The Crushing Equation

New Technology + Innovative Engineering = The Latest Generation of Crushers.

By Mark S. Kuhar

It’s not just about taking big rocks and making small rocks anymore. There is a lot of innovation these days in the area of crushing. Companies are relying on a huge influx of new technology and data-generating tools to make crushers more efficient and profitable on every level. There was much on display at the ConExpo-Con/Agg show in Las Vegas this past March.

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.

Keestrack offers the Keestrack-er telematic system as an option on the latest generation of Keestrack screeners and crushers. Key components are a GSM/UMTS modem and a combined GSM/GPS antenna, which are linked through CAN bus to the machines’ main control unit. Real-time performance values (engine/drive speeds, hydraulic pressures, crusher settings, etc.), stored data and the machine’s accurate position are transmitted via GSM network and the local GSM provider’s internet access to the central Keestrack server.

The information memorized and administered on this server can now be safely and reliably retrieved at any time and from everywhere worldwide. The interactive structure of Keestrack-er also allows direct access on the machine’s PLC-controller to fix or update the plant software.

SPECTIVE is a new, intuitive crushing plant control concept debuted at ConEExpo-Con/Agg 2017 by Wirtgen for its Kleemann line of mobile crushers.

The SPECTIVE control concept is easy to understand, and supports the operator in his work, as it’s simple to use:

• The user is supported right from the beginning with the operation of the touch panel. He or she is guided step-by-step through the startup process, then the system starts.
• On the start screen the operator sees a diagram of the entire plant with its adjustable functions.
• The desired function is selected and the operator is guided through all necessary steps with clear instructions.
• If a fault occurs during machine operation, a fault diagnosis is shown on the display. Downtimes are reduced with fault localization, a description of the fault, and tips on its elimination.
• The 12-in. touch panel is not susceptible to dust and is easy to read with the adjustable light and contrast settings, even in strong sunlight. It responds to the touch of fingers, tools, pens or gloves.

Kolberg-Pioneer (KPI), Johnson Crushers International (JCI) and Astec Mobile Screens premiered its innovative hybrid technology at ConExpo-Con/Agg 2017. KPI-JCI and Astec Mobile Screens’ new hybrid technology was released on the GT205 multi-frequency screen and the GT440 horizontal shaft impactor.

“Our new patent-pending hybrid option allows us to service the needs of our end users, allowing them to run either line power or diesel power when needed,” said Ron Earl, vice president of sales and marketing for KPI-JCI and Astec Mobile Screens. “With the integration of our game-changing hybrid technology, producers are able to save up to $25 per production hour.”

KPI-JCI and Astec Mobile Screens also offer a complete line of pre-engineered modular crushing, screening and conveying components for a variety of applications. The modular systems feature a bolt-together design for simple installation, smaller site footprint and easy access for maintenance compared to normal stick-built systems, noted the manufacturers. These modular systems are available in 150- to 500-tph configurations to meet production needs today and allow for incremental growth in the future.

“Our modular structures are built with proven components including the Kodiak Plus Cone Crusher and the Pioneer Jaw Crusher,” said Ian Pendergrass, product development manager for Johnson Crushers International. “Producers can rely on the proven performance and quality they receive from all KPI-JCI and Astec Mobile Screens products and systems.”

The SPECTIVE control concept for Kleemann crushers is easy to understand, and supports the operator in his work, as it’s simple to use.

McLanahan designs universal primary and secondary horizontal shaft impact (HSI) crushers that can be used in the reduction of semi-abrasive minerals and are useful in processing deleterious material. Universal Impactors provide higher capacities than compressive crushers for a lower capital investment and can be used for processing quarried stone and a variety of minerals, as well as recycling C&D materials and more. These high capacity machines are commonly used in both portable and stationary installations. Weighing less than compressive crushers, they are uniquely suited for highly portable and mobile platforms.

McLanahan Universal Impact Crushers offer a higher level of material control through the crushing chamber with fewer moving parts. All McLanahan Universal Impact Crushers are designed for simplicity and safety. Each Universal Impactor features multiple access doors for easy inspection and maintenance, with each point locked and keyed for additional safety. All Universal HSI Crushers are engineered to minimize fly rock, with a chain and rubber curtain at the feed opening to help eliminate rock ejection. McLanahan Universal Impactors also feature optional PLC automated adjustments. Automation in McLanahan’s Universal Horizontal Shaft Impact Crushers increases efficiency and lowers the cost per ton of producing materials.

As part of its Life Cycle Services offering for the aggregates industry, Metso introduced a new digital solution to help further optimize mobile crushing and screening equipment operations and maintenance. Metso Metrics Services is another step in Metso’s digital development, leveraging the possibilities offered by advanced analytics and cloud-based technologies. Through a remote communication device mounted on a mobile equipment, Metso Metrics Services provides a dashboard view of critical operational and maintenance data – from utilization rates to production levels and fuel consumption. With secured access, the solution allows for data-driven decisions that impact crushing operations.

“Making the most out of the assets depends on data you can trust: Having the right information at the right time helps customers make important operational or maintenance decisions to improve uptime as well as utilization and production rates. Metso Metrics Services is designed to collect and provide this crucial data in one easy-to-use interface. Combined with the expertise of Metso’s network for troubleshooting or optional assistance with analysis, the solution provides tools for continuous improvement, both in performance as well as safety and sustainability,” said Giuseppe Campanelli, vice president, service solutions at Metso.

Metso Metrics Services helps to identify underperforming assets and training opportunities, as well as to control maintenance and inventory costs. With the equipment maintenance plan integrated into the solution, plant operators can stay on top of their equipment’s needs – making it easier to anticipate change-outs of spares and wears.

The new Sandvik CS550 cone crusher, launched at ConExpo-Con/Agg, is a powerful secondary stage crusher for 700- to 750-ton applications. In addition to flexibility and sheer tonnage, it offers advanced automation and maintenance features for maximal productivity and uptime. The Sandvik CS550 is a reliable, high-capacity and high-reduction workhorse for the secondary crushing stages. While nothing prevents Sandvik CS550 from being used in mining applications, its primary mission is construction applications. From a practical standpoint this means aggregate quarries, while contractors looking for mobile solutions may also benefit.

Sandvik CS550 achieves up to 25 percent higher reduction ratios compared to similar types of crushers. This enables a more efficient process already in the secondary stage and relieves the tertiary stage of some of its size reduction load, allowing a sharper quality focus. Furthermore, it decreases the recirculating load by up to 50 percent with no decrease in the output of high-value product. In other words, less material goes back into the crusher to be reprocessed. This extends the service life of the wear parts, including particularly the costly manganese steel used in the crushing chamber.

KPI-JCI and Astec Mobile Screens’ new hybrid technology was released on the GT205 multi-frequency screen and the GT440 horizontal shaft impactor.

The Stedman Model H-54 multi-cage mill is best at pulverizing, grinding, crushing and mixing abrasive and non-abrasive materials – wet, sticky or dry. The H-Series provides a finer, more uniform grind; can handle up to 240 tph and are reversible for extended wear life. Stedman cage mills are engineered and constructed to operate at or near-peak efficiency longer, providing a greater return on capital investment over their life. Cage mills are capable of producing a variety of product gradations and easily adjusted by changing the mill’s cages, speeds and rotation.

The H-Series Cage Mills feature a quick-opening housing for quick inspection and maintenance. It allows for minimum downtime for wear part replacement and inspection. Each H-Series Impact Mill housing can accommodate two-, four-, or six-row cage assemblies. This versatility is further enhanced by the capability to vary the number of pins in each row, to vary the rotational speed of each cage in relation to the other(s), and to change the relative direction of rotation of the cages. For wet material applications, air cannons are mounted at the intake and discharge to help prevent buildup of wet material.

Metso introduced a new digital solution to help further optimize mobile crushing and screening equipment operations and maintenance.

Superior Industries Inc. unveiled a new machinery solution for crushing applications called 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 its 2015 acquisition of Canadian-based 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.  Superior’s Liberty Jaw Crushers are manufactured in feed openings of 18 in. x 36 in. to 36 in. x 48 in.  

Superior also debuted its new patent-pending Valor Vertical Shaft Impactor (VSI). The VSI is Superior’s second equipment solution for crushing bulk materials after launching the compression style Patriot Cone Crusher late last year. Impact style crushers, like the Valor VSI, produce a more cubically shaped product.  Incorporating criteria from several of its existing customers, Superior said its engineers produced a stronger, safer and more convenient design. For example, the VSI is equipped with a cartridge style, right angle pinion gearbox. This allows for a safer deck-mounted motor arrangement, which also simplifies access to the drive and its components. In addition, a hydraulically powered lifting lid allows for safe and easy access to the crushing chamber. Maintenance inspectors are protected by a combination of automatic and manual safety interlocks. Also, an innovative autogenous rotor design encourages more rock-on-rock crushing, which greatly extends the life of many internal parts.  Superior manufactures models of its new Valor VSI for rates up to 800 tph (725 mtph) and maximum feed sizes up to 8-in. (203 mm). 

Telsmith showed two brand new solutions, including the latest innovation in T-Series cone crushers. The newest model in the line-up of T-Series crushers that were originally introduced in 2012 is the T500, which is designed to deliver maximum uptime availability while also minimizing maintenance costs. This 500-hp crusher contains a 356-mm (14-in.) maximum feed opening and is capable of processing between 285 and 775 mtph. Features, such as anti-spin and fewer cylinders than competitive crushers provide the reliability that customers depend upon to maximize their processing operations.

The company also featured an all-new portable jaw plant, featuring the H3450 Hydra-Jaw crusher. The 863mm X 1270mm opening of the H3450 Hydra-Jaw is capable of processing up to 598 mtph, while the hydraulic toggle reduces maintenance and lowers operating costs with fast, safe hydraulic chamber clearing and tramp iron overload relief with auto resets.

Superior has introduced several new high-tech crushers for use in the aggregates industry.

Weir Minerals’ engineering experts showcased the unique range of Trio equipment and tailored plant designs, known worldwide for innovation and manufacturing expertise. The ConExpo-Con/Agg booth featured a variety of Trio equipment including Trio crushers, screens, washers and conveyors. The Weir Minerals team has extensive experience in the construction aggregates market and are able to counsel, design and supply customized solutions from single Trio machines to stationary or portable plants, including turnkey projects, to best suit customers’ requirements.