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Aggregates production innovations delivering efficiency

First publishedin World Highways
July 2017
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Kleeman Crushers
Kleemann is offering its latest crushers in North America

Competition is tough between the key producers of crushing and screening equipment, with an array of new equipment now being introduced

EvoQuip, the newest division of Terex Corporation, is launching a Cobra 230 impact crusher later this year, to sit alongside the Cobra 260. The 24tonne machine will offer a production capacity of 140-150tonnes/hour in asphalt and construction recycling. The Cobra 230 is 11.3m long and 2.46m wide, or 5.15m wide with a side conveyor. It features a quick set-up time and the machine can be moved onsite without having to stop the crusher.

Keestrack says that its novel H4 tracked cone crusher is light and compact and features a KT-H4 cone crusher, adapted for the installation. The fully automated unit produces up to 250tonnes/hour at maximum feed sizes of 178mm. The wide variety of concaves allows a high flexibility in secondary or tertiary production of highly defined end fractions. To optimise production the plant can be equipped as an option with a pre-screen with fines chute, helping to boost throughput and cut component wear. A key feature is its highly efficient, three-deck secondary screen module with recycling conveyor for closed-circuit processing.

The H4 features a hybrid diesel-electric drive concept with a 345kW diesel that meets Tier 4 Final emissions requirements. It also has a 330kVA Genset and a 135kW crusher E-drive. This lowers fuel consumption and maintenance through the use of electric motors on screens and conveyors. In addition the new full-hybrid version H4e allows full electric operation through mains or an external genset. An additional electric motor/hydro pump supplies the hydraulic driven feeder, the secondary screen, tracks and hydraulic cylinders.

The firm also offers its latest R3 and R5 tracked impact crushers. The R3 weighs in at 33tonnes while the R5 is a 55tonne machine. Both share technical features and feature active pre-screening, while they are available with optional equipment including magnetic separators, fines conveyors and secondary screen modules with closed-circuit operation. The units have direct-driven crushers with large and heavy rotors, delivering high output and smooth running. The machines are offered with diesel-hydraulic drives and modern load sensing hydraulics. The R5 can also be equipped with a hybrid diesel-electric drive, offering extra fuel savings of up to 25%.

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Stedman Crusher
Stedman claims increased efficiency for its latest crusher
Kleemann is now introducing its latest crushing technology to the North American market. The Mobicone MCO 11i features the firm’s latest control technology for efficient operations. The Mobicone Pro is a redesign of the previous generation machine and now benefits from a new feeder design. The Tier 4 Final compliant 368kW Scania engine is more powerful and has been set lower in the chassis, making transport easier. The diesel-electric drive is claimed to be more efficient than earlier systems, saving fuel. An important feature is that the machine can also run on electric power, further cutting running costs. The machine can deliver up to 500tonnes/hour, due to the sophisticated control system.

KPI-JCI has new hybrid crushing and screening solutions with its GT440 Hybrid horizontal shaft impactor (HSI) and GT205 Hybrid Multi-Frequency screen. Offering onsite mobility and quick set-up, the GT440 Hybrid HSI delivers up to 30% more uptime with continuous crushing and tracking. The GT440 Hybrid HSI’s Overload Protection System is said to maximise performance and production. The GT205 Hybrid Multi-Frequency Screen suits aggregate, recycling and industrial operations, offering up to 50% higher screening capacity on its bottom deck with multi-frequency technology. Like the GT440, it allows customers to lower running costs.

The GT205 Hybrid’s simple controls ensure that the new hybrid screen is easy to operate. KPI-JCI said its full line of mobile screening plants, which the GT205 Hybrid has just joined, gives onsite flexibility for every application.

Also new from KPI-JCI is the 3365 Jaw Crusher, which offers 25% more capacity and reduced power requirements. The 3365 has replaceable jaw die retention wedges which eliminate costly repairs. Meanwhile shaft integrity is said to be ensured due to an innovative bearing and seal design.
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Metso Crusher
Metso's new cone crushers utilise innovative technology to boost output

McCloskey International has introduced a 914mm-wide by 30.5mm-long VBIN desegregating telescoping stacker. The new SDX100 VBIN sets a precedent for self-powered telescoping stackers in North America and is powered by an onboard diesel engine. Available with either powered wheel or track drives, the SDX100 VBIN is highly mobile and easily transported from site to site.

The new stacker desegregates and maximises stockpile capacity using a sophisticated control system, providing optimised material quality. It is capable of delivering over 750tonnes/hour.

The VBIN section features hydraulic fold and boasts a standard capacity of over 5.5m3, while setup can be accomplished in 15 minutes.

Metso has revealed the first of its new innovative multi-action cone crushers. The Metso MX series, of which the MX4 is the first model, utilises the patented Multi-Action crushing technology, combining the piston and rotating bowl into a single crusher. The new crusher is said to provide a giant leap in profitability by cutting running costs by 10% and enabling 10% higher uptime compared to traditional cone crushers.

The firm has combined two individual crushing methods based on the piston and rotating bowl to deliver the MX Cone with multi-action technology. Designed for demanding rock conditions and with a special focus on automated adjustment features, the Metso MX enables cost-effective and safe operation. It also provides a high reduction ratio with a premium end-product shape and consistency.

Metso says the key benefit of its patented Multi-Action technology is its easy under-load setting adjustment and wear compensation, without having to stop. This combines with extended wear life and better mechanical protection. Optimal cavity design, stroke direction and effective crushing action are said to optimise rock-on-rock crushing. This combines with the innovative multi-action technology for extended maintenance intervals and higher production.

The Metso MX also provides high protection against uncrushable objects and overloading. The crusher can utilise up to 70% of the mass of new wear. The 600tonnes/hour Metso MX4 cone crusher is due to be followed by the MX3 in Q3 2018 and the MX6 in late 2018, or early 2019.

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Powerscreen Models
Powerscreen has a range of new models coming to market

Metso is also launching the Lokotrack Urban LT106, an innovative 46tonne operating weight mobile primary plant for crushing in urban environments, such as city centres. Fitted with a Nordberg C106 crusher, the Urban LT106 is said to offer significant reduction in noise levels and dust emissions, making it easier for operators to get an environmental permit.

Powerscreen is introducing several crushing and screening plants. The next generation Premiertrak 300 and 400 jaw crushers are coming soon, along with the Trakpactor 550 and Trakpactor 550SR impact crushers. On the screening side the firm recently launched the Warrior 1200, the latest addition of the most extensive scalping range in the market.

The firm says it has had success with the double screenbox Chieftain 2200 2-deck and 3-deck models since their launch. These are claimed to offer optimum performance with even the tightest aggregate specs and have a revolutionary patent pending drive system. Meanwhile the Premiertrak 400X jaw crusher offers ease of use, maintenance, serviceability and onsite safety.  Centralised hydraulics and electrics, increased access around the power unit and service areas allow faster set-up and maintenance.

The firm also offers the Powerscreen Pulse telematics tool, which can remotely monitor the crushers and screens and provide up-to-date information on performance direct to a PC, tablet or smartphone. The system reviews fuel usage and production and allows better planning for maintenance and cost/tonne calculations.

High efficiency is claimed by Sandvik for its latest UI310+ wheeled impact crusher. This electrically-driven crushing unit is wheel-mounted and is said to be versatile and productive. According to the firm this unit offers a highly efficient primary crushing solution. It has the patented and highly modular Sandvik CI512 Prisec crusher, allowing the owner to use the machine in primary or secondary applications. A key component is its pre-screen to increase efficiency while other features optimise operation and lower operating costs.

Sandvik is widening its range of mobile crushers with the QJ341+ model. This mobile jaw crusher features additional capabilities and comes with a double-deck pre-screen as standard. Fitting the pre-screen means that the fines can be removed from the feed, boosting throughput, increasing efficiency and lowering crusher wear. Increased throughput, reduced downtime and extended component life, boost productivity over comparable units.

SBM is widening its range of crushing and screening and concrete plant solutions, with versatile new models that are highly mobile. The firm’s new JAWMAX 1006 MAXI unit is a mobile crushing and screening plant that features the STE 100.60 jaw crusher. According to SBM the JAWMAX has been proven in applications with limestone, granite, recycling of construction rubble and slag. The JAWMAX is said to offer ease of setting up onsite as well as operation, according to the firm.

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Sandvik Impactcrusher
Versatility is claimed for Sandvik's wheeled impact crusher

Overload protection prevents tramp metal or other items from damaging or blocking the crusher. The automatic gap adjustment opens the crusher gap so an unbreakable item can safely leave the crusher. Afterwards the movable crushing jaw resumes the predefined normal position and the crushing process continues without any further delay. The STE 100.60 unit can handle feed sizes with dimensions up to 950 mm x 550 mm at a throughput capacity up to 200tonnes/hour, which can be processed to a final grain size of 0/32mm up to 0/200mm.

Stedman’s new H-54 cage mill features improved productivity and a finer, more uniform grind. The firm says that due to its efficiency, there is no need for secondary screening. That productivity is consistent across many materials and it is said to be suited to pulverising, grinding, crushing and mixing abrasive and non-abrasive materials, whether wet, sticky or dry.

The H-Series can handle up to 240tonnes/hour and is reversible for extended wear life. The H-Series Cage Mills feature a quick-open housing for efficient inspection and maintenance. Each H-Series impact mill housing can accommodate two-, four-, or six-row cage assemblies. This versatility is boosted by the capability to vary the number of pins in each row – and to adjust the rotational speed of each cage in relation to the others. The operator also can change the relative direction of the cage rotations.

For wet material applications, air cannons are mounted at the intake and discharge to help prevent build-up. A hydraulically-operated, quick-opening retractor provides rapid access to crushing components for inspection or changeout.

Superior Industries is introducing new crushing, washing and screening solutions as well as its conveying and components products. The new crushers being launched at the event include the Liberty Jaw Crusher, Patriot Cone Crusher and Valor Vertical Shaft Impactor (VSI). Meanwhile the new screens being unveiled are the Guardian Horizontal Screen, Anthem Inclined Screen and Intrepid Vibrating Grizzly Feeder (VGF). Additional crushing and screening solutions will be incorporated into portable plants. Higher performance, longer wear life and reduced maintenance needs are key features.

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EvoQuip Compact Mobile Crusher
EvoQuip now offers a range of compact mobile crushers
Terex Finlay is offering its I-140 direct drive 1,270mm x 1,240mm horizontal impact crusher with variable speed and the proven Terex CR032 chamber, which is said to give excellent reduction ratios and high consistency of product shape. A significant engineering approach being introduced in this model is the material flow through the plant, which has been improved by increasing the width of components as the material moves through the machine. The I-140 features an advanced electronic control system that monitors and controls the speed of the rotor and regulates the heavy-duty vibrating feeder with integrated pre-screen to maintain a consistent feed of material into the impact chamber for optimal crushing conditions.

Terex MPS is to re-launch its Simplicity brand, and introduce the CRC1150S portable closed-circuit cone plant. The new CRC1150S plant features the TC1150 300 HP Terex cone crusher; the TSV6203 1.8mx6m three-deck screen, and the TSH6203 triple oversized surge buffering cone shaft high g-force three-deck screen.

Tesab’s 700i tracked jaw crusher replaces the company’s 10570, but with revisions designed to boost productivity. Those changes include a stepped deck with vibrating feeders - claimed to be better suited to wetter materials - a new discharge belt, new side conveyor and a choice of Scania or Caterpillar power units. These changes are said to contribute to outputs in excess of 350tonnes/hour.

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