The Latest Equipment for the Toughest Job in the Quarry.
By Mark S. Kuhar and Josephine Patterson
Crushers, simply put, make small rocks out of big rocks. There are a myriad of ways to accomplish this, based on the specific needs of the operation. The following is a comprehensive listing of companies and some of the crushing products available on the market today. It’s time to get crushing.
CEMCO Inc.’s Turbo 80 VSI Crusher is an efficient, highly productive vertical shaft impact crusher capable of processing a variety of aggregate materials and industrial minerals. Available in two models, the Turbo 80 offers a mid-sized option powerful enough to process materials up to 4-in. wide into a uniform, cubical, crushed, high-quality product. Fully customizable, from internal components to portable or stationary configuration, the Turbo 80 is ideal for multiple industries including aggregates, energy production, mining and recycling. CEMCO’s Turbo 54 VSI Crusher is an efficient, highly productive vertical shaft impact crusher capable of processing a variety of aggregate materials and industrial minerals. The Turbo 54 offers a mid-sized option powerful enough to process materials as large as 2-in. wide into a uniform, cubical, crushed, high-quality product. Fully customizable, from internal components to portable or stationary configuration, the Turbo 54 is ideal for multiple industries including aggregates, energy production, mining and recycling.
Eagle Crusher Co. Inc. announced its two newest product innovations, RapidDeploy and RipRap. RapidDeploy is the industry’s only portable plant with built-in, retractable conveyors that can crush, screen, separate and stockpile – all in one pull. It was specifically designed to significantly reduce mobilization costs and expensive set-up and tear-down time for aggregate/asphalt producers and concrete recyclers, while offering numerous advantages compared to track plants. RipRap was specially designed to provide aggregate producers with the ultimate portable plant in high-production screening – featuring two, 5-ft., adjustable grizzly decks and the widest feeder in the industry at 67-in. x 24-ft. The plant’s reversible cross conveyor allows for a variety of on-site set-up options to further accommodate producers’ needs and help expand their product portfolios. RipRap is available in both diesel and electric.
Eagle Crusher, www.eaglecrusher.com
FLSmidth’s Traylor single- and double-toggle jaw crusher installations include some of the largest primary jaw crushers ever built. Traylor jaw crushers are capable of withstanding the extreme conditions of the mining industry. Both the single- and double-toggle jaw crushers are constructed of heavy duty fabricated plate frames with reinforcing ribs throughout. The crusher’s components are of high strength design to accept high power draw. Manganese steel is used for both fixed and movable jaw faces.
The TC-20 track impact crusher from IROCK Crushers combines a larger feeder, a high-performance four-bar impactor and heavy-duty components for exceptional efficiency, reliability and precision. The TC-20 produces a uniform, cubical product, and IROCK’s hydraulically adjustable aprons provide better control over sizing. The unit has the versatility to process soft to medium rock, recycled concrete and recycled asphalt. The rotor measures 40 in. x 56 in. and can process a variety of materials up to 24 in. in diameter. A 440-hp Caterpillar C-13 ACERT Tier 3 engine powers the impact crusher, which can process up to 500 tph.
Keestrack offers its new H4 tracked cone crusher. The light and compact plant features the KT-H4 cone crusher, adapted and supplied by a world-leading cone specialist. The fully automated unit produces up to 250 tph at maximum feed sizes of 7-in. The wide variety of concaves allows a high flexibility in secondary or tertiary production of highly defined end fractions. To optimize production, the plant can be optionally equipped with a pre-screen with fines chute and – as a world’s first – with a highly efficient three-deck secondary screen module with recycling conveyor for closed-circuit processing. A big feeder volume, large screening areas and high stockpile capacities allow very productive operations as in-line or stand-alone unit. The H4 features a hybrid diesel-electric drive concept [345 kW Diesel (Tier 4f)/330 kVA Genset/135 kW E-drive for crusher]. This guarantees economic fuel consumption and ease of maintenance through the wide use of electric motors on screens and conveyors. The recently introduced full-hybrid version H4e even allows full electric operation through mains or an external genset. An additional electric motor/hydro pump then supplies the hydraulic driven feeder, the secondary screen module, the tracks and all hydraulic cylinders.
KPI-JCI, Astec Mobile Screens
Kolberg-Pioneer Inc. (KPI), Johnson Crushers International (JCI) and Astec Mobile Screens offer modular structures to their system offerings. KPI-JCI and Astec Mobile Screens offer a complete line of pre-engineered modular crushing, screening and conveying components for a variety of applications. The modular systems feature bolt-together design for simple installation, smaller site footprint and easy access for maintenance compared to normal stick-built systems. These systems are available in 150- to 500-tph configurations to meet production needs and allow for incremental growth. The cost-effective modules are easily transported in standard shipping containers or flatbed trailers for quick reassembly at different sites.
KPI-JCI and Astec Mobile Screens, www.kpijci.com
Lippmann’s wheel-mounted portable jaw plants provide a durable, high-production jaw crusher on a stout, easy-to-move truck frame. These plants also feature the rugged Lippmann feeder, capable of handling side or rear loading from various types of equipment. Lippmann also offers multiple discharge conveyor configurations, including a front discharge configuration, an extended front discharge configuration, and a side discharge configuration. Combining standard configurations for various applications with a willingness to develop custom solutions for every plant gives each customer the kind of flexibility that translates into success in the field.
Masaba stocks all types of portable plants for crushing: rock crushing plants, cone crushing, for a single crusher operation, jaw crushing, for an all-in-one crusher, HSI (horizontal shaft impact), perfect for secondary crushing, and VSI (vertical shaft impact), a specialized crusher. Masaba plants are fabricated with quad-axle, stepped-frame chassis and are road portable, giving strength and versatility. Work with its engineers to find the right crusher for your quarry needs, or put together a full plant operation for a complete aggregate solution. Masaba partners with several major brands of crushers including Raptor, Metso and Cedarapids. Masba can standardize your portable crushing plant with components of the same company or it can work with you to build a fully customized plant featuring elements from several different manufacturers.
With 1,270- x 735-mm (50- x 29-in.) single-toggle jaw (the widest jaw in its class), the J50 places McCloskey International at the fore of portable crushing machinery. Maximum productivity is delivered through the enhancements to the jaw box including heavier flywheels and optimization for all crushing applications. The J50’s jaw speed leads to better reduction and material being processed faster through the crushing chamber. McCloskey International has a proven reputation for designing quality, best-in-class equipment and the J50 Crusher brings even more power and productivity together in one machine. With its class-leading throughput and capacity and the largest stockpile height in its category the J50 crusher continues to push the boundaries of industry performance.
McLanahan’s Universal VersaCap Impact Crusher is designed with both safety and profitability in mind. Its low-profile design is excellent for portability. Each Universal VersaCap is engineered for high productivity, as well as low maintenance and downtime. This highly versatile design works in a broad scope of applications, including C&D recycling, aggregate, and mining applications. They feature interchangeable components that can be custom-fit to each producer’s specific application. Two-curtain designs are standard but can be field modified to a three-curtain design to include a third curtain assembly with a fully lined and spring loaded hydraulic-shim adjustment. Curtains automatically retract for relief from uncrushable tramp iron, immediately resetting to the original gap setting. Wrench-free curtain adjustment is standard with simple hydraulic-shim adjustment on all curtains. Shims provide a visual indicator outside the impactor for improved maintenance planning.
The Metso MX cone crusher is based on the patented Multi-Action crushing technology, which combines the piston and rotating bowl into a single crusher. The new crusher provides a giant leap in profitability by cutting operational costs 10 percent and enabling 10 percent higher uptime compared to traditional cone crushers. Features include:
- Up to 70 percent wear part utilization. Optimal cavity design, stroke direction and an effectively distributed crushing action lead to the ultimate rock-on-rock crushing motion.
- Multi-Action technology. The Metso’s patented Multi-Action technology is a revolutionary way to optimize the crusher setting and wear compensation in real time, requiring no human actions.
- Selective production. The smart optimization of Multi-Action technology is the key advantage to reach the desired end-product shape and particle size distribution while eliminating waste.
- Safe and simple. Metso MX is designed to be the safest cone crusher to operate and maintain. During the crushing operation, all moving parts are inside the crusher. Lifting devices and hydraulic tools make maintenance simple and safe.
In the past, the limits on impact crushers have been their high cost to operate when the material is hard and abrasive. Historically, hard rock such as granites, quartzite and other materials with high abrasives content have caused severe wear on the crushing members of vertical shaft impact crushers making them prohibitively expensive to operate. REMco VSI RockMax crushers are autogenous vertical shaft crushing machines designed to operate as third stage crushers in the processing of all types of rock, ores and minerals. RockMax crushers can be operated in either open or closed-circuit. Closed-circuit operation is recommended in order to achieve the lowest net operating cost, best particle shape and the highest production. RockMax crushers are intended for producing crushed products between 1 ½- to 3/8-in.
Targeted at the most demanding of aggregate producers, the compact Sandvik QS331 has been designed to accept large feed sizes and achieve high production capacities. This produces benefits for customers by delivering improved productivity on such applications as Type 1, crusher run or in primary gravel crushing. The “S” type gyratory cone crusher has been incorporated into a self-contained, diesel driven track-mounted plant, providing producers with superior performance and high product quality, but in a fully mobile version. Many direct customer benefits are delivered as the “S” type gyratory cone is able to accept a feed size up to 90 percent larger than current standard cones. This enables maximum productivity to be enjoyed from your primary crusher, or even facilitates the use of the “S” cone as a primary crusher itself on gravel applications. The Sandvik CS430 cone crusher truly sets the 36-ton mobile Sandvik QS331 apart: with a choice of three concaves, and four bush settings to control the closed side settings and material gradation, the Sandvik QS331 delivers ultimate flexibility. Due to the large feed acceptance, jaw crusher production may be optimized by opening the CSS, thereby also reducing fuel consumption and wear.
The CST Cone Crusher is a large, track-mounted, portable crusher plant designed for secondary crushing of hard rock into cubical sizes. Mounting a heavy built “quarry duty” cone crusher on a wireless remote controlled track-mounted plant is rare and the placement of a shaker screen to pre-screen the fines out prior to entering the crushing chamber is unique. This feature increases overall production and significantly reduces wear costs. Features include:
– 51-in. (1.3m) “quarry duty” standard head cone crusher.
– Hydraulic tramp relief and hydraulic adjustment.
– Single deck 5- x 7-ft. (1.54- x 2.1-m) screen to remove fines prior to crushing.
– Caterpillar C-9 ACERT 350-hp (261-kw) engine.
– Cattron wireless remote control operation.
– 42-in. (1.07m) main belt.
– 10-ft., 10-in. (3.3-m) discharge height.
- Unique Features:
– Smooth Start Technology – U.S. Patent #6,669,026.
– Single deck fines screen.
– Tramp relief and hydraulic adjustment of crusher.
– U.S.-made Grade 80 steel construction.
– Heavy-duty tracked undercarriage.
Screen Machine, www.screenmachine.com
Stedman multi-row cage mills pulverize, grind, crush and/or mix abrasive and non-abrasive materials – wet, sticky or dry. The cage mills offer:
- Fine, uniform grind up to 240 tph.
- Reversible for extended wear life.
- Single-, two-, four-, or six-row cage assemblies are available.
- Optional heaters and air cannons are available to reduce buildup of wet and sticky materials.
- A quick-opening housing provides minimum downtime during maintenance.
- Cage inspection requires about five minutes, complete change-out in as little as one hour.
- Aglime, coal, fertilizer, salts, potash, corn, aluminum dross, grains and gelatin applications.
- Full-scale toll processing and testing available.
Stedman Machine Co., www.stedman-machine.com
Superior offers the Liberty jaw crusher. Functioning as a primary crusher, the unit compresses material in stone, concrete, asphalt and ore applications. Superior acquired the original design in their 2015 acquisition of Clemro Western. After collecting customer feedback, Superior engineers redesigned the unit and added a number of new features. According to the manufacturer, the Liberty jaw crusher is engineered with an aggressive nip angle that maintains the machine’s ability to consistently grab and process material at a high level of efficiency. In addition, a set of integrated lifting points are designed into the jaw dies for safe replacement or installation. Other unique features include pitman toe protection. This replaceable component offers an insurance policy if wearing occurs in the pitman fabrication. Furthermore, the unit’s motor is frame-mounted, allowing a smaller footprint and freeing up deck space for maintenance. More maintenance time is freed with the addition of hydraulic tensioning system and hydraulic wedge adjustment. Liberty jaw crushers are manufactured in feed openings of 18- x 36 in. to 36- x 48 in.
Superior Industries, www.superior-ind.com
Telsmith promoted its Hydra-Jaw Crusher at AGG1 2018 in Houston. To showcase the Telsmith promise that “The Extra Mile Isn’t Extra. It’s Included,” the team explained how Telsmith goes the extra mile with their concept to completion services for the Hydra-Jaw Crusher, which provides ease of maintenance and durable components for increased uptime and safety. The Hydra-Jaw is ideal for a number of processing applications such as aggregates, mining, and recycling, and is available in three configurations; stationary, track and wheeled portable plants. The jaw series includes four models, the H2238, H2550, H3244 and H3450 Innovative in its simplicity, the Hydra-Jaw toggle tensioning system saves time and costs by eliminating the need to adjust springs when changing the setting. A simple mechanical spring assembly secures each hydraulic toggle end to its respective toggle seat. By securing each end independently, there is no need to adjust the springs when the setting is changed. Quick to assemble and reliable in operation, the assembly requires no special tools or maintenance. The core of the Telsmith hydraulic toggle system is the robust Hydra-Jaw hydraulic cylinder. Custom built specifically for the crushing environment, the cylinder incorporates a large piston for high crushing forces and an “oversized” rod for stability and strength. The unique bushing and seal are designed to hold up to the rigors of constant crushing in a dusty environment to deliver long service life with minimal maintenance.
Terex MPS’s CRC1150S closed-circuit crushing plant features the TC1150 300-hp Terex Cone Crusher and the TSV6203 6- x 20-ft. triple-deck screen. The CRC1150S offers big capacities in a highly portable plant. Key features include:
- TSV6203 triple-shaft, high g-force screen.
- TSH6203 triple-oversized, surge buffering, cone-shaft, high g-force, triple-deck screen.
- Compact low maintenance “walk-over” flex shaft screen drive.
- Quick release, hopper with integrated overflow chute system.
- Tri-axle suspension with 57.5 in. axle spacing.
- 42-in., 20-hp main feed conveyor, impact rollers in feed hopper, rubber discharge hood.
- Metal detector on main feed conveyor.
- 36-in, 10-hp under-crusher conveyor with diverging hopper.
- 54-in., 10-hp under-screen fines conveyor
- Simple transfer and mid-plant product chutes.
- Maintenance friendly chute liners; bolted side liners and keyed bottom liners.
- Four-section blending system to mix second and bottom decks products.
- All motors including 300-hp crusher motor.
Terex MPS, Terex MPS, www.terexmps.com
The Terex Finlay I-140 direct drive horizontal impact 50- x 48-in. crusher with variable speed gives operators unprecedented levels of production in both recycling, mining and quarrying applications. The robust and proven Terex CR032 chamber gives 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. The flow of material has been significantly improved by increasing the width of components as the material moves through the machine. The machine features an advanced electronic control system that monitors and controls the speed of the rotor and regulates the heavy duty vibrating feeder (VGF) with integrated pre-screen to maintain a consistent feed of material into the impact chamber for optimal crushing conditions. Material from the integrated pre-screen can be diverted to a stock pile via the optional by-pass conveyor, or it may join the crushed product on the main belt. The standard hopper capacity of 6 m³ (7.5 yd.³) places the machine at the forefront in this competitive market sector.
Terex Finlay. www.terexfinlay.com
Terex EvoQuip showcased the Cobra 230 at AGG1 in Houston. No matter what line of work you’re in, whether it is construction & demolition, asphalt recycling, quarrying or contract crushing, the Cobra 230 will enhance your profitability. The rapid set up time and intuitive control system on the Cobra 230 enables the operator to be crushing minutes after unloading the machine. The operator can also adjust the crusher setting easily without the need for any tools using the user friendly hydraulic assist that is standard on the machine. There are a number of key design features in the Cobra 230 that ensure an optimal material flow through the crushing process. As material moves from the feeder through the impactor onto the product belt each section becomes wider ensuring an unrestricted flow. The excellent under crusher clearance, the short distance from the crusher discharge to the magnet and the ability to lower the product conveyor while running make the Cobra 230 the ideal machine in all applications. The Cobra 230 uses an extremely fuel efficient and high performing direct drive system to power the impact crusher. This along with the two independent hydraulic controlled aprons allows the operator to optimize the material throughput and reduction whilst ensuring the best fuel efficiency.
Terex EvoQuip, www.terex.com/EvoQuip
The high-performance Powerscreen 1000 Maxtrak has been designed for direct feed applications without pre-screening on clean rock. At its heart is the Automax cone crusher which provides an excellent reduction and product cubicity for the production of high quality aggregate and sub-base material. Hydraulic release capabilities ensure that any un-crushable material entering the chamber is safely discharged. The product features:
- Output potential up to 253 tph.
- Automax crusher technology.
- Accepts clean all in feed.
- Excellent product shape.
- High reduction ratio.
- Cone feed box level control to maintain choke feeding.
- Hydraulic crusher setting.
- Cone overload protection.
- Heavy-duty chassis and track frame.
- Metal detector.
- Dust suppression system.
- Economical to operate with a highly fuel efficient direct drive system.
- Fitted with Powerscreen Pulse Telematics system.
Terex Powerscreen, www.powerscreen.com
CT Series jaw crushers from Weir’s Trio crushing brand are offered with an extensive range of sizes suitable for mobile or stationary jaw crushing applications. The CT Series jaw crushers incorporate a steeply designed toggle seat for the efficient nip angles and high production rates. The primary models offer hydraulically adjusted wedges for quick and easy adjustments to closed side settings. All CT Series jaw crushers incorporate a fixed jaw die configuration with a wrap-around design that protects the crusher frame. CT Series jaw crushers are heavier in class than many other jaw crushers on the market. The extra weight leads to improvement of their mechanical capabilities. CT Series jaw crushers have a steep nip angle that provides a more aggressive bite. The steep nip angle and optimized toggle help to the reduce the machine resonance which allows the CT Series jaw crushers to run smooth and steadily, improving the life cycle of mechanical and hydraulic parts.
Weir (Trio) www.global.weir/brands/trio/crushing-equipment
Roll crushers are simple in design and construction, long lasting, economical and versatile, according to Williams Crusher. Roll crushing surfaces operate at a fixed distance apart, as opposed to the continually changing distances in a jaw or cone crusher. Product size is much more consistent. Both oversized pieces and fined are minimized. Wet, sticky materials are more easily handled. The rolls act as flywheels, contributing to smooth operation and efficient use of power. Roll crushers are low in profile and relatively easy to install. They can be fed with a minimum of headroom, or even choke fed. Adjustments are simple. Internal parts are readily accessible. Typical feed materials include bauxite, cement clinker, chalk, cinders, clay, coal, glass, gypsum, limestone, burnt lime, rock salt, sandstone, shale, sulfur ore, sea shells and sewer sludge clinker. Single-roll crushers, sometimes called lump breakers, can also be used for breaking frozen or agglomerated materials.
Williams Crusher, www.williamscrusher.com
High-performance and enhanced aggregates processing technology built into Kleemann products from Wirtgen America, like the Tier 4 final-compliant Mobirex MR 130 Zi EVO2 impact crusher shown at AGG1 2018 in Houston, and the smaller MR 110 Zi EVO2, are boosting productivity and product quality for operators. These mobile impactors can be equipped with optional, highly productive secondary vibrating screen with extra-large screening surface mounted on the discharge conveyor. This secondary screening unit can produce spec material, potentially eliminating the need for a separate screen. The feeding unit has hydraulically folding hopper walls and locking system, which speeds setup. A vibrating, independent double-deck prescreen between hopper and crusher eliminates fines from the product flow before they ever enter the crusher, reducing wear and cutting fuel costs. These crushers feature:
- A new inlet geometry, which allows even better penetration of the material into the range of the rotor.
- An extremely efficient direct drive, with which the machines are equipped.
- A latest-generation diesel engine transmits its power almost loss-free directly to the flywheel of the crusher.
- The Kleemann Continuous Feed System (CFS) manages a more equal loading of the crushing area.
- The MR 130 Zi EVO2 is equipped with the new SPECTIVE control system. The use of clear symbols makes all plant functions recognizable at a glance.
- Hydraulic Gap Adjustment.
- With these new Mobirex impact crushers, the fully hydraulic adjustment capability of the crushing gap permits greater plant uptime, while improving quality of end product.
Wirtgen (Kleemann), www.wirtgen-group.com/america