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Watching fuel costs in crushing and screening

First publishedin Aggregates Business Europe & International
May June 2016
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Terex Finlay J-1170AS
A new Terex Finlay J-1170AS is carrying out work previously undertaken by two machines
The demand for new crushing and screening equipment continues to rise in various parts of the world to cope with the need for aggregates. As with a variety of such equipment from various manufacturers, a reduction in fuel costs, and thus production costs, are a major factor.

In India, German manufacturer Kleemann, which unveiled its Mobicone MCO 11 Pro mobile cone crusher at bauma 2016, has proved a success with Sairaj Developers of Jalgaon, in the western India state of Maharashtra. Its new Kleemann Mobicat MC 110 Z EVO Series, 250tonnes/hour, track-mounted jaw crusher from the Wirtgen Group company joins another Kleemann plant, which was bought at the end of 2015 so the company could enter the contract crushing business.

The crusher will produce -53mm aggregates for concrete to construct the new 298km, fourlane road between Jabalpur and Iqbalgarh in the state of Madhya Pradesh, central India. Work has been contracted to Larsen and Toubro (L&T) to whom Sairaj Developers will supply 1.5 million tonnes of granular sub-base materials.

The crusher will take feed material between 400-500mm, sourced from excavated overburden material left from a marble quarry and a canal project.

Sairaj is also be taking delivery of one new 350tonnes/ hour horizontal shaft impactor from Kleemann, which will be utilised to supply 1.8 million tonnes of aggregates of -42mm for the upcoming mega Western Dedicated Freight Corridor Project of the Indian Railways.

Keeping crushing equipment updated and well maintained are ways to save on operating costs, and Metso’s three new Life Cycle Services (LCS) packages are aimed to help customers reach their lowest sustainable cost structure.

The company says that the packages secure assets through inspections, extended warranty coverage and inventory and parts planning.

It is also launching a new generation of upgrades that it says aim to increase the productivity of old crusher models, while also reducing maintenance costs and bringing equipment into line with enhanced safety practices.
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Rubble Master RM 120GO! crusher
Rubble Master's new flagship 34tonne RM 120GO! crusher
The upgrades are available for Symons and Nordberg cone crushers and Superior gyratory crushers, and are offered in packages that are said to be easy to take into use with every kit including installation instructions. Alternatively Metso can provide the customer with a field service team for support or for the complete installation.

The complete range has been specifically designed for the mining market and includes Symons cone crushers (advanced bowl adjustment control; hydraulic motor bowl adjustment system, and hydraulic tramp release and clearing system); Nordberg HP800 and MP cone crushers (jack screw locking nut); top mount clamp cylinder; heavyduty head; MP1250 retrofit kit, and head maintenance stand), and Superior gyratory crushers (super spider; arched spider; shimmed spider bushing; hydraulic shell separators; and dual balance cylinder).

Meanwhile, Finnish transport company Seinäjoen KTK’s decision to expand its business to crushing and screening has seen a Metso two-stage diesel-electric Lokotrack crushing and screening chain cost-effectively crushing and screening more than 450,000tonnes of aggregate.

KTK targets an annual production of 600,000tonnes with the Metso Lokotrack LT120E jaw crushing plant and LT330D crushing and screening plant, which Metso’s Tampere unit delivered.

On both plants a diesel engine drives the generator, and in turn the crushers are electrically driven instead of the conventional hydraulic drive. When there is an external power source available, power for the Lokotrack plants can be supplied from the electricity network.

Seinäjoen KTK has reached an average consumption of 22litres/ hour with the LT120E jaw crushing plant and 38litres/hour with the LT330D.

Meanwhile, Terex Minerals Processing Systems has launched its MC380X modular cone plant featuring the Terex Cedarapids high-performance MVP380X cone crusher.
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CH870 cone crushers from Sandvik Construction
One of the four Zhongshan Xinlong Aggregate's CH870 cone crushers from Sandvik Construction
Prewired with a plug and play design the Terex MPS modules require minimum on-site wiring, and the MVP380X cone, with patented Rollercone design, is said to provide high-efficiency crushing from a single drive 225kW electric motor. Application capabilities are between 150–450tonnes/hour.

Another example of fuel efficiency is being reported by O’Reilly Bros of Ballylusk Quarry, county Wicklow, Ireland, which says its updated Powerscreen 1000 Maxtrak is saving over 20litres of diesel/hour.

The quarry’s configuration sees a Powerscreen jaw crusher being fed blasted rock. This in turn feeds the Powerscreen 1000 Maxtrak a 75mm product; the cone crusher in turn reduces the size further, and once this has cleared the Powerscreen 2100 Chieftain, the quarry has three products: 60% is a14mm chip, 30% is dust and 10% is an 11mm chip. The dust is later rescreened to remove the 10mm and 6mm chip.

Powerscreen’s globally launched electrically-driven Warrior 1400XE mobile heavyduty screen can process up to 450tonnes/hour material processing and offers multiple power options. It can be self-powered with its own 72kVA generator or be connected to a mains electricity supply for even further reductions in cost of ownership. The Warrior 1400XE can also be powered from an electric drive crusher.

Keestrack announced at bauma 2016 its new trackmounted cone crusher H4 as the first of its kind in the world. At the heart of the model, designed for high-value secondary or tertiary production in the 120-200tonnes/hour performance range, is the proven cone crushing technology of a worldrenowned supply partner, with whom the company is working closely to optimise its machines for deployment in mobile situations.

According to Keestrack, a pioneering factor has been the advanced solutions in crusher control and monitoring systems, directly impacting output capacity and product quality.

As the successor to the Galleon series, the Keestrack H4, which has a transport weight of 35-50tonnes, has been given a completely new frame design, enabling the incorporation of efficient pre and post-screening units but also the use of innovative drive technologies.
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Terex MC380X modular cone plant
Terex Minerals Processing Systems has launched its MC380X modular cone plant
For example, the Keestrack says the H4 is the world’s first mobile cone crusher with a threedeck post-screening module with an oversize material recycler for the production of three highgrade end products in one pass.

Keestrack is offering a choice of three economical drive combinations: direct diesel drive of the crusher with electrical or electrohydraulic peripherals, such as conveyors and screen units, or the fully hybrid/plug-in version with similar electrical crusher drive via onboard diesel generator or mains power.

In China, leading aggregate supplier Zhongshan Xinlong Aggregate, of Zhongshan City, Guangdong Province, has invested in four state-of-theart CH870 cone crushers from Sandvik Construction to help produce high-quality aggregate for its customers’ increasing requirements, primarily in the Pearl River Delta area.

Its main quarry is the largest in the area, and in order to acquire a new cone crushing solution the company turned to Sandvik Construction in China, and agreed with its proposed solution of four CH870 cone crushers. These four units are now producing the required end product fractions of 28-24mm; 24-11mm; 11-5mm, and 5-0mm.

Zhongshan Xinlong Aggregate plans to work with Sandvik Construction on the rest of the upgrade at the quarry.

Austrian company Rubble Master has added a new flagship model to its crusher range, the 34tonne RM 120GO!, which it says takes it into “a new league.” Having passed the 30tonne mark, the machine will “open up a new segment for us,” being capable of processing 350tonnes/ hour fed from its 4m³ hopper, says crusher founder and CEO Gerald Hanisch.

The company also says that its Spec2App, a “groundbreaking” ethos behind a system for configuring RM machines based on their next field of application, extends the product portfolio horizontally. As a result, one RM machine can be used for all applications in the natural rock and recycling industry.

In county Devon, southern England, Jeremy Bishop Haulage (JBH) is scaling up productivity with a new Terex Finlay J-1170AS, supplied by Finlay Plant SW, which is carrying out work previously undertaken by two machines at the company’s facility near the city of Plymouth. The J-1170AS is the latest Terex Finlay plant purchased by JBH, and the new plant is producing a high-quality specification of recycled products, working alongside the existing Terex Finlay plant on the site, including a 595, as well as a four-way 684 and 883.
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Keestrack H4
The Keestrack H4 has been given a completely new frame design
Concrete and brick rubble, brought in as construction and demolition waste from building sites is initially processed by the company’s existing Terex Finlay 883, which screens out to a minus 50mm material, a 50-75mm aggregate and plus 75mm product.

The 50-75mm and the plus 75mm material is taken to the J-1170AS, where it is fed by a swing shovel and is doing the work previously carried out by a Terex Finlay J-1175 crusher and 595 screener.

The new crusher creates one Type 1 product, which can then be processed through the Terex Finlay 684 on site, which produces a dust, 10mm, 20mm and 40mm chippings.

“The new machine is saving on fuel, as well as the cost and wear of a secondary machine,” says Matthew Shute, senior site representative at JBH.

Weir Minerals’ new Trio TP260 cone crusher is capable of processing up to 260tonnes/hour of material.

The versatility of the model stems from its suitability as either a secondary or tertiary crusher when fitted with the correct crushing chamber.

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