AI makes an impact in crushing and screening

October’s bauma show saw a host of new crushing and screening plant launches from the major manufacturers. Liam McLoughlin looks at the latest offerings to hit the market
Crushing Static & Mobile / January 10, 2023
By Liam McLoughlin
Celebrating the launch of SBM’s AI-based REMAX 600 mobile impact crusher
Celebrating the launch of SBM’s AI-based REMAX 600 mobile impact crusher

Visitors to the giant bauma show in Munich (October 24-30) were able to check out a range of interesting new offerings in the crushing and screening sector, including AI-based crushers and hybrid screens.

SBM Mineral Processing (SBM) has developed the REMAX 600 track-mobile impact crusher as a ‘technological platform’ for an AI (artificial intelligence)-based, fully automatic production monitoring and control system.

The technology is currently being developed by the company and researchers at Montanuniversität Leoben, Austria’s university for mining and metallurgy.

Kleemann’s electric-drive MOBIREX MR 130(i) PRO impact crusher
Kleemann’s electric-drive MOBIREX MR 130(i) PRO impact crusher

The REMAX 600 features a cutting-edge sensor system, video technology, powerful communication and IT networks. It will offer a set of technological innovations, such as an automatic gap adjustment facility.

It can offer up to five fractions in one cycle. With a feed capacity of 600t/h, the new machine can accommodate material feed sizes up to 900mm and a maximum total weight of 75 tonnes depending on the equipment.  

Triple wind sifting and an ultra-efficient overbelt magnetic separator with longitudinal discharge as an option (a novel feature in highly mobile impact crushers) are said by SBM to ensure high purity of final products, even in recycling applications.

SBM stresses that the industry-first introduction of an 'autonomous crusher' will help users and operators with all decisions, permanently support efficient operation, assure optimum product quality at all times, as well as make an important contribution to save energy and costs during crushing.

The autonomous crushing R&D project has been running for two years and features interdisciplinary teams from the Montanuniversität Leoben chair of mineral processing and SBM research departments.  

The project aims to make the decisive step from today’s already extensively monitored and optimised crushing operations to autonomous fully automated production by means of ‘intelligent self-learning’ mobile crushers.

The machine independently assesses feed material and final products via sensors and camera systems, registers better-than-before-the-load conditions of crusher and conveyor equipment, and optimises all separation processes down to overbelt magnetic separators and wind sifters.

The SBM control system, Crush Control, validates all operating conditions and material properties in real-time and sends the values to SBM’s headquarters via the cloud. A ‘digital twin’ compiled there matches the real machine data with thousands of stored reference data coming from 1:1 quality testing, laboratory tests and computer simulations (including rock properties, grain-size distribution curves, particle shapes, etc).

The optimisation potentials determined from this are sent back to the machine control system in real time. This allows immediate and permanent adaptation of all process steps on site without any stoppages, says SBM.

By means of an interactive menu control, SBM says even inexperienced operators can precisely adjust the production process – depending on whether maximum output, minimum fuel consumption (eco mode) or quantity-optimised production of certain valuable grain sizes are required.

The newly integrated tool monitoring system in the REMAX 600 is another benefit, one which counteracts shortfalls in quality due to wear during production and provides key support for preventive maintenance.

Large-scale test runs will take place in the coming year to make sure everything works as it should in practice.

The new RM H50X hybrid screen was unveiled at bauma
The new RM H50X hybrid screen was unveiled at bauma

Kleemann premiered its Mobirex MR 130(i) PRO mobile impact crusher. The latest member of the Wirtgen Group brand’s PRO line, the extremely powerful plant is used as a primary and secondary crusher in natural stone and recycling and meets high environmental standards, according to the company.

Local emission-free operation is said to be possible thanks to the model’s E-DRIVE diesel-electric drive with the option of external power supply.

Thanks to this external supply, the system can be operated without emissions. This ensures low energy consumption per tonne of end product. The electric drive also means that hydraulic oil is only required for setting and set-up functions. This minimises risk to the environment and further increases the system’s sustainability.

When the Mobirex MR 130(i) PRO is operated via the diesel unit, the performance and load-dependent fan is said to ensure efficient use of fuel and low noise emissions. The formation of dust is also said by Kleemann to be greatly reduced by water spraying at all relevant points, such as the crusher inlet, the discharge belts and the post-screening unit, as well as various belt covers.

The Kleemann PRO-Line system can process up to 600 t/h of material. The high output is made possible by the crushing unit with a heavy rotor and a 250kW drive in conjunction with efficient pre-screening. The Continuous Feed Systems’ (CFS) continuous feed control is said by Kleemann to ensure consistently high utilisation.

The company says it counters the increasing complexity of crushing plants with its intuitive operating concept Spective.  

In addition to a large touch panel and two Spective radio remote controls - one of them for operating all relevant functions of the automatic mode from the comfort of the excavator - Kleemann also offers Spective Connect.  

The digital solution simplifies the construction site digitisation of the Mobirex MR 130(i) PRO. Spective Connect transmits all important system data to the user's smartphone and simplifies reporting.

With the Mobirex MR 130(i) PRO, the proven, robust crushing unit with its two impact rockers and versatile blow bar options, as well as the 8.4m² optional double-decker post-screen, are said to ensure very good product quality.  

Kleemann’s new impact crusher can produce and discharge two classified end sizes – without using an additional screening plan. The use of optional wind sifters is said by the German company to further increase end product quality.

Austria-based RM has launched the new H50X hybrid screen, which can run in diesel or fully-electric modes.

The redesigned Keestrack I4e tracked crusher has a diesel-electric drive
The redesigned Keestrack I4e tracked crusher has a diesel-electric drive

As a hybrid variant, RM says the machine can be operated electrically to notch up zero emissions. It adds that the screen delivers impressive modularity and versatility.

“It’s a whole new conception of doing a scalper,” said Gerald Hanisch, founder and CEO of the RM Group. “It is not only electrified, it has all kinds of features – the mobility, the versatility, the simplicity and the energy.”

RM says that both the RM5H50X hybrid screen and the RM J110 jaw crusher – which will make its debut at Conexpo in March 2023 – have incorporated countless ideas and customer requests to redefine the application options of processing equipment.

RM says the use of a hybrid machine brings a 25% reduction in fuel costs compared to a diesel-direct crusher or a hydraulic screen, while combining them into one machine train increases the savings even further.

It adds that, when a diesel-direct crusher drives the new RM hybrid screen, the customer saves up to 33% on fuel. In combination with an RM hybrid crusher, which drives the RM hybrid screen, the savings potential reaches up to 50%.  

In addition, if only one engine is running because the crusher is driving the screen, the customer only has to refuel and service one engine, effectively saving fuel, time and money.

Hanisch added: “We have been electrifying our plants for decades, and consequently have the necessary know-how. Now the time is ripe for us to fulfil the needs of customers with our product-ready solutions. The lowest possible fuel consumption and smallest carbon footprint are the order of the day for our customers to be successful.”

McCloskey International has unveiled the latest entry into its jaw crusher line in the European market, the heavy duty J4. The crushers are particularly suited to aggregates, construction and demolition recycling, and site preparation. The Metso Outotec-owned Canada-headquartered manufacturer says the J4 builds on the robust features of the existing product range, with a line-up of features aimed at boosting productivity and offering enhanced durability across applications.

Designed to withstand the toughest conditions worldwide, the J4 delivers high production due to its jaw chamber design and enhanced material flow. The large 1060mm x 700mm jaw opening accommodates large feed sizes, contributing to higher production in material processing.

The material path is enhanced with the 1064mm x 4247mm grizzly pan feeder under the hopper that allows for better sizing of material with a variety of mesh options. Options of either a short pan feeder to suit the pre-screen or a double deck grizzly pre-screen are available, ensuring suitability and better sizing of material based on the application.  

McCloskey says the J4 delivers effective stockpiling, with wide main and side conveyors for enhanced material flow. The angle adjustable 1200mm wide ToughFlex main conveyor features a 3.912m high stockpile, and with quick release and ground level access, the belt is designed to be easy to maintain and service.

ToughFlex is constructed with a special weave of 2 fabric plies and an additional binder warp (without the need for steel wire) resulting in reduced belt weight. The plies are reinforced to resist puncturing and are protected with heavy duty wear resistant top and bottom covers.

McCloskey says that portability has not been compromised with the J4, despite its powerful capabilities. Mobility on-site and between sites continues to be a feature with remote control tracks to move and position the crusher and maximise the efficiency of a project site. The company adds that technology has been a key factor in the development of the J4, with a DSE control panel for the highest operational performance and reliability providing push button control of the jaw, track and feeder functions. The crusher is fitted with a telematics modem for the new 365SiteConnex programme, a complete connectivity solution for highly accurate monitoring of McCloskey products.

365SiteConnex is based on the latest communication technologies to collect, analyse and deliver information on the crushers, screeners and stackers customers rely on to produce the high quality products with the least amount of downtime.

“The J4 continues the momentum for our jaw crushing product range, as we continue to develop new products that meet the evolving needs of our customers across industries,” said Toni Laaksonen, senior vice president, McCloskey International. “We have always designed our equipment to ensure it contributes to the productivity and business success of these operations. As a company that is involved in the handling and processing of the earth’s resources,  we also have our sights set on sustainability. Our next commitment to an environmentally responsible strategy will be the introduction of our electric crushers, scheduled to be available in 2023.”

The heavy duty J4 is suited to aggregates, C&D recycling and site preparation
The heavy duty J4 is suited to aggregates, C&D recycling and site preparation

Keestrack has premiered the completely redesigned I4e tracked mobile reversible impact crusher with an advanced diesel-electric drive.

Due to its RIC (reversible impact crusher) technology, this machine can be used in secondary and tertiary crushing of rock, oversized gravel and recycling building materials (for example asphalt).

Keestrack says the specific design of the reversible horizontal impact crusher with a large variable crushing chamber, powerful rotor and electronically monitored hydraulic gap adjustment (+80 to -220 mm with new tools) allows feed sizes up to 250 mm and ensures consistently high-quality end products of up to 0/2 mm in closed circuit.

Secondary and tertiary crushing can be combined in one highly mobile solution, which Keestrack says makes the I4e a real alternative to mobile cone crushers or vertical impact crushers, especially with regard to its outstanding production capacities from 100 to 250 t/h.

The manufacturer adds that the system also offers lower wear, better quality of the end products (grain shape) and significant energy savings in typical applications (for example sand production 0/4 mm: approx. -30% compared to cone crushers; -30 to -40% compared to VSI impact crushers) also due to the advanced electric ZERO drive concept, backed up by the drop-off engine/gen-set consisting of a 447kW diesel engine and 300kVa generator.

Electric drives for the crusher (160kW), feeders and conveyor belts as well as the system hydraulics enable particularly cost-efficient and emission-free plug-in network operation. Keestrack says that three specific patents illustrate the innovative potential of its new I4e concept.

The material enters the hopper of the I4e, the loading apron feeder, which grants no loss of fine material and ensures a long life time is then gradually feeding the reversable loading conveyor which has an integrated metal detector. When metal is detected the conveyor reverses and a drum magnet separates only the metal. The compact system (transport dimensions: 15,270mm  x 3,000mm x 3,310mm), weighing 42-tonnes includes a single-deck after screen with return conveyor of oversized material.

“The closed circuit ensures a production of 100% final material with very high quality for any European norms,” Keestrack comments.

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