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First up crushing and screening

First publishedin Aggregates Business Europe & International
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LongCliffe Quarries has invested in a Nordberg C160 jaw crusher

A UK-plant first and the launch of a new vibrating screener packed with cutting-edge technology have caught the eye of the global aggregates crushing and screening sector. Guy Woodford reports.

After deciding to replace its existing primary jaw crusher at Brassington Moor quarry, near Ashbourne, in central England, Longcliffe Quarries chose to invest in a Nordberg C160 jaw crusher, the first fixed Metso plant of its kind installed in Britain. Longcliffe Quarries supplies a wide range of specialty high-quality calcium carbonate products in both granular and powder format for a variety of manufacturing sectors. As such, the business requires a constant flexible approach to production.

Metso assisted Longcliffe’s management team to model various operating scenarios to satisfy the long-term objectives. Having carried out extensive feasibility studies and after reference visits to view the new Nordberg C150 jaw crusher in operation at Back Lane Quarry in Carnforth, Lancashire, England, and the Lokotrack LT160 at Swinden Quarry, near Grassington, North Yorkshire, England, Longcliffe’s project team had the confidence they needed. The order was placed with Metso to supply and install the Nordberg C160.

Metso appointed Roltech Engineering (Roltech) as its installation partner to make the necessary changes to the existing support structure and chute work required to complete a successful installation of the new crusher into the existing primary station. Roltech took on both principal designer and principal contractor roles under the Construction (and Design and Management) regulations and had a full-time site manager supervising the overall installation, as well as Metso engineers building up the crusher from the new support level.

The new crusher had to be installed into the existing space, respecting the feed and conveyor system; to gain access, the roof and existing lifting beam had to be removed. The scope of installation also included a new magna start for the slip ring motor and electric control panel. During the planning stage, which included all the stakeholders, it was determined that the best solution was to build up the crusher ‘in situ’. This overcame the challenge of crane access for the size of lifts involved with sufficient reach available for the best position near the primary building.

With the effort made during the planning stage and with everybody’s co-operation, the installation proved successful – with commissioning and start-up completed three days before the deadline.

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A Rockster R1100S impact crusher is said to have proven its reliability, flexibility and compactness during road construction work in Gaziantep Province, southern Turkey
According to Andy Meadows, group engineering manager for Longcliffe Quarries, the results are comprehensive. “The Nordberg C160 is already impacting our business with improved production at the primary station through better utilisation of the load and haul fleet asset and associated manpower,” he explained.  “We have also noticed that even with the increased production there hasn’t been an increase in power consumption with the new Nordberg C160 compared to the old primary crusher.”

Meadows is pleased to see the crusher delivering the forecasted production improvements, justifying Longcliffe Quarries’ capital investment.

“Longcliffe Quarries takes a long-term view on the purchase of equipment, and that is why we have also agreed to a crusher extended warranty and care package with Metso”, he concluded.

Haver & Boecker has launched the Tyler F-Class portable plant which includes several new technologies said to improve setup time and extend equipment longevity in quarry and mining operations. The portable plant features a new custom-built chassis equipped with six hydraulic run-on jacks that quickly level the plant, eliminating the need for cribbing. The run-on jacks also ensure the chassis stays level during operation, which minimises equipment wear.

“Portable plants should not only give producers the flexibility to move from site to site or within a quarry,” said Karen Thompson, Haver & Boecker Canada president, “they should also be fast and easy to set up. We are committed to producing portable vibrating screen plants that possess these qualities, with the same durability, longevity and minimal maintenance as stationary vibrating screens.”

Haver & Boecker says producers can move and set up the portable F-Class in less than 30 minutes. The chassis’ hydraulic system raises the vibrating screen to its inclined operating position — usually 20°. Takedown is even faster, requiring less than 20 minutes to lower the unit so it can move to the next location.

In addition to run-on jacks and hydraulic walkways, several other features offer enhanced durability and minimise maintenance. These include a new bolted-on suspension that can be removed during operation to eliminate the risk of damage. The chassis is also sandblasted and coated with a heavy-duty finish for optimal wear life and rust resistance.

Haver & Boecker’s F-Class portable plant offers three screen decks. Its feed conveyor, cross conveyor and fines conveyor are hydraulically operated for precise material placement. The plant’s fines chute has a full-width access door allowing users to easily unload material build-up, and the model’s oversize chute features AR liners that are bolted on for easy replacement.
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Haver & Boecker's new Tyler F-Class portable plant includes several new technologies said to improve setup time and extend equipment longevity in quarry and mining applications
The F-Class vibrating screen has an advanced double eccentric shaft design, supported by four high-performance, double-spherical roller bearings. The F-Class is said by Haver & Boecker to be ideal for screening situations that require consistent, load-independent performance at constant g-force. Featuring novel, reliable and proven four-bearing technology, the vibrating screen delivers a consistent stroke which two-bearing screens cannot provide. With the right media choice, the F-Class virtually eliminates blinding, pegging and material contamination.

The F-Class portable plant can be customised to include a crusher, conveyors or other components for enhanced productivity. The machine is ideal for tough applications, such as scalping and classifying ores, minerals, stones, sand and gravel.

Approved applications are eligible for Haver & Boecker’s Uptime 36-month warranty, featuring a full-service approach to equipment optimisation — from parts inspection and equipment assessment to screen media evaluation.

Additionally, Haver & Boecker offers the Pulse vibration analysis program to monitor the ongoing health of vibrating screens through real-time views, logged reports and data analysis. It’s designed by Haver specifically for vibrating screens to catch small inconsistencies before they grow into problems and downtime.

After delivering an average of 150tonnes/hour of material over more than 9,000 continuous hours of operation, the Rockster R1100S impact crusher is said to have proved its reliability, flexibility and compactness during road construction work in Gaziantep Province, southern Turkey. Located on the border with Syria, Gaziantep is one of Turkey’s most important industrial provinces.

Rockster’s long-standing Turkish partner Alfamobil is looking after the buyer of the R1100S unit. Apart from planned maintenance work and the replacement of wear parts, the impact crusher is said to be operating problem-free.

Equipped with the screenbox RS104 and the double-functional return/stockpile belt RB95, the Rockster R1100S crushes limestone with edge lengths of up to 700mm to 0-35mm final grain. By using the pre-screen, the sandy part of the broken material is removed and – in just one step – a high-quality cubic final grain is received. This is said to be the best carrier material for road construction.

The compactness and the resulting simple transport are major advantages of the Rockster crusher, especially in road construction. Operators such as the Gaziantep road-building customer like the easy handling of the crusher, along with the quick setup, as the machine is put into operation within 10 minutes. Rockster says the adjustment of the entire crushing plant to the requirements at the site is also very easy to accomplish.

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Over 100 guests attended the inaugural Kleemann Technology Day, held at the Wirtgen Group's new UK headquarters
Due to the positive experiences with the first crushing plant, the Gaziantep-based customer decided to order another mobile crusher from Rockster Recycler. The additional R1100DS crushing plant has been delivered and has already been put into operation. Again, it is said to fully meet the customer’s requirements.

The two plants working together are said to be helping to ensure a more rapid expansion of important transport links in southern Turkey.

More than 100 guests recently attended the inaugural Kleemann Technology Day, held at the Wirtgen Group’s new UK headquarters in Newark, central east England.

Kleemann organised the interactive event to showcase its latest crushing and screening plants and highlight to guests how the investment made in the German Wirtgen Group brand’s new headquarters will further improve its after-sales and support services capability in the UK.

Over the course of the day, customers had the opportunity to hear about Kleemann’s future plans from Wirtgen Group’s CEO, Domenic Ruccolo, and meet the brand’s UK team. Outside, in the new facility’s dedicated demonstration area, they were also able to see demonstrations of a variety of machines including the MS703 MOBISCREEN, MC09Si MOBICONE, MC110Z MOBICAT and the MR110Z NOBIREX.

Wirtgen UK’s managing director, Paul Holmes, said: “The excellent attendance at our recent Technology Day reflects the continued high level of interest in Kleemann’s mobile crushing and screening equipment. Outstanding product quality, coupled with our increased spare parts and servicing capability, means we are confident that this will continue to be one of the group’s fastest growing markets.”

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