Advances in aggregate production machines

Aggregate production equipment continues to become more efficient and more productive as development continues – Mike Woof writes

During 2016 all the major aggregate production equipment specialists have put a good deal of new machines on the market, highlighting their investment in research and development. These firms are also investing in developing their facilities, with new manufacturing capability coming on stream.

Materials washing specialist 3168 CDE Global is now offering its modular M-Series washing plant range, which benefits from a compact footprint, efficient transfer of materials from one processing phase to another and electric power. The range continues to expand with the latest M2500 E5X now able to produce up to five washed and classified products. Other developments include a refined chassis design to allow for rapid installation, easy transportation and minimal civils requirements. This model also incorporates the patented Infinity screening technology on both the P-Line inclined sizing screen and D-Line dewatering screen.

The P-Line screen on the M2500 uses the CDE VibroCentric drive system which allows a higher power-to-weight ratio. The D-Line dewatering screen utilises the innovative VibroSync motor bridge which ensures an even distribution of power across the full screening area for superior performance.

Meanwhile, 7142 Haver & Boecker says that its Tyler F-Class Split-Bucket Mounting System simplifies maintenance and bearing change-outs, cutting service downtime in half. The rubber mount housing, or split-bucket system, provides operators easy access to critical components, such as rubber mounts and body brackets.

All new Tyler F-Class Vibrating Screens feature the upgraded mounting system, which includes 16 rubber mounts and four body brackets. The split-bucket rubber mount includes a two-piece body bracket, which allows operators to remove the side arm and bucket in one piece. In addition, the F-Class includes Haver & Boecker’s exclusive four bearing Tyler design, which allows for multiple machine installations within the same building or structure.
From 2992 Keestrack comes the C8 track-mounted large-scale screening unit, which is said to feature an efficient double screen. The large surfaces (2 x 6000 x 1900mm) can be equipped with different screening systems, including the expansion-shaft BIVITEC Flip-Flow technology of its Austrian partner Binder + Co. This allows applications such as processing materials with high moisture levels, or large volumes of standard products. Using different screening combinations allows the processing of small grain sizes while changing the linings in the upper-deck circular vibratory screen allows the unit to be used behind a crusher or for processing hot materials. The machine weighs 43.5tonnes for transport and is said to offer rapid set-up time. As with other Keestrack models the C8/K8 unit is available with diesel-hydraulic and diesel-electric drives. From 2017 the firm will offer diesel-electric drives with plug-in options for its mobile jaw crushers, screeners and impactors as an alternative to the diesel-hydraulic drives.

These drive options are already offered for the H4 tracked cone crusher. It has a new frame design and has a total transport weight of only 46tonnes and a compact transport width of 3m. It also has an intelligent plant control that can be combined with the firm’s GPS-supported remote machine monitoring system.

And 6934 Metso says that demand is strong for its novel NW Rapid system, a crushing plant that fits inside standard 12m shipping containers for ease of transport. The wheel-mounted plant can be commissioned in just 12 hours and the firm claims it offers a potential production gain of 30% over rival systems. The increased capacity is said to be achieved by the combination of its Nordberg GP220 cone crusher and its new four-deck dual-slope screen. This is said to deliver high screening performance while the whole plant can be adjusted as required by a process control system. The NW Rapid complies with European safety standards, and it can be issued with a CE marking.
A novel development from the firm is the availability of upgrades for old crusher models intended to reduce maintenance costs and also boost throughput and safety. The upgrades are available for Symons and Nordberg cone crushers, as well as Superior gyratory crushers. The kit include installation instructions while Metso also offers the option of a field service team for support or for installation. These upgrades are said to offer increased productivity, easier setting adjustments, better crusher reliability and reduced bridging from oversized materials. Maintenance is also reduced with improved component life, more reliable crushing and easier maintenance.

The productive Premiertrak 400 model from 2991 Powerscreen has been redesigned to run at a low engine speed, boosting fuel efficiency and lowering working noise. The machine is said to offer a lower cost/tonne, while suiting duties in urban sites and has rugged GRP panels designed for ease of access. The machine is offered with an optional post screen system allowing users to generate a type one product at high volume from one machine. It has been designed with a quick release system, to ensure maximum uptime and easy service and maintenance.

The firm is also offering its Trakpactor 550 horizontal impact crusher, which is said to offer high reliability, efficiency and performance. It benefits from a robust and heavily engineered chassis and has been designed to optimise material flow to minimise material build-ups. Its optional pre-screen unit allows fines to be removed efficiently, maximising production and minimising wear. It also has a new chamber design and optional features such as the hydraulic inlet lid and the automatic adjustment system, as well as auto rotation system for blow bar changes.

5074 Rockster Recycler says that it has developed key innovations for the crushing and screening sector including its patented duplex system, patented double functional return belt and its novel hybrid crusher. Rockster’s R900 impact crusher R900 is a mobile track-mounted machine equipped with a large entry opening and a heavy duty, hard aggregate rotor. It can be used in recycling applications and in areas involving hard or abrasive aggregates. Its hydrostatic drive allows continuous adjustment of the rotor speed to suit operating conditions. The circular motion vibrating screen can be assembled directly on the main discharge conveyor while no separate drive is required to power the screenbox and return belt as they are driven by an additional hydraulic system.
Both the R900 impact crusher and R800 jaw crusher can be equipped with the firm’s novel duplex-system, which allows the crusher units to be exchanged. The machines have an identical drive system so that either the impact or jaw crusher can be installed on the same basic frame. According to 325 Sandvik, its new QJ341+ model offers improved efficiency, lower rates of wear and higher productivity. This new jaw crusher also incorporates a double deck pre-screening system, offering high amplitude for efficient separation. This allows for the removal of a large quantity of fines, boosting productivity and reducing crusher wear. The QJ341+ suits applications where a high proportion of fines are found in the feed and the firm claims tests show productivity gains of up to 38% in certain duties. 

The unit also features a new telescopic natural fines conveyor, with a discharge height of 3.1m. The dirt chute has been designed with a steeper angle to enable a faster transfer of material and can also handle sticky material. The three-position dirt chute allows all material passing the pre-screen grizzly to be diverted onto either the main conveyor or the natural fines conveyor. 

The QJ341+ model also includes a hydraulically adjustable CSS setting, reversible jaw and hydraulic drive, allowing it to start under load as well as featuring the Sandvik PLC control system and control screen. Customers can select also select emissions compliant Caterpillar or Volvo diesels.

 

2979 Superior Industries has developed its first ever aggregate screen. The Guardian horizontal screen features a triple-shaft design with an oval stroke and a key feature is its patent pending bottle jack lifting points to simplify spring replacement and boost safety. The unit also has a segmented belt guard and sectioned tailgate, requiring only one person to remove and return the guards and gates during maintenance. Other features include bolt-locking, hinged access doors that allow access for screen media maintenance and a fully-enclosed belt guard for safety as well as an integrated, on-board tensioner to ease belt maintenance. The screens are offered in two- and three-deck configurations and each unit is equipped with spray bar knockout holes for wet processing applications.

2431 Terex Minerals Processing Systems says that its new Cedarapids CRC1150 portable cone plant offers high production. Highly mobile, the plant features the new TC1150 cone crusher with roller bearings, automated cone controls and larger closed side settings. The crusher is powered by a 224kW motor and drive mounted on a rubber isolated frame to reduce vibration. The plant includes an oversize cone feed hopper extension with overflow chute, straight-line undercrusher conveyor, metal detector, and service platforms.

The CRH1313R offers high throughput as well as versatility and can handle rock crushing, concrete recycling, and asphalt recycling. The plant features a high production Cedarapids IP1313 impactor with a three- or four-bar rotor powered by a Tier 4 compliant diesel engine rated at 335kW, as well as featuring a 150kW generator. Uptime is maximised with a heavy-duty undercrusher pan feeder that protects the conveyor belt from damage. It offers high capacity due to the patent-pending dual-slope, two-deck screen that can handle heavy loads. It has a rugged, high-stroke Cedarapids feeder and is said to be easy to operate, set up and transport.

3501 Terex Finlay is introducing its C-1540 direct drive cone crusher, 674 3-deck inclined screen and its I-140RS impact crusher. The C-1540 direct drive cone crusher has been developed to satisfy the requirements of medium sized owner operators and contract crushers. The Terex Finlay 674 inclined screen is a small- to mid-size unit and is designed for contract crushers and small-scale owner-operators wanting to produce four products from one platform. The firm has also developed its sophisticated I-140RS impact crusher to meet the needs of customers. These are all said to offer high performance, efficient working, good product quality, long working life and low maintenance needs.

7258 Terex Washing Systems (TWS) says that its AggreScalp scalping unit can boost profitability for quarry operations. The Terex AggreScalp is a versatile, high performance heavy duty electric screening machine that has the flexibility to operate as a two- or three-way split screener. The aggressive screen can accept media including bofor bars, finger screens, woven mesh and 3D punch plates, which allows it to be used across a wide variety of applications. It has on-board hydraulic folding product conveyors, hydraulic screen angle adjustment and single lift set-up.
The AggreScalp can work in conjunction with the Terex AggreSand range by providing a consistent feed material even in difficult applications. Together they are said to form an efficient, lower operating cost aggregate and recycling solution.

The Terex FM UltraFines is system is said to offer efficient management and recovery of ultrafines sand from waste water streams. This ultra-fines recovery unit can process up to 450m³/hour of slurry recovering material as low as 40micron, reducing the volume of solids reporting to storage ponds or water treatment plants.

3243 Tesab’s new 700i Jaw Crusher is based on the proven 10570 but is said to be easier to transport due to its reduced weight. High power and throughput are claimed with a maximum output of 400tonnes/hour. The 700i is said to be easier to manoeuvre, whilst still featuring the firm’s productive jaw crusher. The 700i is quicker and easier to set up than before, cutting downtime between jobs. It also features hydraulic locking extension cribs, eliminating the need for lifting gear and improving overall health and safety by eliminating risks during setup. It has a two-deck independent pre-screen, allowing a sized product to be fed from the side belt while the new and improved step deck vibrating feeders allow a higher throughput tonnage, improved material separation quality and the ability to handle dry, damp or wet material.

7310 Weir Minerals claims that its Trio cone crusher range combines aggressive crushing with high crushing forces and high power. According to the firm, the new TP cone crushers operate at a higher speed than earlier models, with higher reduction with better shaped product.

These compact, robust crushers have advanced cone crusher automation technology for continuous high performance and versatility. The crushers feature steep crushing chamber angles, large crushing strokes and optimum speed and deliver fine product quality due to efficient comminution.

Key features include self-protecting systems for reliability in severe operating conditions. The optional direct drive systems can be combined with variable frequency drives to further optimise performance. The Trio TP cone crushers offer high flow, high pivot point, large throw and large head diameters and are fully instrumented with advanced lubrication and hydraulic systems.