ENDURON® EC Series Cone Crushers

About this product

The ENDURON® EC series live-shaft cone crusher designed for secondary, tertiary and even quaternary rock crushing within mining, aggregate or industrial applications. Overview The ENDURON® EC series cone crusher is the latest iteration of the live-shaft cone crusher design. This design has been proven to perform in heavy-duty secondary and tertiary crushing applications - being tough, reliable, simple to operate and easy to maintain. Embodying the tried and tested design elements of the original live-shaft cone crushers with added hydraulic and control functionality, these crushers offer a proven approach to processing primary crushed ores, quarry rock products and are the first choice for any pebble crushing applications in mill circuits all over the world. These types of crushers work by crushing material multiple times as it passes through the crushing chamber. Within the live-shaft design of the ENDURON® EC series cone crusher, both the shaft and the head are moved in unison eccentrically during operation. The ENDURON® EC series is typically heavier than the pedestal (fixed-shaft) crushers, when compared by installed power, enhancing its crushing force and inertia in tough applications. It also features: • ESCO wear parts made of premium alloys • High strength alloy steel castings and wear resistant mainframe liners • Hydraulic bowl adjustment • Large head diameter • Remote operation and integration capability • Modern hydraulic features and automatic tramp-release functionality • Available in sizes up to 450 kW (600 hp) Alternatively, if you're seeking a high speed, pedestal style crusher, the ENDURON® EP series cone crusher could be better suited to your needs. ENDURON® EC Series Cone Crushers - FAQs What is the difference between a live-shaft cone crusher and a pedestal-style cone crusher? In live-shaft cone crushers, the head is rigidly fitted onto the main shaft, forming a single component which sits at an angle inside the eccentric. In these live-shaft machines, the countershaft transfers the motor movement via the bevel gears into the eccentric to create the shaft/cone motion and resulting crushing action. However, because of their design, there is a limit to increases in stroke and speed due to off balance forces. Regardless of these limitations, live-shaft crushers exceed all expectations in applications where the end goal is size reduction. The type is also less sensitive to low or intermittent feed rates due to a longer parallel crushing zone. The installation into an existing site is quick and easy, giving instant safety, capacity and reduction improvements. In pedestal style crushers, the main shaft is centrally fixed in its position. It doesn’t move at all and acts as the pedestal for the cone and the eccentric assembly to spin around. The design doesn’t necessarily guarantee operators greater production but normally ensures an overall better particle shape due to higher speed and thus more crushing interactions when passing through the crushing chamber. This is a result of large head strokes that lead to crushing actions already taking place at the crushing chamber entrance. Additionally, interparticle crushing generates more crushing interaction per pass. With its moveable head and stationary pedestal, the fixed-shaft style machine was widely celebrated as a faster running “modern” cone crusher. While this style cone doesn’t necessarily guarantee operators more production, it does ensure more compressions (between the head and the bowl) as well as interparticle crushing – per pass. These extra stages of crushing (during one pass through the crushing chamber) usually result in an overall better particle shape. What is the difference between the closed-side setting (CSS) and open-side setting (OSS)? The closed-side setting of an ENDURON® cone crusher relates to the narrowest point between the mantle and bowl liner and dictates the product size produced. As the head “rolls” around the inside of the bowl liner and the cavity gets tighter, the rocks are forcefully crushed into smaller components. The crushing method is called compression crushing. The tightest point is the closed-side. The open-side setting is the gap 180 degrees from the closed side and is equal to the closed side plus the stroke of the machine. After passing through the crushing chamber numerous times and being crushed, via compression crushing, the rock is finally discharged through the open-side of the cone crusher at the bottom of the crushing chamber. What does throughput mean? A machine’s throughput is the material weight passing through the machine over time. Normally expressed as MTPH, metric tons per hour. What is the effect of stroke and high pivot point to the crushed product? A large stroke increases the capacity through the crusher and improves the reduction ratio. A higher pivot point raises the first crushing actions closer to the crushing chamber entry and allows for increased interparticle crushing throughout the whole crushing chamber length. It has normally also a positive effect on the shape of the end product. Why is it necessary to choke-feed a cone crusher? Choke feeding ensures that the whole crushing chamber is filled with material. This ensures a more even and higher pressure in the crushing chamber, as well as consistent motor power utilisation, and ultimately a more controlled crushing process. A uniform distribution of crushing forces reduces the risk of the crusher operating with pressure peaks and provides optimal conditions for the crusher to perform at a higher level with increased reduction. It also prevents increased localised wear, thereby extending the overall wear life, as the entire crushing chamber is effectively utilised. How can I calculate the wear of the liners? The automation system on all ENDURON® cone crushers calculates liner wear to support the operator. The automation system stores the position of the rotating bowl as new liners are installed and then measures the difference from the current state towards calculated end of life. This indicates wear to the millimetre—depending, of course, on wear rates and operator calibrations. How do I know when it is time to change my liners? It is time to inspect and/or change over your cone crusher liner if: • You feel that the crusher is not delivering to your expectations. Uneven liner wear has a direct effect on the tonnage and product size produced by your crusher —therefore in these circumstances, a liner exchange should be scheduled. Possibly consider changing into another crushing chamber configuration. • The control system sends a warning that the remaining liner thickness is close to end of life. • A mark on the outside of the crusher, for quick visual inspection of the current setting, indicates a necessary liner exchange. What effect does recirculation bring to the quality of the final product? Recirculation normally improves the shape of the end-product due to better filling of voids in the feed (especially in coarse feed conditions) and increasing internal pressure. It also increases shape due to the fact that the stones then have had more crushing actions/cycles due to more than one pass through the crushing chamber. Why is the consumed power lower than the installed power The installed power indicates the maximum design specification under which the crusher can operate under over time. This max power is only consumed when the machine is operating choke-fed with a hard and competent rock in coarse applications. In finer crushing chamber configurations, it is typically the internal pressure that becomes the limiting factor, not the installed motor power. The power consumed reflects the force required to reduce the material so that it passes through the set opening of the crushing chamber. When should I consider changing to another crushing chamber? You should consider changing to another crushing chamber in any of the following circumstances: • The expected product quantity (capacity) cannot be achieved. • Uneven wear indicating excessive wear either in the upper, or most commonly lower part, of the crushing chamber. • When your crusher does not deliver the product quality that you could expect. Features and benefits Strong and Durable The ENDURON® EC series cone crusher is cast in high- strength alloy steel to deliver maximum strength, durability and reliable performance under severe crushing conditions. It also contains bronze bushings, designed to extend wear life under maximum load, resulting in increased uptime and lower maintenance. The main shaft and spiral bevel gears of this crusher are made from high alloy steel forgings. The bevel gears are set with hardened teeth to promote quiet, smooth and highly efficient power transmission. Heavy and Robust The rugged and heavy-duty design of the ENDURON® EC series cone crusher ensures greater durability in demanding mining operations, giving peace of mind to operators and maintenance teams. Effective Hydraulic Clearing and Tramp Release System Tramp metal poses a major threat to mining and sand & aggregate operations, potentially causing equipment damage and lost production time. The hydraulic clearing and tramp release system of the ENDURON® cone crusher helps to prevent interruptions of operation due to uncrushable materials. Once tramp material is detected, it is dealt with safely and automatically by allowing the bowl to move upwards to clear the crushing chamber. This helps to prevent blockages, sudden disruptions in production and additional stress placed on the machine. Easy Hydraulic Setting and Adjustment The ENDURON® cone crushers contain a threaded bowl with hydraulic gear, providing easy, safe and more precise closed side setting (CSS) adjustment. It also has a fully integrated hydraulic console with push button controls for clamping, clearing and adjustment close to the crusher. The modern hydraulic features of the ENDURON® EC series cone crusher allow push button adjustment of the CSS and easy bowl installation and removal for servicing. Remote Operation Available The ENDURON® EC series cone crusher can be operated remotely, and fully integrate into a plant’s control system as required. Flexible and Compact Design The ENDURON® EC series live-shaft crusher range is robust and reliable. They can easily retrofit into existing installations to replace underperforming crushers. Instantly increasing safety, productivity and plant utilisation. Enhanced Safety Features This cone crusher is equipped with numerous safety features to ensure extended and safe operating time. Dual-acting cylinders can extend to lift the upper assembly so that objects stuck inside the chamber can be cleared safely. Defined lifting point ensures safe lifting and reduces risk during maintenance. Low Component Wear Rates ENDURON® cone crushers are manufactured using a combination of heat-treated, stress-relieved cast and fabricated, high strength alloy steels. This combination delivers long service life, while allowing weld repairs and rebuilds of major components, even after operating for several years within heavy duty secondary or tertiary crushing applications. Greater Crushing Force The ENDURON® EC series cone crusher is able to handle a variety of feed types due to its installed power. The combination of power, inertia, improved machine dynamics and a heavy-duty construction allow the ENDURON® EC series to efficiently deliver high crushing forces. Ideal for Pebble Crushing Pebble crushing is one of the toughest applications, yet the powerful design of this ENDURON® cone crusher is perfect for such conditions. The closed side setting (CSS) is an important crusher parameter because it defines the maximum product size and has a significant effect on crusher capacity and reduction. Advanced technology within the ENDURON® EC series cone crusher allows the closed side setting (CSS) to adjust down to as low as 6mm*. It is therefore recommended for effective crushing of pebbles between 12 - 63mm in size. * Operating with a CSS of this size should be reserved for special applications only. Please consult a Weir Minerals representative for more information. Why Weir? At Weir, our reputation for quality engineering and exceptional service is second to none. With over 150 years of engineering expertise and decades of creating innovative designs from the highest quality materials, our range of crushing and grinding equipment is built to last. We provide a diverse range of high-performance jaw, cone and impact crushers of different sizes to meet your crushing needs, be it in Mining or Sand & Aggregates. Our new range of ENDURON® cone crushers also come with ESCO® wear linings. Nearly a century of metallurgical experience and commitment to unsurpassed quality make these alloys THE choice for exceptionally long wear life across all crushing applications. All ENDURON® crushers are backed by our global service centre network which contains more than 160 service facilities across 70 countries globally. Our teams are always there for you, no matter how remote your operation is. We can also service machinery onsite for added convenience. Applications The ENDURON® EC series cone crusher is designed for tough secondary, tertiary and quaternary crushing — including pebble crushing applications. frequently used to process precious metal ores and a wide spectrum of other minerals. In the aggregates industry, it's typically used for feed materials such as hard and abrasive rock, limestone, river gravel, slag, asphalt and concrete recycling. Suitable to be used with the following feed materials: • Aggregate • Aggregates • Asphalt • Bauxite / Alumina • Chrome • Coal • Concrete • Copper • Diamonds • Frac Sand • Glass • Gold • Granite • Graphite • Gravel • Iron • Iron Ore • Kimberlite • Limestone • Lithium • Marble • Mill Pebbles • Mineral Sands • Molybdenum • Nickel • Oil Sands • Other Hard Rock • Palladium • Phosphate • Platinum • Platinum/ Palladium • Potash • Quarry Tile • Rare Earths • Salt • Sand and Aggregates • Silica Sand • Silica/Mineral Sand • Silver • Slag • Zinc Processes • Cement Manufacturing • Fertiliser Production • Glass Recycling • Pebble Crushing / Milling • Processing Coarse Materials • Quaternary Crushing • Recycle Crushing • Secondary Crushing • Tertiary Crushing Product specifications Replacement parts The materials used to manufacture spare and wear parts play a key role in the performance and ultimate success of your cone crusher. Manganese steel has been used in crusher wear parts for decades because of its work-hardening properties. As rocks are compressed against the outer layer of the manganese steel, its exterior layer hardens. This results in a material that is hardening during operation. Depending on the alloy composition ,manganese steel can also handle higher impact compared to other wear materials, making it ideal for a vast range of tough crushing applications. A successful crushing chamber configuration strategy is critical to achieving optimal crusher performance. Chamber configuration and settings should be continuously optimised to adapt to changing mine conditions. Our range of ESCO® wear parts and liners for crushers is designed using the highest quality materials. The Mn/C ratio in each recipe has been carefully optimized and tested to ensure increased reliability and wear life. For more information about our range of cone crusher wear parts and liners, click here. Services and maintenance All ENDURON® cone crushers are backed by our unrivalled Weir service centre network. This means that our experts are here to support you, every step of the way, regardless of your site's location. Our expert team will work alongside you to deliver: • High quality wear and spare parts • Personalised crusher advice and crushing chamber/process solutions • Servicing of machinery at our service centres or onsite for added convenience • Ongoing support and training Our aftermarket experts work with you to maximise your up-time. This includes comprehensive flow sheets and equipment reviews to ensure you have the correct resources at the right time to keep your crushing process running.