Recent Product Introductions and Improvements Give Aggregates Producers New Options to Move and Handle Material.
By Mark S. Kuhar
At an aggregates operation, conveyors, stackers and ancillary equipment are important cogs in the production process. Here are some of the latest developments to keep material moving.
ASGCO’s line of Tru-Trainer tracking idlers now includes the Dual Return model to accommodate high speed and tonnage associated with aggressive mining operations. The tapered ends sense any potential belt alignment issues and initiate the tracking corrections to take place instantly, without the need for edge contact rollers.
A seize-proof external central pivot mechanism was designed, eliminating the need for a single, large drum, and enabling a concentric and balanced rotation to be achieved. This proprietary design also makes Dual Return an excellent choice for reversing belt applications.
This integrated design also extends bearing life and is proven to withstand the toughest mining applications worldwide.
“With the effectiveness of our Tru-Trainer flat return, it was natural to develop a variation that could handle the intense demands of high speed and high tonnage operations. We designed the Dual Return for those exact specs and have seen tremendous results in virtually every application,” said Vice President of New Business Jeff Jurasits.“The urethane version incorporates rollers that withstand even the most abrasive conditions while continuing to provide excellent grip.”
Available for 48- to 96-in. belt widths, the Dual Return can accommodate conveyor belt speeds that exceed 800 fpm and/or greater than 1500 piw. Installation can be performed at the location of existing idler attachment points and can be configured to both push down or pull up depending on the belt’s operation.
Incredibly powerful and rugged Eriez SE Series 7000 Suspended Electromagnets remove damaging tramp metal from coal, limestone, sand, gravel, municipal waste, wood products, recycled materials, other ores and almost any nonferrous material conveyed in heavy burden depths on flat conveyors or chutes. Twenty-three magnet sizes, 69 standard models and hundreds of designs are available to suit specific application requirements.
Approved by leading safety agencies, these air-cooled, dry-type electromagnets require no coolant fluids and reduce power consumption by up to 50 percent. UL-Listed construction is offered on units for use in hazardous, dusty and gassy locations.
Eriez manufactures both Manual Cleaning (MC) and Self Cleaning (SC) models. All SE Series 7000 Suspended Electromagnets are backed by Eriez’ exclusive five-year coil warranty.
SE Series 7000 Suspended Electromagnets feature several new design elements such as state-of-the-art, adjustable oil expansion tanks that prevent condensation and protect against hot spots to extend coil life.
An array of special options are also available, including upgraded coil design for elevations greater than 3,000 ft. above sea level, high fire point coolants, zero speed switches, dust covers, pulley guards and controls, permanent extensions and monitoring devices, force-cooled units for high temperature applications and more.
Kolberg-Pioneer Inc. (KPI), which goes to market with Johnson Crushers International Inc. and Astec Mobile Screens Inc., offers a 170-ft. SuperStacker, its latest model of telescoping stackers.
The 170-ft. SuperStacker is a new addition to the product line. SuperStackers minimize material segregation by stockpiling in layers. Tail end counterweights and its wide operating footprint provide safe and efficient stockpiling, while also maximizing stockpile capacity.
The new SuperStacker also features an updated, more user-friendly Wizard Touch automation control system.
”The improved Wizard Touch system is designed to prevent material segregation and degradation,” said product manager Jodi Heirigs. “The refined system features an expanded selection of stockpile options and is capable of inputting multiple stockpile recipes for operation diversity.”
“Our SuperStacker is not just high-performing and easy to use, but durable as well,” Heirigs said. “By choosing the SuperStacker, our customers save significant amounts of time, which in turn saves them money and increases their profitability.”
The SuperStacker is available in 10 different sizes for a range of production capacities and is available in a containerized option.
As bulk-handling equipment suppliers continue to make use of new and evolving technologies to develop “smarter” conveyor systems, Martin Engineering has introduced data tracking with QR codes on its belt cleaners.
Customers benefit from regularly scheduled inspections by factory-trained and MSHA-certified technicians, providing operators with easy access to a wealth of data on the application, operating environment, service life and condition of conveyor components, updated on every belt cleaner maintenance visit.
By avoiding the common “run it until it breaks” approach, a Martin Engineering proprietary smartphone app helps maximize performance and service life – while minimizing carryback and spillage – to improve safety and reduce unscheduled downtime.
Currently being implemented in select markets around the world, the new tracking program captures a wide array of information to create a detailed record on all components. Date codes are imprinted on the blades during manufacture – very important for urethane because it has a limited shelf life – and technicians also affix tags on existing equipment to begin monitoring condition and recording observations.
Conceived as part of Martin Engineering’s factory-direct “Mr. Blade” program, technicians perform regularly-scheduled inspections and adjustments, with an 18-point operational assessment from head pulley to tail pulley and a report for each visit. The visual inspections include the condition of pulleys, belts and idlers, as well as belt tracking, sealing, support and containment. This constant vigilance contributes to greater safety, efficiency and dependability of the conveyor systems, minimizing hazards and unplanned outages.
With the new tagging and capture ability, component data can be recorded and analyzed in much greater detail than ever before. Every inspection a technician makes will be logged, along with operational factors such as the material being handled, conveyor speed and remaining wear life, as well as visual observations and other info. The overall goal is to deliver more effective control of bulk material, improving predictive maintenance scheduling and contributing to a lower total cost of ownership.
The TS4080 stacker from McCloskey International is the newest addition to the materials handling division. It was shown at this year’s Steinexpo show in Germany.
Designed to allow operators to stockpile/transfer material directly from mobile crushing and screening plants it offers the flexibility and mobility needed to ensure that the stockpiling process is as fast and efficient as possible, while eliminating the use of a loader and double handling of materials.
The TS4080 can be containerized for transport, with minimal setup time, substantially reducing transport costs, according to the company.
McCloskey stackers are designed for strength and reliability, and are available in a variety of lengths and belt sizes. “With more than 30 years of experience in stacker production, we’ve introduced features that continue through the line today including a patented counter weight design and heavy-duty frame,” the company said.
Easy-to-setup and easy to use, the stackers feature hydraulic main lift and top fold.
Sandvik’s new addition to its scalper range is the Sandvik QE441 Free Flow, a versatile and highly efficient solution for processing difficult-to-screen materials and products with high moisture contents.
The Sandvik QE441 Free Flow provides a mobile solution for handling sticky, moist and wet materials with a high percentage of fines. It is your ideal solution for processing materials such as soils, aggregates, ores, waste, biomass and other waste derived fuels including products with high moisture contents.
“We have designed this unit based on the sturdy crusher-style chassis of our class leading Sandvik QE441, combined with a highly productive and aggressive double deck Free Flow screen,” the company said. “The heavy duty scalping screen allows you to process large un-screened material on the rigid scalping top deck, whilst providing a fine screening solution on the dual motion lower deck. The powerful snapping of the bottom deck media generates an active ‘flip-flow’ movement which generates a huge throw that propels material upwards and outwards separating material as it does so and thereby eliminates any plugging and blockages. This results in the processing of more sellable products and less waste.”
Sandvik QE441 Free Flow has been designed with the same user-friendly features of the 1-Series screens. These include Sandvik’s easy to use control system and user interface with sequential start, whilst two speed tracking will help to reduce travel time between jobsites. Sandvik QE441 Free Flow offers increased plant durability and operator comfort, without sacrificing on performance.
With a large choice of screen media and a wide range of adjustable throws and speeds available, this enables the Sandvik QE441 Free Flow to be configured to suit the specific requirements of the application. It complements the company’s Premium jaw crushers and QI341 Prisec impact crusher, and can also work as a stand-alone unit.
Key features of the Sandvik QE441 Free Flow are:
- Heavy-duty modular top-deck scalping screen allows you to process large un-screened material, whilst a dual motion Free Flow screen separates fines and sticky material on the bottom deck.
- Aggressive Free Flow screen with wide range of adjustable throws and speeds enables the bottom deck to be tailored for numerous applications.
- Highly efficient and easy-to-use electrical control system with color-coded numerical push buttons for ease of operation.
- Heavy duty crusher-type chassis designed to accommodate interchangeable side conveyors and compatible for two-way or three-way split configurations.
- Modular design screen box for easy replacement of screen media.
- Feeder load sensing facility to prevent blockages and unnecessary downtime.
- Capable of operating in the most hostile environments.
- Massive stockpiling capability through integrated hydraulic conveyors.
- Spacious and easily accessible hydraulically folding maintenance platforms.
Superior Industries Inc. expanded its conveyor components accessories line with the release of its new Impact Cradle. The curved design of the Impact Cradle eliminates the space between the belt and bed, adding extra protection.
Designed to fit into an existing idler mounting footprint, the Impact Cradle is built to receive the blunt force of material flow at transition points in conveying systems, lessening the wear on the conveyor belt. Without support, conveyor belts are vulnerable to rips, tears and other impact related damage. The Impact Cradle’s thick urethane segments absorb shock and dissipate contact energy, reducing conveyor belt wear and tear.
The company also added a new Speed Sensor to its conveyor component accessories offering. The Speed Sensor monitors the speed of a conveyor belt by producing electronic pulses interpreted by a PLC or Superior Speed Sensor module.
The unit’s sensors help operators control conveyor shutdowns, monitor belt slippage, and trigger warning systems.
Fitted for CEMA C and D idlers, Superior Speed Sensors are available for belt widths ranging from 24 to 72 in. and are protected by a two-year components warranty. They can be mounted on a clean side roll, return roll or troughing wing roll.
Van der Graaf
For the past 30 years, aggregate plants have been adapting the drum motor or motorized pulley to drive their belt conveyors. Although the drive of choice for quarry conveyors has been the external mounted motor and gear box, the drum motor has been gaining popularity due to the all-enclosed design that protects all vital components such as the electric motor, gear reducer and bearings from the environment.
Any mechanical equipment that is used in a quarry has to withstand harsh, abrasive and dusty conditions. Abrasive dust ultimately finds its way into the air ducts of the electric motor, cutting the airflow substantially, which causes the motor to overheat resulting in a complete motor failure. It also penetrates the bearing, seals, couplings and other mechanical conveyor components, creating conveyor failure, which results in loss of production.
The Van der Graaf motorized drum is designed to address all the above points of failure. The extreme duty series drum motor for aggregate use, features an all enclosed design. Bearings, electric motor and all gear reducer components are inside the drive drum (head pulley) working in an oil bath that ensures optimum lubrication and longevity that averages four times the life of a standard external motor/gear box drive arrangement.
Since all bearings are housed inside the drum there is no need for maintenance, such as re-greasing the bearings, noted the company. The Van der Graaf drum motor features standard class “H” inverter duty motor windings for extreme duty applications, and the VPI (Vacuum Pressure Impregnation) process protects the motor under high vibration conditions.
The inline design of the motor and gear reducer results in a 96 percent mechanically efficient conveyor drive that saves an average of 30 percent on the electrical consumption.
Van der Graaf, www.vandergraaf.com
Respirable Crystalline Silica
Companies governed by OSHA are now required to follow rules of compliance by using a personal dust monitor worn by a trained employee to monitor the amount of respirable crystalline silica (RCS) and determine whether the exposure is under the average “action level” of 25 µg/m3 (micrograms of RCS per cubic meter of air). MSHA could follow suit in the future.
Plants must protect workers if they have an amount of RCS dust above the PEL of 50 µg/m3, averaged over an eight-hour day. To control these levels, OSHA provides guidelines regarding methods of compliance, advising companies to:
- Use engineering controls – These include isolating dust in sealed chute systems and dust collectors, and/or using water-based atomized suppression systems.
- Provide respirators – Compliance cannot be achieved by respirators alone, but respirators must be provided for use in areas where engineering controls cannot adequately limit exposure.
- Limit worker access to high exposure areas – Limit access to areas where workers could be exposed to dust concentrations above the PEL.
- Develop a written exposure control plan – Have it available along with monitoring results.
- Offer medical exams to highly exposed workers – Review the regulation for compliance details.
- Train workers on silica risks and how to limit exposures – Workers should be able to identify to OSHA inspectors, the dust control supervisor and the compliance details when asked.
Source: Martin Engineering and BossTek.