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Crushing and screening looks to cost and energy efficiency

First publishedin Aggregates Business Europe & International
March April 2014
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CH540 cone crusher from Sandvik Construction
The newly-developed CH540 cone crusher from Sandvik Construction
Soaring, unstable fuel prices create demand for plants that are increasingly energy efficient and for new ways to operate.

This is the view of Jarmo Vuorenpää, project manager at Metso Mining and Construction, who was outlining the design process of his company’s new crusher/screen.

“However, you can only increase the efficiency of a single machine up to a certain limit. Going beyond that point requires out-of-the box thinking and new innovations,” continued Vuorenpää.

Martin Johansson, Sandvik Construction’s product line manager, echoed the thoughts of many manufacturers, saying: “Our customers need to produce high quality aggregates in a cost-efficient way.”

Metso’s two-in-one Lokotrack LT220D, the latest addition to its mobile crushing and screening equipment range, is the combination of a cone crusher and a screen in a single track-mounted plant.

“The Lokotrack LT220D is the first-ever track-mounted crusher/screen combination with such compact dimensions and good transportability,” Vuorenpää continues.

Its fuel economy is said to be the sum of several features: running the crusher and the screen with a single Caterpillar C13 309kW diesel engine and an efficient power transmission system that enables maximum power for operating.

Adrian Wood, vice president, sales support, Crushing and Screening Equipment business line, says the LT220D offers a 25% reduction in fuel consumption, requires 30% less maintenance, and has a hydraulic set-up.

“The machine has an intelligent control system; an ST4.8 screen with crusher options of GP220 or HP200 cones, but the real secret is in the patented centrifugal conveyor which takes material and turns it through 180º through centrifugal force,” says Wood.

Weighing 43.5tonnes, with a transport height of 3.5m and transport width of 3M, Metso says that the LT220D secondary unit, when paired with Metso’s Lokotrack LT106 mobile primary jaw plant, is capable of producing up to three calibrated end products.

Metso has also introduced the new Nordberg NP15 impact crusher, for secondary and tertiary applications, to its range of NP Series machines.

Astec Industries company Telsmith has a new size in its line-up of Hydra-Jawcrushers, the H3450. The 863mm X 1,270mm opening of the H3450 is capable of processing up to 598tonnes/hour with the hydraulic toggle reducing maintenance and lowering operating costs with fast, safe hydraulic chamber clearing and tramp iron overload relief with auto resets.  

The newest model in the company’s line-up of T-Series crushers is the T400, which contains a 305mm maximum feed opening and is capable of processing between 136-544tonnes/hour.

Meanwhile, Sandvik Construction says its newly-developed CH540 cone crusher, the latest crusher in the series, is attracting a lot of attention.

The all-new CH540, and the bigger CH550 (launched in 2013), are cone crushers that have “endless combination possibilities, being the perfect match for any aggregate plant or quarry looking to increase production capacity, eliminate bottlenecks, reduce operating costs, and/or to improve the quality of the end product,” says Sandvik Construction.
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Kleemann MR 110 ZSi EVO 2 impact crusher
Kleemann's Mobirex MR 110 ZSi EVO 2 impact crusher
The crushers can be configured for either secondary or tertiary applications.

“In order to optimise their business our customers require as few, and as short maintenance interruptions as possible: this is now achieved by the CH500 series that gives them a versatile cone crusher which combines a small carbon footprint with high performance,” says Martin Johansson.

“Sandvik has developed the new CH500 crusher series based on valuable input from our customers. So as to increase performance, while reducing weight and height, we had to optimise all our components.”

The series is based on the proven Hydrocone process, facilitating the production of a high quality end product with excellent cubicity.

In order to maximise operational uptime the CH500-series comes with Sandvik’s Control System fitted as standard, and this enables the crusher to run at maximum performance levels, automatically adjusting to variations in feed conditions, pressure peaks and wear.

German manufacturer Kleemann (part of the Wirtgen Group) offers two new impact crushers, the Mobirex MR 110 ZSi EVO 2 and MR 130 Zi EVO 2, and two new mobile jaw crushers, the Mobicat MC 110 Ri EVO and MC 110 Zi EVO.

“EVO 2 represents the continuing evolution of the successful EVO Contractor Line, with additional benefits in terms of economy and operational safety,” says Mark Hezinger, marketing manager.
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Weir Minerals’ new Enduron SP series cone crushers
Weir Minerals' new Enduron SP series cone crushers are said to deliver a very high production capacity
The new impact crushers are differentiated by their size and productivity with the MR 110 ZSi EVO 2 having a crusher inlet opening of 1,100mm, and the MR 130 Zi EVO 2 a crusher inlet opening of 1,300mm. These provide feed capacities of up to 350 or 450tonnes/hour respectively.

The S indicates a Mobirex unit with optional, highly productive secondary vibrating screen with extra-large screening surface mounted on the discharge conveyor. Both units are Tier 4 Final-compliant, and they utilise direct drive crushers and electric drives for the vibrating conveyors, belts and the pre-screen, permitting high fuel efficiency and allows optimal loading of the crusher.

The crushers feature a new inlet geometry which allows even better penetration of the material into the range of the rotor.

The Kleemann Continuous Feed System (CFS) manages a more equal loading of the crushing area in which the conveying frequencies of the feeder trough and the pre-screen are adapted independently of each other to the level of the crusher, thus significantly boosting performance.

Of the Mobicat MC 110 Ri EVO and MC 110 Zi EVO jaw crushers, Nick Ford, technical sales manager for the Mid-West (USA) for Kleemann, says: “We have redesigned the crushers to make them more lightweight for ease of transport and quicker to set-up.”

The MC 110 Ri takes 15-20 minutes to set-up says Ford, and the Ri and  Zi weigh in at 38.5tonnes and 39.5tonnes respectively.
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Metso’s Lokotrack LT220D
Metso's two-in-one track-mounted Lokotrack LT220D crusher/screen
The MC 110 Ri has a vibratory feeder with integrated grizzly, while the MC 110 Zi incorporates a vibrating feeder with an independent, double-deck, heavy-duty pre-screen. Both feature a crusher inlet of 0.7m by 1.1m.

Kleemann says that both systems result in less wear in the system because medium and smaller gradations bypass the crusher, with an increase in end product quality through discharge of fines via the side discharge conveyor.

The machines’ crusher units have been redesigned.

“This means that they consume less fuel. Between 5 and 7gallons an hour,” says Ford.

Weir Minerals’ new Enduron SP series cone crushers are said to deliver a very high production capacity per ore ratio, which is achieved by combining the power of a higher eccentric speed (375rpm) with the potential of a bulkier crushing chamber.

With an emphasis on improving productivity and safety, Weir Minerals says the new Enduron SP series equipment is designed to maximise customers’ operational efficiency, and operates at up to 298.5kW, although larger sizes are being developed.

“It is a heavier piece of equipment than some of the machines on the market,” says Bruce Christensen, Weir Minerals North America, sales manager.

“We have had many inquiries about the Enduron SP series and are hoping that many orders will follow.”

A number of SP models are available, and depending on the settings, throughput ranges from 55-550tons/hour (49.9-499tonnes/hour).
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Terex Finlay 684 tracked mobile inclined screen
The Terex Finlay 684 tracked mobile inclined screen
For the past two years McLanahan Corporation has collaborated with customers to fully understand their needs when it comes to primary crushing.

“Since being first introduced in 1906 by Universal Engineering Corporation [eventually bought by McLanahan], the jaw crusher design has remained much the same over the last century, until now,” says the company.

“The answer to customers’ needs is a whole new crusher that is able to meet today’s challenges and help producers do even more at the primary crushing stage.”

McLanahan has engineered its new Freedom Series jaw crusher line to give producers a high performance primary crushing solution.

Features of the new Freedom Series 4450 jaw crusher include safety lock pins, and hydraulic assist for wear parts change-out makes maintenance safer with McLanahan engineers designing a simpler way to adjust close-side settings (CSS) and provide tramp iron relief. Hydraulic rams are isolated from crushing action, allowing longer life and full automation, while virtually eliminating toggle migration.

“This has been a huge investment. The new features on the jaw crusher are subtle, but revolutionary. This will change the way that customers will look at primary crushing,” says George Sidney, JR, president and COO.

This Triple Shaft technology, exclusive to Powerscreen heavy-duty mobile screens, is designed so the 4.88m x 1.5m screen box is highly effective and efficient while maintaining exceptional throughput productivity.

The extreme screening acceleration is said to offer the Warrior 2100 screen improved capabilities, especially in sticky scalping applications.

The machine can process mixed demolition waste which includes grass, soil, concrete, wood and asphalt, and can be configured with a combined top deck of 60mm fingers with 60mm punch plate and a bottom deck of 40mm mesh.

Among new screening products from Telsmith is the new 820 tracked screening plant that includes an 8203 Telsmith TL screen; 1,372mm feed conveyor and an 1,829mm under screen conveyor, combined to process up to 907tonnes/hour. The 820 produces up to four products simultaneously and can be easily operated through a wireless remote control.

Terex Finlay’s new 684 tracked mobile inclined screen has a screen box featuring three full-size 4.3M x 1.7m inclined decks giving a large screening area of 21.9m².

“All four discharge conveyors hydraulically fold for transport providing the operator with rapid set up and tear down times,” says Terex Finlay.

“The fourth product oversize plus conveyor can work at varying angles to accurately discharge material for recirculation and stockpiling.”

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