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New machines help lower costs in crushing and screening

First publishedin Aggregates Business Europe & International
2014 September October
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Rubble Master’s RM V550GO!
Rubble Master's RM V550GO! offers the technology of a cone crusher/VSI. (Pic: Rubble Master HMH)
As authorities worldwide introduce steadily declining limits for soot particles, nitrogen oxides and hydrocarbons for off-road machines, manufacturers of mobile plants are being requested to develop fuel consumption, noise and resource-saving technologies. Patrick Smith reports.

Sandvik Construction has given the global launch to its track-mounted UH450E crushing and screening unit at the recent Steinexpo in Germany, while Rockster says it has met the challenge with an entirely new machine, and Austrian manufacturer, Rubble Master, has developed a new two-in-one system.

“Harsher environmental requirements, high costs for logistics, plus growing environmental awareness make people more receptive to environmentally friendly alternatives such as mobile, on-site processing,” says Gerald Hanisch, Rubble Master’s CEO.

Neil Hirse, president of Cemco, says: “When you are in the crushing business, you have got to crack into more than just aggregates and minerals to stay ahead of the game.

“You also need equipment that can optimise efficiencies while reducing maintenance and overhead costs.”

He points to a vertical shaft impact (VSI) crusher as one way to achieve this, saying that understanding the different configurations will help get one that can help an operation.

Rockster has developed a “completely new impact crusher,” the R1100DE, for Eurovia, one of France’s largest road construction companies.

“Rockster’s Duplexable R1100D served as the basis of the new machine. The crusher is known mainly for its robustness and its good performance with high crushing ratio of any material, from asphalt, concrete and demolition debris to hard virgin stone,” says the company.
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Rockster R1100DE impact crusher
Rockster has developed its new R1100DE impact crusher
“The customer also wanted to increase its flexibility and ordered the preparation for Duplex, the patented system that allows switching from a jaw to an impact crusher (and vice-versa) within a few hours.”

Rockster’s R&D department also developed a parallel hybrid solution in cooperation with a Finnish manufacturer of components, based on electrification.

“Unlike diesel engines, electric motors deliver full torque from the state within milliseconds; handle load cycles more efficiently, and allow a continuous, constant speed of the crushing unit regardless of the engine’s load condition,” claims Rockster.

“In the world of mobile crushers electricity is not often available, so Rockster has implemented the strengths of an electric motor in a hybrid solution. The diesel engine operates nearly constant at optimal speed to drive the generator for the electric motor.

“Any load peaks are cushioned by condensers, so-called power caps, which buffer the energy. The fuel consumption is reduced and through the use of virtually maintenance-free electric motors also maintenance costs are minimised. With this technology you can save up to 16,000litres of diesel annually.”

Rubble Master’s new, fully mobile gravel and sand plant, the RM V550GO! offers the technology of a cone crusher and vertical shaft impactor (VSI) with the RM GO! principle.

Global customers saw the machine showcased at the company’s Demo Days in Eferding, Austria.

“It unites two machines in one. Small and medium-sized stone quarries and gravel pits will benefit from it. Now you only have to invest in one machine instead of what was previously two or three,” says Jean-Yves Voghel, RM sales partner from Quebec, Canada, after seeing the machine in action for the first time.
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Sandvik UH450E cone crusher
Sandvik Construction's UH450E combines the Sandvik cone crusher with a recirculating conveyor and aggressive screening system
The RM V550GO! combines the proven drive concept of the RM GO! line with the high-performance crushing technology of the crusher unit and specialises in two application fields: the production of sand from waste material and the processing of hard stone such as granite or basalt.

The RM V550GO! produces around 50tonnes of 0-4mm sand/hour from 8-16mm waste aggregate while the throughput for hard stone (input 70-200mm) is in the region of 140tonnes/hour with an end product size of 0-32mm.

Described as “powerful, economical and intelligent,” Sandvik Construction’s UH450E combines the Sandvik cone crusher with a recirculating conveyor and aggressive screening system.

The company says it was built to customer’s requirements, and it has the ability to operate via electrical mains or an onboard diesel generator, and either as a secondary or tertiary unit. Both the cone and screen come with a choice of crushing chambers and screening media respectively, and with a wide range of options available, it is adaptable to suit many different applications worldwide.

The UH450E has been designed with a pre-screen to optimise production and product quality, with the pre-screen also offering the operator flexibility in directing the flow of material. A pre-determined portion of the flow can be extracted on a side conveyor, be fed to the crusher or bypass the crusher.

The coarse material is fed directly into the Sandvik CH440 cone, and then into the newly-developed Sandvik product screen via the recirculating conveyor.

The aggressive double-deck banana-styled screen features a steeper angle at the feed end to accelerate the removal of fines and gentler lower section increases screening accuracy.
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Terex Finlay I-100RS processing stone
A new Terex Finlay I-100RS processing stone in South Wales
“The complete process is fully automated, with a high level of intelligence on board to maximise production, quality of material and minimise downtime,” says Sandvik.

“This includes a level sensor over the crusher chamber to keep the crusher choke fed, and Sandvik’s ASRi (Automatic Setting Regulation) as standard. This is integrated with the intelligent onboard canbus system, ensuring the process is continuously monitored and adjusted, providing optimal and automatically controlled operation.”

Meanwhile, a horizontal impact crusher, the new Terex Finlay I-100RS, is helping a contracting company ramp up productivity and efficiency.

“It has variable speed to give operators unprecedented levels of fuel efficiency and production, while the robust chamber gives a highly-consistent product shape,” says Finlay Plant SW (UK), who supplied the machine to Tom Prichard Contracting.

It is currently processing stone at a site near St Athan, South Wales, delivering single size material at up to 40mm, at a rate of around 140tonnes/hour.

The I-100RS is fed material from an existing J1160 jaw crusher, one of several Terex Finlay machines owned by the company, which were also been supplied by Finlay Plant SW.

“The configurations of the I-100RS enable the team to remain flexible to meet market demand,” says Finlay Plant SW.

“Features include a 2.44m x 1.2m single-deck screen for sizing and recirculating oversize material back to the crushing chamber. The sizing screen can also be quickly detached for applications that do not require resizing or recirculation of materials for further processing.”
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Kleemann Mobicat MC 100 R EVO crisher
The Mobicat MC 100 R EVO, the smallest plant in Kleemann's mobile jaw crusher range
The smallest plant in Kleemann’s range of mobile jaw crushers, the Mobicat MC 100 R EVO is the fourth new development in the Kleemann EVO Line, and was given its German premiere recently.

Based on the company’s MC 110 R, and as with all other plants in the Kleemann EVO Line, it boasts an efficient drive concept with crusher direct drive, as well as electric drives for the chutes and conveyor belts.

With its 165kW power plant the crusher can process up to 200tonnes of material/hour and has an inlet width of 950mm x 550mm.

In Russia, SBM Mineral Processing, with its partner Brise Stroitelnie Maschini, Moscow, says it has a list of successful top flight projects to “prove the special productivity of the plants under demanding conditions.”

The company’s mobile track-mounted Remax 1312 Eco impact crusher is handling 350tonnes of limestone/hour with a feed size of 0/350mm and a final product of 0/40mm at the Vinjevski Karier project in the Tula region (Central Russia), while in another application an STE 100.65 T combined with the Remax 1312 ECO has been in use in the Tschita region, Siberia, since May 2013.

The mobile track-mounted primary and secondary crushing unit, consisting of a jaw crusher and an impact crusher, is loaded with hard gabbro basalt with a feed size of 0/600mm. With a throughput of approximately 200tonnes/hour, a final grain size of 0/45mm is achieved.

“Traditionally in Russia such a task would be realised with two further crushers. With this optimum plant combination, which combines an MFL jaw crusher with an SBM impact crusher, the customer has secured a considerable competitive advantage in regard to effectiveness and profitability,” says SBM.

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