Increasingly, flexibility and equipment uptime are at a premium as aggregate producers try to get the most profitability from larger and larger quarries.
Increasingly, flexibility and equipment uptime are at a premium as aggregate producers try to get the most profitability from larger and larger quarries. Key equipment components of this pursuit of profitability are portable plants of various types ó crushing, screening, washing, separation or a combination of all of these processes.
Crisp Industries describes the increasing popularity of portable plants as the most dramatic trend in the industry. From its view, the current industry direction is for quarry operators to invest in portable equipment due to its production efficiency, lower capital cost and the advantages of portability. The mobility offers several advantages.
The first advantage is to locate the plant at the deposit; second, reduce the cost of transportation; and third, the ability to move between operating locations. The result is a lower cost per ton. Locating the plant at the deposit eliminates haulage costs. The high cost of highway transportation has led to the development of on-site processing, especially in the recycling and demolition industries. The cost-per-ton-a-mile basis often will exceed the cost to process, which has prompted producers to eliminate hauling demolition material to a stationary plant.
Mobility also allows producers to keep plants at full utilization by relocating to another jobsite and to serve the area which, otherwise, could not be served by individual stationary plants. Below is a review of what manufacturers are currently offering the industry in portable plants.
PRODUCE AT LOWER COST PER TON
PTSC Series screening plants from Astec Mobile Screens are designed for in-line material processing, durability for site-to-site movement and extra protection in high-impact areas for longer machine life. The units reportedly accomodate fines removal in pre-screening applications.
Astec also has combined PEP Duo-Vibe dual-frequency screen with a triple-deck horizontal screen onto one portable chassis. The PEP Duo-Vibe removes the majority of fines first, reportedly resulting in high production and efficiency.
Crisp Industries Inc.'s Pro-Agg multi-chassis portable plant system allows customers to change layouts ó typically consisting of a crushing plant, screening plant, wash plant, conveyors and a control center ó depending on desired production material.
The manufacturer also cites the design of the Pro-Agg series, which facilitates maintenance, tear-down and setup. The units are designed for strength and durability, allowing less bulk and reducing the need for heavy and expensive support equipment. In addition, the multi-chassis configuration of the Pro-Agg is intended to provide superior portability and versatility, the company says.
Crisp Industries Inc., (800) 315-0871, http://www.crispindustries.com
Stedman says that its 4-Row Cage Mill allows aglime producers to meet most state aglime specifications by economically producing aglime to any specification. Feed does not have to be dry, according to the company, and clogging, jamming and plugging are eliminated.
Material is loaded into the feed hopper or hoppers, conveyed to the cage mill, crushed and discharged out the side. Discharge requires no screens or grate bars, eliminating the need to clean or replace discharge screens or grate bars. The unit is available with capacities from 5 to 100 tph.
Stedman, (800) 262-5401, http://www.stedman-machine.com
Mormak's screen plants are designed and built according to the customer's needs, the manufacturer says. Features include a heavy-duty main frame and all supporting structural members; screens in sizes from 3 by 6 feet to 7 by 24 feet in various configurations; single-, double- or triple-deck screens; under-screen discharge conveyors designed for high output. Other features include reversible cross-discharge conveyors; chutes in customized locations and lined per customer requirements; under-screen hopper with flashing to the belt and lined; access ladder, walkways, toe board and hand rails/chains on three sides of the screen; left-hand or right-hand screen drive motors; required blocking legs; and axle assemblies designed to suit plant weights.
Mormak Equipment, (250) 542-7350, http://www.mormak.com
Terex Cedarapids introduced a new portable aggregate-processing system called MACS, Mobile Aggregate Crushing System, whose units are highly integrated to optimize production and minimize setup time, according to the company. The system utilizes larger crushers and screens than are typically used in track-mounted or wheeled plants, and the unique trailer designs can be permitted for travel throughout most of the continental United States.
Interplant conveyors are designed into the units so that separate transfer conveyors are not required. Folding conveyors and walkways are set up using on-board hydraulics, thus eliminating the need for cranes or lifts. Also, large hydraulic support legs level and stabilize the units to speed setup.
Cedarapids Inc., http://www.cedarapids.com
The McCloskey S130 flatdeck screener, which utilizes High Energy Screen technology, is designed to meet the demands of operators who require significantly more screening capacity than a 10- or 11-foot screenbox, but not the massive throughput of a 20-foot plant. Operations served by the S130 include quarrying, crusher circuits, sand and gravel, and coal screening. The unit is equipped with 130 square feet of screening area across a 14-inch-by-5-foot top deck and a 12-by-5-foot bottom deck.
The screen box can be hydraulically angled between 25 and 38 degrees for adaptability, while the higher angle settings permit high production levels in sand screening. Optional configurations include track-mounted, wheel-mounted, a hydraulically lifting shredder unit and single- or double-deck livehead. Options include a 15-foot long hopper with 13.2-cubic-yard capacity and a detachable tandem axle transport bogie.
McCloskey International, (877) 876-6635, http://www.mccloskeyinternational.com
The XL400 suits a secondary crusher following a large jaw crusher to yield more usable and saleable aggregates per ton processed, says FLSmidth Excel. The portable machine accepts primary crushed ore with greater flexibility due to its high pivot point crushing action and large feed opening. With the larger 52-inch head diameter, the XL400 reportedly can accept a feed up to 25 percent larger than a smaller crusher can accept, with less throw or head diameter. The XL400 also suits tertiary crushing when making concrete and asphalt products as it is designed to provide high gradation control and a cubical product.
The Raptor cone crushers utilize bronze sleeve bearings for all moving load bearing or load transmission internal components. Features include countershaft bushings for operation over a wide range of speeds without bearing failure, thrust bearings to support a rotating eccentric, a head bushing and eccentric bushings that absorb normal operating loads and intermittent overloads such as tramp metal events, and a socket liner for support of the head and dominant vertical loads.
The manufacturer's cone crushers use overload-sensing technology to detect crushing force overload; an alarm is activated and the automation system takes the necessary corrective action. This system also can optimize crusher performance with feed control, setting adjustment and monitoring of critical lubrication and hydraulic parameters. The crushers use ìFail Safeî hydraulics to ensure protection from mechanical overload should an accumulator bladder fail. An internal relief valve within the dual acting tramp-release cylinders provides an immediate alternative protection of the Raptor cone crusher from severe and costly structural damage.
FLSmidth Excel, (262) 968-9095, http://www.flsmidthminerals.com.htm
Telsmith's QuarryTrax Model TI6060 is a track-mounted, primary impact crushing plant designed for production of up to 800 tph. The plant features the Telsmith Model PA6060 primary impact crusher and a massive, solid-type rotor set on oversized 220-mm-wide series bearings. With its heavier rotor, the impact crusher yields higher inertia to optimize crushing and consistently crush 40-inch stone or concrete slabs. The unit processes a specification product in either concrete recycling or low-abrasion quarried stone applications.
The plant's PA6060 impact crusher incorporates technologies designed to prevent damage from uncrushable materials and reduce maintenance. The hydraulic system is configured for fingertip control of apron adjustments. A PLC allows operation in an auto mode that returns the apron to preset spacing and tracks wear parts consumption. A hydraulic tilting feed plate clears bridging. Interchangeable and reversible mono-block aprons are incorporated to reduce maintenance costs and downtime.
A Trax-Max control system monitors plant operations including engine systems, hydraulic systems, component settings, alarm conditions and troubleshooting. A handheld wireless remote provides crusher, feeder, engine and conveyor controls from a safe distance. The plant is powered by a CAT-15, Tier III, 540-hp engine. Options include a hydraulic hammer, 18-cubic-yard hopper extensions, a folding conveyor extension and a scrap-metal magnet.
Telsmith, Inc., (800) 765-6601, http://www.telsmith.com
Lippmann's 6500LP crushing plant offers a larger feeder, larger impact crusher and larger screen deck combine to make the 6500LP the highest producing plant for its size in recycle crushing, the company reports. A continuous flow design allows rebar to bend and material to discharge smoothly with the rotation of the rotor for uninterrupted production. A pan feeder under the crusher prevents conveyor belt damage. Flow design handles rebar as long as 10 feet. On-board return conveyors are used, so only two pieces of equipment, instead of four, need to be moved to the jobsite.
The manufacturer also offers its 5062 jaw crusher, two of which reportedly can be installed for mineral and aggregate processing operations for the price of one gyratory installation. In addition, aggregate producers can use the unit in place of a gyratory primary crushing station, according to the company. The hydraulic toggle cylinders can be adjusted under load.
Lippmann-Milwaukee Inc., (414) 744-2565, http://www.lippmann-milwaukee.com
The new TXR5624 portable rip rap plant is the latest addition to Terex Simplicity's new portable line. The self-contained unit features a heavy-duty 56-inch-by-24-foot vibrating grizzly feeder with two 5-foot sections of adjustable grizzly bars. The wheeled chassis is designed with heavy-duty I-beam construction and a triple-axle suspension and the main drive is a John Deere 147KW GenSet.
The primary grizzly section discharges to a æ-inch Hardox-lined chute onto a 30-inch-wide cross conveyor. The conveyor includes a heavy-duty impact bed, 5-inch-diameter Cema B troughing idlers and heavy four-ply belting. The secondary grizzly section discharges to a side chute made of æ-inch plate with æ-inch Hardox bolt-in liners. The feeder discharges to a Ω-inch plate over a chute with æ-inch Hardox bolt-in liners. A hung rubber curtain and a heavy fender on the feed side prevent material spillage and buildup.
The company also has introduced the TXW620HT Horizontal twin screw wash plant. The plant features a 6-by-20-foot TSH Cedarapids screen with a complete spray system. The wheeled chassis has heavy-duty I-beam construction with a triple-axle suspension. The screw is a GreyStone twin 36 inch by 25 foot with two 15-hp drives. The unit also features a hinged slurry box, collection flume and washout. Discharge chutes are lined with Hardox 450 liners. Standard plants have top and middle deck over chutes and a bottom deck cross conveyor.
Terex Simplicity, (989) 288-3121, http://www.simplicityengineering.com
The Rubblebuster SR500 from Pilot Crushtec is a hydraulic-driven machine, with a feed hopper, a crusher and a discharge conveyor combined into one unit on tracks. The crushing component is the heavy-duty BRO605. The electrically powered BRO605 skid-mounted, horizontal impact crusher is designed for a niche market with limited capital expenditure. The equipment has been designed with several updates. A belt scraper (mounted onto the belt feeder) scrapes material into the crusher; it is mounted on self-tensioning rubber elements. The belt feeder drive and stockpile drive are mounted on a heavy duty torque arm arrangement to eliminate coupling failures. A hand pump is provided as part of the closed hydraulic system for filling the hydraulic tank via the return line filter. The power pack is mounted on a sliding frame so that no hoses or cables need to be disconnected.
Pilot Crushtec, http://www.pilotcrushtec.co.za
FastPack cone crushing plants from KPI/JCI feature a small footprint and are designed to yield a lower energy cost per ton. Their portability facilitates in-pit moves to reduce haul costs and makes small jobs economically feasible, according to the manufacturer. A flexible design allows high production of spec material in varying conditions. The units can operate as a complete system or as individual standalone components capable of stockpiling up to seven different products. The primary jaw crusher has a hydraulically positioned hopper. Wings increase hopper capacity and reduce road travel height. The unit can be positioned to feed from either side of the plant. The variable-speed vibrating grizzly feeder features ìRock Solidî main frame construction for increased durability.
KPI/JCI, (800) 665-9311, http://www.kpijci.com
The Nordberg NW Series from Metso Corp. is designed to provide low-cost-per-ton crushing and screening. Built around the Nordberg and Barmac crushers, they include feeders, screens and power installations. They are suitable for two- and three-stage crushing applications and use a king pin arrangement for quick road transportation. The NW Series can be operated as independent units or as a two- or three-stage crushing application, from primary to secondary, tertiary and fine crushing. A portable screen also can be used in the process. It handles applications from coarse to fine crushing and screening.
The Nordberg C Series is based on a modular, non-welded frame construction for superior strength, crushing performance and reliability in demanding applications. The company says it combines a high reduction ratio and increased capacity with feed materials from extra hard rock to recycled materials. Wedge-setting-adjustment system features manual or hydraulic alternatives. NW Series cone plants use GP or HP Series cone crushers, which are designed to combine crusher speed, throw and cavity design. The GP and HP cone concepts use large feed openings with a fairly small cone diameter for larger capacities, especially in secondary crushing. Seven GP and two HP plants are available.
Metso Minerals Industries Inc., (262) 717-2500, http://www.metsominerals.com
Eagle Crusher's UltraMax 1400-45 can replace dual-crusher circuits and is designed to produce uniform, cubical spec product. The exclusive blow bar metallurgy of a solid-steel, 3-bar rotor is intended to offer longer life in harsh aggregate feed material applications while delivering reduction ratios in excess of 24:1.
The plant's feed opening is a full 56 by 35 inches, and the feed hopper capacity is 19 cubic yards per 25 tons. The discharge system features a 42-inch-wide conveyor to screen. An optional separate 6-by-20-foot triple-deck screening plant also is available. A return conveyor with 30-inch by 50-foot conveyor from screening plant to feed hopper, and stockpiling conveyors with three 30-inch by 50-foot smooth belt conveyors, are optional.
Eagle Crusher Co., (800) 25-EAGLE, http://www.eaglecrusher.com
The Water Scalping-Classifying Tank from Eagle Iron Works removes large volumes of water from the feed material for processing of sand. Typical large water-volume applications include dredging, pumping and high silt materials. Hydraulic classification removes the excess sand particles that would otherwise throw products out of specification. Along with removing excess particles, the unit is designed to smooth out feed fluctuations.
A large settling area easily retains fine mesh particles to meet tight construction sand specifications. Other components include two fine material washers, along with a support structure/chassis, electrical and piping in a compact unit configured to be easily maneuvered. The manufacturer says the unit does everything a stationary sand section can do and can be erected at multiple plants. The equipment can be used to produce secondary and tertiary products such as masonry/mortar sand, asphalt sand and golf sand.
Eagle Iron Works, (515) 243-1123, http://www.eagleironworks.com