A roll crusher which provides higher throughputs, energy efficiency and flexibility is said to optimise comminution processes, mines and quarries.

FLSmidth has developed its patented Eccentric Roll Crusher (ERC) which is designed to reduce energy consumption in the primary crushing of hard rock, while offering increased throughput and reduced wear.  

Comminution is an energy-intensive process, so improved efficiency impacts the overall energy consumption of processing plants and also improves the sustainability of mining and quarrying activities. Suited for use in both underground and surface operations, the ERC is said to offer higher efficiency and flexibility than conventional crushers in the processing of hard rock.

“A particularly effective kinematic of the oscillating roll with constant stroke in the entire crusher cavity allows for a higher reduction ratio and more effective use of crushing energy,” says FLSmidth regional product line manager: crushing and screening, sub-Saharan Africa, Middle East and South Asia region Demitri Kokoroyanis.  “The reduction ratio of 1:10 potentially allows for elimination of secondary crushing stages, depending on the material characteristics.”

In addition, the high moment of inertia of the roll and flywheels contributes to accumulated crushing energy, reducing the power requirements and compensating load peaks in the comminution process.

The low profile of the crusher offers a construction height up to 50% lower than other hard rock primary crushers, making it compact and robust. The compact design and reduced number of components simplifies transportation, installation and maintenance, and reduces costs.

The integrated pre-screen is designed to allow for efficient bypassing of fines to boost crusher capacity as well as reduce energy consumption and increase liner life. Bypassing fines also helps reduce the risk of compacting and overloading of the crushing chamber.

“The back-turning of the roll occurring during the crushing process distributes the loads over the entire circumference. This prevents local wear zones and results in uniform wear,” says Kokoroyanis.

With impact resistance and wear in mind, the large chunks of feed material in the crushing chamber do not fall directly onto the mounted working element, but hit the hood, which is more resistant to such loads than other components.