Mobile crushing and screening solutions have become a key component for the aggregate production sector - Mike Woof writes. The market for mobile crushing and screening solutions has grown enormously in recent years. With the first track-mounted mobile units having appeared in the 1980s and pioneered by a small number of manufacturers, the range and variety of units on the market has grown enormously since.
The TC20 from IROCK Crushers is powerful and productive for its size
Mobile crushing and screening solutions have become a key component for the aggregate production sector - Mike Woof writes
The market for mobile crushing and screening solutions has grown enormously in recent years. With the first track-mounted mobile units having appeared in the 1980s and pioneered by a small number of manufacturers, the range and variety of units on the market has grown enormously since.
Mobility and versatility have been drivers of this huge growth in demand for the mobile units. These machines can be moved to sites for short periods and then elsewhere, for projects of short duration. Even for quarries with long-term permission, using mobile units can offer benefits as the equipment can be relocated during operations as extraction progresses and new working areas are developed, ensuring higher working efficiency. Competition is now tough between manufacturers as a very wide range of firms now offer machines into this market, providing customers with many choices. The technology too is wide and varied, with different crusher types suiting different feed materials, product types and applications. Sophisticated technologies also offer remote control of equipment and computerised batching options for some units.
Crushing at the face with mobile units remains a niche segment however, with loading and hauling units still favoured for removing blasted material to crushing and screening machines.
7408 IROCK Crushers, in the shape of its new TC-20 Track Impact Crusher. The unit combines a large feeder, a high-performance four-bar impactor and heavy-duty components and is said to offer efficiency, reliability and precision.
The TC-20 produces a uniform, cubical product, and IROCK’s hydraulically adjustable aprons provide accurate control for sizing. The unit can process soft to medium rock, recycled concrete and recycled asphalt. The rotor measures 102mm by 1.42m and can process a variety of materials up to 610mm in diameter. A 328kW178 Caterpillar C-13 Tier 3 engine powers the crusher, which can process up to 451tonnes/hour.
The track crusher features a fixed, Hardox hopper with an 11.77m3 capacity. It is paired with a 1.32m by 4.88m vibrating grizzly feeder, which has 19mm liners on the pan and side walls. The feeder is up to 914mm longer than comparable units, making it possible to feed material with a large wheeled loader.
The TC-20 features a standard crusher bypass chute to reduce wear on the crusher. With this chute, fines that fall through the grizzly feeder can either bypass the crusher and mix back in with the crushed material or be removed through the dirt conveyor.
The TC-20 also incorporates IROCK’s ROCK BOX, which uses a shelf system with abrasion resistant wear bars that allow crushed material to build up and act as a wear liner. The 1.22m-wide discharge conveyor can stockpile from as high as 3.3m. Operators can hydraulically lower or raise the conveyor to adjust drop heights and make maintenance easier.
The TC-20 is highly mobile and comes standard with a wireless remote control for full plant operation, with two tracking speeds as standard. To reduce cleaning and for dust control, the TC-20 features a dust-suppression system.
For greater throughput,6934 Metso has developed its new NW Series, which is said to be fast and simple to bring on stream while delivering high throughput and product quality. The firm claims that this system allows full-scale crushing and screening plant commissioning in 12 hours, without need for heavy cranes. The Metso NW Series is a wheel-mounted crushing plant that fits into standard 12m containers so that it can be shipped quickly and cost-effectively.
The combination of Metso NW106 primary jaw crushing plant and the NW220GPD secondary cone crushing plant with a large dual-slope screen has been optimised, allowing frequent relocation. Hydraulically fine-adjustable support legs, hopper walls and screen lifting facilitate fast installation and dismantling. The firm has developed a new plant conveyor with fewer support legs and without needing heavy cranes or concrete foundations during set-up.
The NW Series portable plant is said to be able to process hard feed materials and can deliver four calibrated end products, delivering an output 20% higher than conventional equipment in the same size class. The Nordberg GP220 cone crusher and new dual-slope screen are crucial for the high throughput, while the whole process can be adjusted by Metso's innovative process control.
The Metso IC50C process control system provides a smart link between primary crushing, secondary crushing and screening. The IC50C system has been developed for consistent production, safety and control of the whole process. Features include feed and discharge conveyor control, wear compensation, auto setting adjustment and computer remote control.
From3501 Terex Finlay meanwhile comes the C-1545, the latest addition to the firm’s range of tracked mobile cone crushers. The mid-range Terex Finlay C-1545 is said to offer operators a high capacity and aggressive cone crusher for aggregate production.
This machine is said to be efficient and highly productive and incorporates the new Terex TC1150 cone crusher with direct variable speed clutch drive, automatic tramp relief and on-the-fly hydraulic adjustable closed side setting (CSS) adjustment.
The large hopper/feeder has an automated metal detection and purge system to protect the cone and reduce downtime by removing metal contaminants through its purge chute.
Additional benefits include rapid set up time, ease of maintenance, high reduction ratio, advanced electronic control system, high output capacity and good product cubicity.
Other important features are a fuel-efficient direct drive transmission through wet clutch and a hydraulic tramp relief system with automatic reset that protects the chamber and minimises downtime. A metal detection system on the feed belt protects the cone from tramp metal while the purge system removes contaminants from the machine.
The TC1150 was developed by sister firm2431 Terex Minerals Processing Systems and has been designed using expertise from the proven, high-performance Terex TC1000 and TC1300 cone models. However, there are several improvements to boost performance and functionality. The TC1150 has a new upper frame to suit all available concave liners. The locking ring design also now eliminates the need to hammer in concave retaining wedges. The wedge ring and upper frame have additional improvements. Key features include the inner skirt with better protection to accommodate larger CSS, increasing product size. The TC 1150 also has increased stroke clearance allowing for larger maximum CSS and tramp clearance.
The TC1150 has a nominal cone head diameter of 1150mm. Maximum feed size of medium course 190mm and extra course 220mm with a 65mm standard long throw at 224kW and optional 50mm short throw at 186kW.
3168 CDE Global, is rolling out its novel R-Series range of primary screens. The range includes two new machines. The R1500 has a maximum feed capacity of 200tonnes/hour while the larger R2500 machine offers a maximum feed capacity of 500tonnes/hour.
The R-Series combines a feed hopper, screen and conveyors in a variety of different configurations. The feed hopper on the R1500 has a maximum capacity of 7tonnes when fitted with the optional extendable hopper sides while the hopper capacity on the R2500 unit rises to 20tonnes. Both machines can be provided with either a belt feed or apron feed. The hopper has been designed to allow for feed to be delivered to the R-Series from three sides to allow maximum flexibility to cope with specific site conditions.
The R-Series also comes with two new galvanised Infinity screens, both of which include their new patented side wall technology. This is said to eliminate welds and result in a stronger, lighter screen which produces the same acceleration as traditional units while using less power. The R1500 includes the Infinity P1-36R screen which measures 2.4m x 1.5m while the R2500 integrates the Infinity P2-75R screen measuring 5m x 1.5m.
The cartridge design of the screen decks maximises machine life as it increases durability. The Infinity range also includes the development of cast U-Span cross members which reduce floor flex – reducing stress and extending the life of the machine.
Further weight is removed from the screen due to the novel lightweight screen shaft, which generates the same force as a conventional unit. This design helps optimise energy efficiency. Extensive use of replaceable wear liners at feed and impact points maximises machine life.
The R-Series has7153 SKF bearings with a novel double seal, which prevents contamination during operation by reducing the risk of material and water ingress. The design cuts maintenance costs and maximises output. Safety benefits include higher side walls for the screen to prevent rogue rocks from bouncing off the top deck.
A 9m feed and stockpile conveyors can supply materials for a variety of configurations. The 9m stockpile conveyor for oversize material allows for a stockpile capacity of 150m3. The R-Series includes a collection conveyor underneath the integrated Infinity screen which delivers material to an additional stockpile conveyor, or directly to the feed boot of the M2500 or M4500 modular washing plants.
And from Metso come two new screening product ranges: Metso PREMIER Screens and Metso COMPACT Screens. The Metso PREMIER Screen range includes the CVB incline, circular motion screen; the ES horizontal, elliptical motion screen; and the TS multi-slope, variable motion screen. These screens appeal to customers that rank operational availability and application flexibility as the primary concern to achieve low OPEX in high cost markets to secure the lowest cost of ownership over the long term.
The Metso COMPACT Screen range includes machines that have been incorporated with mobile crushing and screening plants, but are now available for single unit sales and use in stationary plants. These screens, including the CVB-M inclined screen with circular motion and the FS horizontal screen with elliptical motion are proven on Lokotrack mobile plants and Nordberg NW Series portable plants. In addition to the CVB-M and the FS, the DF banana screen with linear motion will be offered for primary screening. The Metso COMPACT screens include features in a standard configuration for easy, reliable and safe operation. The key design characteristic that allows the COMPACT screens to be economical in terms of both size and price is the configuration for side tension screening media.
In addition, the Tyler F-Class Vibrating Screen from Haver & Boecker offers a solution for challenging screening applications requiring minimal vibration transmission during operation. This allows for multiple machine use within the same building or structure, without the reinforcing required for conventional vibrating screens. The F-Class also suits screening situations that require consistent, load independent performance at constant g-force in all operational modes. Featuring a reliable, proven four-bearing technology, the vibrating screen minimises structural vibration and delivers a consistent stroke, which two-bearing screens cannot provide, minimising blinding and pegging.
The design features an advanced eccentric shaft, supported by four high-performance, double spherical roller bearings. The double eccentric shaft creates a constant positive stroke that handles material volume spikes without losing momentum. As the eccentric shaft turns, the screen body is forced to follow the shaft movement. While it travels upward, the counterbalance weights move in the opposite direction and create an equal force. As a result, the forces cancel each other, allowing a dynamically balanced system that eliminates vibration.
Designed for high-tonnage outputs, the F-Class can process as much as 4,510tonnes/hour while providing fast, accurate sizing of materials. In addition to traditional screening, the vibrating screen is often used before primary crushers to screen out fines and eliminate crusher wear.
To maximise versatility, the F-Class can operate with up to three screen decks. The unit features inclines from 15-25° and comes with a base frame that simplifies installation in an existing structure.
The F-Class features a rugged HUCK-bolted screen body fastening, allowing for extra strength and rigidity. Side plates are constructed with high-strength carbon steel. A reinforced plate strengthens the shaft and ties together the side plate, screen panel and shaft assembly.
The market for mobile crushing and screening solutions has grown enormously in recent years. With the first track-mounted mobile units having appeared in the 1980s and pioneered by a small number of manufacturers, the range and variety of units on the market has grown enormously since.
Mobility and versatility have been drivers of this huge growth in demand for the mobile units. These machines can be moved to sites for short periods and then elsewhere, for projects of short duration. Even for quarries with long-term permission, using mobile units can offer benefits as the equipment can be relocated during operations as extraction progresses and new working areas are developed, ensuring higher working efficiency. Competition is now tough between manufacturers as a very wide range of firms now offer machines into this market, providing customers with many choices. The technology too is wide and varied, with different crusher types suiting different feed materials, product types and applications. Sophisticated technologies also offer remote control of equipment and computerised batching options for some units.
Crushing at the face with mobile units remains a niche segment however, with loading and hauling units still favoured for removing blasted material to crushing and screening machines.
Crushing
One of the latest crushing models coming to market is fromThe TC-20 produces a uniform, cubical product, and IROCK’s hydraulically adjustable aprons provide accurate control for sizing. The unit can process soft to medium rock, recycled concrete and recycled asphalt. The rotor measures 102mm by 1.42m and can process a variety of materials up to 610mm in diameter. A 328kW
The track crusher features a fixed, Hardox hopper with an 11.77m3 capacity. It is paired with a 1.32m by 4.88m vibrating grizzly feeder, which has 19mm liners on the pan and side walls. The feeder is up to 914mm longer than comparable units, making it possible to feed material with a large wheeled loader.
The TC-20 features a standard crusher bypass chute to reduce wear on the crusher. With this chute, fines that fall through the grizzly feeder can either bypass the crusher and mix back in with the crushed material or be removed through the dirt conveyor.
The TC-20 also incorporates IROCK’s ROCK BOX, which uses a shelf system with abrasion resistant wear bars that allow crushed material to build up and act as a wear liner. The 1.22m-wide discharge conveyor can stockpile from as high as 3.3m. Operators can hydraulically lower or raise the conveyor to adjust drop heights and make maintenance easier.
The TC-20 is highly mobile and comes standard with a wireless remote control for full plant operation, with two tracking speeds as standard. To reduce cleaning and for dust control, the TC-20 features a dust-suppression system.
For greater throughput,
The combination of Metso NW106 primary jaw crushing plant and the NW220GPD secondary cone crushing plant with a large dual-slope screen has been optimised, allowing frequent relocation. Hydraulically fine-adjustable support legs, hopper walls and screen lifting facilitate fast installation and dismantling. The firm has developed a new plant conveyor with fewer support legs and without needing heavy cranes or concrete foundations during set-up.
The NW Series portable plant is said to be able to process hard feed materials and can deliver four calibrated end products, delivering an output 20% higher than conventional equipment in the same size class. The Nordberg GP220 cone crusher and new dual-slope screen are crucial for the high throughput, while the whole process can be adjusted by Metso's innovative process control.
The Metso IC50C process control system provides a smart link between primary crushing, secondary crushing and screening. The IC50C system has been developed for consistent production, safety and control of the whole process. Features include feed and discharge conveyor control, wear compensation, auto setting adjustment and computer remote control.
From
This machine is said to be efficient and highly productive and incorporates the new Terex TC1150 cone crusher with direct variable speed clutch drive, automatic tramp relief and on-the-fly hydraulic adjustable closed side setting (CSS) adjustment.
The large hopper/feeder has an automated metal detection and purge system to protect the cone and reduce downtime by removing metal contaminants through its purge chute.
Additional benefits include rapid set up time, ease of maintenance, high reduction ratio, advanced electronic control system, high output capacity and good product cubicity.
Other important features are a fuel-efficient direct drive transmission through wet clutch and a hydraulic tramp relief system with automatic reset that protects the chamber and minimises downtime. A metal detection system on the feed belt protects the cone from tramp metal while the purge system removes contaminants from the machine.
The TC1150 was developed by sister firm
The TC1150 has a nominal cone head diameter of 1150mm. Maximum feed size of medium course 190mm and extra course 220mm with a 65mm standard long throw at 224kW and optional 50mm short throw at 186kW.
Screening
Materials washing specialists,The R-Series combines a feed hopper, screen and conveyors in a variety of different configurations. The feed hopper on the R1500 has a maximum capacity of 7tonnes when fitted with the optional extendable hopper sides while the hopper capacity on the R2500 unit rises to 20tonnes. Both machines can be provided with either a belt feed or apron feed. The hopper has been designed to allow for feed to be delivered to the R-Series from three sides to allow maximum flexibility to cope with specific site conditions.
The R-Series also comes with two new galvanised Infinity screens, both of which include their new patented side wall technology. This is said to eliminate welds and result in a stronger, lighter screen which produces the same acceleration as traditional units while using less power. The R1500 includes the Infinity P1-36R screen which measures 2.4m x 1.5m while the R2500 integrates the Infinity P2-75R screen measuring 5m x 1.5m.
The cartridge design of the screen decks maximises machine life as it increases durability. The Infinity range also includes the development of cast U-Span cross members which reduce floor flex – reducing stress and extending the life of the machine.
Further weight is removed from the screen due to the novel lightweight screen shaft, which generates the same force as a conventional unit. This design helps optimise energy efficiency. Extensive use of replaceable wear liners at feed and impact points maximises machine life.
The R-Series has
A 9m feed and stockpile conveyors can supply materials for a variety of configurations. The 9m stockpile conveyor for oversize material allows for a stockpile capacity of 150m3. The R-Series includes a collection conveyor underneath the integrated Infinity screen which delivers material to an additional stockpile conveyor, or directly to the feed boot of the M2500 or M4500 modular washing plants.
And from Metso come two new screening product ranges: Metso PREMIER Screens and Metso COMPACT Screens. The Metso PREMIER Screen range includes the CVB incline, circular motion screen; the ES horizontal, elliptical motion screen; and the TS multi-slope, variable motion screen. These screens appeal to customers that rank operational availability and application flexibility as the primary concern to achieve low OPEX in high cost markets to secure the lowest cost of ownership over the long term.
The Metso COMPACT Screen range includes machines that have been incorporated with mobile crushing and screening plants, but are now available for single unit sales and use in stationary plants. These screens, including the CVB-M inclined screen with circular motion and the FS horizontal screen with elliptical motion are proven on Lokotrack mobile plants and Nordberg NW Series portable plants. In addition to the CVB-M and the FS, the DF banana screen with linear motion will be offered for primary screening. The Metso COMPACT screens include features in a standard configuration for easy, reliable and safe operation. The key design characteristic that allows the COMPACT screens to be economical in terms of both size and price is the configuration for side tension screening media.
In addition, the Tyler F-Class Vibrating Screen from Haver & Boecker offers a solution for challenging screening applications requiring minimal vibration transmission during operation. This allows for multiple machine use within the same building or structure, without the reinforcing required for conventional vibrating screens. The F-Class also suits screening situations that require consistent, load independent performance at constant g-force in all operational modes. Featuring a reliable, proven four-bearing technology, the vibrating screen minimises structural vibration and delivers a consistent stroke, which two-bearing screens cannot provide, minimising blinding and pegging.
The design features an advanced eccentric shaft, supported by four high-performance, double spherical roller bearings. The double eccentric shaft creates a constant positive stroke that handles material volume spikes without losing momentum. As the eccentric shaft turns, the screen body is forced to follow the shaft movement. While it travels upward, the counterbalance weights move in the opposite direction and create an equal force. As a result, the forces cancel each other, allowing a dynamically balanced system that eliminates vibration.
Designed for high-tonnage outputs, the F-Class can process as much as 4,510tonnes/hour while providing fast, accurate sizing of materials. In addition to traditional screening, the vibrating screen is often used before primary crushers to screen out fines and eliminate crusher wear.
To maximise versatility, the F-Class can operate with up to three screen decks. The unit features inclines from 15-25° and comes with a base frame that simplifies installation in an existing structure.
The F-Class features a rugged HUCK-bolted screen body fastening, allowing for extra strength and rigidity. Side plates are constructed with high-strength carbon steel. A reinforced plate strengthens the shaft and ties together the side plate, screen panel and shaft assembly.
