ERC – a new generation of mining equipment

thyssenkrupp’s eccentric roll crusher revolutionizes primary crushing

The new eccentric roll crusher (ERC) boosts efficiency in mining operations

For the mining industry, competitiveness is about having efficient and productive operations. New technologies can help mine operators increase productivity, cut wasteful costs and get the most out both their deposits.

thyssenkrupp’s expertise in mining equipment and industrial machinery has led us to develop an innovative and unique hard rock crusher, the ERC eccentric roll crusher. Its low-wear design and durable components enhance efficiency in mining operations.

Extensive tests carried out under industrial conditions with the first ERC defined the most important process and machine parameters: throughput, power consumption and product benefits.

Thanks to its particularly flat and robust design with an integrated screen and high throughputs of up to 8,000 metric tons per hour, the ERC is suitable for operation in both underground mines and in mobile or semi-mobile crushing plants in open-pit mining.

The raw material that we process into high-quality aggregates for the construction industry at our site is extremely hard and relatively tough. It places high demands on the performance and stability of the primary crushers. The crushers we have used so far have suffered machine damage resulting in costly downtimes. That is why we started looking for a more reliable technical solution and found it at thyssenkrupp.

Dr. Jürgen Aretz, Mitteldeutsche Hartstein-Industrie AG
Eccentric Roll Crusher

Eccentric Roll Crusher

Eccentric Roll Crusher

Interview about the functionality of the ERC with Frank Drescher

Applications

  • Primary crushing
  • Stationary, mobile and semi-mobile applications
  • Hard rock and ores
  • Below and above ground

Innovation

For mine operators, carrying out the primary crushing below ground and directly at the working face is generally an attractive solution that offers a number of advantages compared to open cast mining. Underground operations place particular demands on the processing technology especially in terms of compactness, mobility and maintenance friendliness.

Above all, machines for the first in-mine crushing stage need to fulfill special requirements resulting from the specificity of these mining methods. The working faces and processing sites are relocated relatively often. In order to minimize costs, the underground plant sites (aka caverns) are kept as small as possible. Each additional meter in the height of such a cavern entails high investment costs so the comparatively large height of conventional hard rock crushers is disadvantageous.
This resulted in four important requirements for the new crusher: a flat, compact design, transportability, easy underground maintenance, and the ability to process hard rock with a feed size of up to 2,000 x 1,500 x 1,000 mm.

Read more about the ERC types here

In ore processing the strength and quartz content of the rock are mostly high, which places high demands on the machine in terms of wear resistance and easy interchangeability of the crushing elements. Moreover, as the crusher may well be overloaded due to foreign bodies or other causes during the mining process, a suitable overload protection has to be installed.

Read more about the operation principle here

The patented design of the ERC featuring a roll mounted eccentrically between the crushing chamber and the integrated screening chamber results in greater efficiency and productivity, which allows mining operations to be optimized, better integrated and automated. The ERC was tested in the crushing of andesite, a material with strengths of up to 200 MPa that are similar to many copper and iron ores. Its characteristics make it ideal for effective primary crushing of hard rock and ores in any mining industry.

Advantages

  • Compact, robust design (20-50% height reduction vs. conventional primary crushers)
  • Integrated screening chamber for greater productivity and efficiency
  • High throughputs of up to 8,000 metric tons per hour
  • High crushing intensity
  • Economical operating costs thanks to low-wear design and durable components
  • Vibration-optimized for smooth running
  • Integrated automatic gap adjustment and overload protection system

Find out more about the Advantages of our new ERC here