grizzly
feeders for primary ROM applications as well as medium
duty apron, grizzly and pan feeders for crushed primary or
secondary feed.
FLSmidth has supplied feeders for more than 65 years and
continues to modernize their design to meet the demands
of the industry. The rugged and reliable construction makes
installations easy to operate and maintain, and only a
minimum of operator attention is required. The feeders are
designed for uninterrupted service.

Application

Equipment

Primary

Apron Feeder
Ludowici BRU
Ludowici PGM

Belt Feeder
Rollerscreen
Feeder Breaker

Apron Feeders
FLSmidth offers horizontal and
inclined Apron Feeders for extracting bulk materials from under a
dump hopper or regulated feed to a
crusher. Apron Feeders can provide
volumetric feed and even metering
to prevent flooding. They can also
provide a constant mass feed if
there is feedback from a beltscale.
FLSmidth apron feeders come in
different sizes for any feeding
application.

Eccentric shaft linear

motion pan feeders and
grizzly feeders
The Ludowici PGM range is a
medium and heavy duty design of
linear motion pan feeders and
grizzly feeders. It offers powerful
straight-line motion through geared
mechanism drive and a high G-force
action to guarantee maximum
efficiencies.

Secondary

Tertiary

Features

Main frame construction designed to

absorb impact when loading big
lumps

Effective take-up system to ensure

constant chain tension

Available with either an

electromechanical or hydraulic drive

Can be installed horizontally or on an

incline

Aprons and chains can be accessed

from the take-up end of the feeder
for inspection and replacement

Features

Widths and lengths to suit all

applications

Grizzly bars can be incorporated later

if required

Horizontal or declined configuration

with fully lined pan

Wear resistant grizzly bars

Fully replaceable pan wear liners

Linear motion provided by the Malco

dual eccentric shaft mechanism

17

Exciter driven pan feeders

and grizzly feeder
The Ludowici BRU model grizzly
feeders are used in primary sizing
applications. The machines are
specifically designed to handle large
material lump sizes at high feed
rates. Operating at up to 5.0
G-force, the grizzly feeders are
guaranteed to minimise pegging
and deliver efficient separation.

Belt feeder
FLSmidths references include several
of the worlds largest belt feeders.
Well known for their ruggedness
and ease of maintenance, we have
custom designed and developed
belt training systems and take-up
mechanisms to better handle the
arduous duty under which a belt
feeder operates.

Rollerscreen
FLSmidth offers rollerscreens to feed
crushers and sizers while removing
undersize material from the feed
stream. Rollerscreens are typically
used for size separation when the
feed characteristics prevent the use
of traditional vibrating screens. They
are ideal for applications with high
moisture levels and/or sticky feed.

Feeder breakers
FLSmidth offers flight-bar feeders,
flightless-feeders, and feeder
breakers for truck-fed, loader-fed,
and dozer-fed applications. The
FLSmidth Buffalo line of feeders and
breakers are ideal for low-height
applications such as underground
mining, and also open-pit reclaim
operations. This equipment can be
supplied for fixed or semi-mobile
installations.

Features

Wide range of sizes with widths up to

3.6 m

Extra-heavy duty design and driven by

our proven exciter mechanisms

Deck cross-members are individually

bolted for ease of replacement

Guaranteed maximum positive

displacement and material throughout

High G-force performance provides

increased capacities and efficient
separation

Features

Specially designed belt training

systems and take-up mechanisms for
arduous duty

Worlds largest belt feeders with

widths up to 3150 mm and capacities
in excess of 12,000 tons per hour

Variable frequency drives for high

tonnage feeder applications

Features

Insensitive to wet / sticky feed

Independently driven shafts eliminates

chains and belts

Self-cleaning disc arrangement

Adjustable disc settings for easy

wear-part replacement and screen size
modifications

Roll-out maintenance design

Features

Flightless feeders continue to operate

with a damaged chain

Low head height

Capacities of 100 to 3,000 mtph

Electromechanical or hydraulic drive

options

18

Testing & services

Plant & field services

FLSmidth is your One Source for spare parts, service,
maintenance, asset management and operational services.
Our Customer Services support mineral processing
equipment and systems including raw material testing,
process design, equipment installation, troubleshooting,
process and mechanical analysis and commissioning of new
plants.
Customers are our most important assets. Once we have
designed and installed your processing systems, we do
everything possible to ensure that those systems continue
to operate at optimum levels, all the time. We deliver on
this promise.

Technical services
Erection & commissioning
Operations & maintenance
Expert services
Technical assistance
Training
Operation and maintenance
Our Customer Services experts have the know-how to help
plan your preventive maintenance and shutdown programs,
manage scheduled repairs, and can even implement these
programs for you.
Mill management
Plant maintenance
Asset management
Optimization

19

Rebuilds & modernizations

Keep your equipment current with the latest advancements
to enhance your operations and provide for better
efficiencies. FLSmidth can rebuild your equipment or
provide the most current state-of-the-art equipment
improvements and/or system upgrades for operational
efficiency and enhanced functionality.
Quality & reliable OEM parts
Contact our trained service personnel to get authentic, high
quality, original equipment manufacturer (OEM) spare and
replacement parts for your FLSmidth, Fuller, Traylor,
ABON, EIMCO, Raptor, Conveyor Engineering, Krebs,
KOCH, Knelson, Ludowici, Mller, MVT,
Pneumapress, RAHCO, WEMCO, Dorr-Oliver, Shriver,
Summit Valley, and FLSmidth supplied equipment.
FLSmidth is the only place to find field engineers and
technicians trained specifically to deal with the unique
characteristics of this equipment.
Products
Original OEM spares
Product review & improvement
Life cycle analysis
Repairs & Retrofits
Supercenters
FLSmidth Supercenters provide localized service with facilities
customized to our global customers needs. Supercenters are
able to offer strategic OEM spare parts stock, training facilities,
satellite testing facilities and world-class personnel ready to
assist with specific requirements.
Testing
FLSmidth continues to look for ways to improve service to
our clients and now operates a Minerals Testing and
Research Center. This facility has created expanded services
for increased process testing capabilities.

The Minerals Testing and Research Center houses the

Separation Technology Laboratory
Dawson Metallurgical Laboratory
Analytical Laboratory
Ore Characterization & Process Mineralogy Laboratory
Research & Development Laboratory
Testing capabilities
Ore amenability testing
Process development
Flowsheet layout
Plant design
Detailed engineering
Constructability analysis
Quantitative XRD Rietveld mineralogy
SEM and optical microscopy
Automated mineral analysis
NIR data base development
Clay analysis
AAS, ICP, ICP-MS, LECO and fire assay
Hydrometallurgical testing
Flotation concentration
Grinding & classification
Bench testing
Pilot testing
Research and development
FLSmidth is committed to strong and on-going research
and development, which is focused on developing new and
improved equipment and processing technologies that
provide solutions to the ever-changing needs of our
customers and the industries that we serve. Our R&D and
technology centers are globally located. In addition to our
own facilities, we foster and fund cooperative R&D efforts
with global universities and contracted research
organizations. Interaction with our customers is the
foundation of many of our R&D activities, as seen by the
numerous projects being conducted jointly with customers
throughout the world.

Mineral Processing
Technology Center
7158 S. FLSmidth Drive
Midvale, UT 84047-5559
Tel: +1 801 871 7000
Fax: +1 801 871 7001
E-mail: [email protected]

For ABON Sizers and Rollerscreens

contact:
FLSmidth ABON Pty Ltd
24-28 Marshall Road
Airport West, Victoria
Australia 3042
Tel: 61-3-9338 7011
Fax: 61-3-9338 3765
Email: [email protected]

For Impact Crushers & medium

duty apron feeders contact:

For HD Apron and Belt Feeders

contact:

Cement Project Centre

Material Handling North

America Region
FLSmidth Spokane Inc.
605 E. Holland Ave., Suite 300
Spokane, WA 99207
USA
Tel: +1 509 467 0770
Fax: +1 509 466 0212
E-mail: [email protected]

FLSmidth A/S
Vigerslev All 77
DK-2500 Valby
Copenhagen
Tel: +45 3618 1000
Fax: +45 3630 1820
E-mail: [email protected]

Copyright 2014 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or
warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time.

www.flsmidth.com

Rev. 9/16/2014 al-us

For Gyratory, Jaw, and Cone

Crushers, Screens or Vibrating
Feeders contact: