Here Are Some of the Latest Crushing Products on the Market.
By Mark S. Kuhar
There is never a lack of innovation when it comes to crushing equipment. Here are some of the latest products on the market, some introduced at bauma, AGG1, and over the past year.
Kleemann Mobirex MR 130 Zi EVO2 Impactor
High-performance and enhanced aggregates processing technology built into Kleemann products like the Tier 4 final-compliant Mobirex MR 130 Zi EVO2 impact crusher shown at AGG1, 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. Also, the wear behavior of the new C-form impact ledges has been improved to such an extent that the edges remain sharper longer, leading to improved material shape. The rotor ledges are held securely by a new and extremely user-friendly clamping system, which means that they can be changed even quicker, and thus contribute to greater plant uptime.
Outstanding performance is made possible in part by the 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, via a robust fluid coupling and V-belts. This drive concept enables enormous versatility, as the rotor speed can be adjusted in four stages to suit different processing applications.
Wirtgen/Kleemann, www.wirtgen-group.com/america
Johnson Crushers International Kodiak Plus K350+ Cone Crusher
Johnson Crushers International Inc. expanded its Kodiak Plus cone crusher series with the new K350+, which it showed at AGG1. This mid-range model offers higher production with a smaller footprint.
In comparison to the K300+, the K350+ features increases in drive train, stroke, horsepower, weight, head diameter and hold-down force, resulting in a capacity increase up to 10 percent. With the same bolt pattern, the K350+ can be mounted in most current K300+ applications.
“We have been testing the K350+ for a few years, especially on portable plants, and it has far surpassed our expectations. We are excited to release the K350+ to the market,” said Ian Pendergrass, product manager for Johnson Crushers International.
Like other cones in the Kodiak Plus cone crusher series, the K350+ will feature an industry-leading tramp iron relief system, fully-protected internal counterweights, precision roller bearing design, patented liner retention system and 360-degree thread locking ring for consistent product quality.
KPI-JCI, www.kpijci.com
Telsmith T400 Portable Cone Crusher
Telsmith Inc. unveiled its T400 Portable Cone Crusher Plant at AGG1. Ideal for producers and contractors in mining, aggregates, crushed stone production, and recycling applications, the T400 portable cone crusher plant offers quick, safe maintenance access, consistent crushing, and easy mobility as the result of direct customer feedback. The T400 cone is part of the T-Series Cone Crushers line by Telsmith that offers large clearing circuits that are designed to safely and quickly allow uncrushable materials to pass, avoiding costly damage and associated downtime for repairs. The patented anti-spin feature prevents head spin to help extend manganese service life. Like other key components, it’s mounted on top of the machine for safe, top-service access.
In addition, the anti-spin operates with pressure lubrication oil eliminating the need for a gearbox, separate hydraulic circuit, and associated maintenance. The use of a single bowl for all liners over its life of operation helps reduce downtime and inventory costs while allowing optimum versatility, flexibility, and efficiency in portable crushing applications.
Furthermore, Telsmith Inc. patented hybrid bearing technology within T-Series Cone Crushers provides the ability to crush at lower horsepower from improved lift that helps carry the crushing forces, when compared to roller bearing machines. Engineered to hold up to tough, abrasive aggregate and mining processes, the T-Series cones with hybrid bearings deliver tested productivity, safety and ease of maintenance with maximum uptime.
Telsmith, www.telsmith.com
thyssenkrupp Multirok Vertical Shaft Impactors
Multirok vertical shaft impactors, manufactured by thyssenkrupp can be used flexibly in stationary, semi-mobile and mobile plants. thyssenkrupp also carries out intensive research and development work to continuously optimize the proven concept.
In vertical shaft impactors, the material is fed centrally into the rotor from above. The centrifugal forces inside the rotor throw the material against the sidewall, resulting in a highly cubical product.
Multirok impactors from thyssenkrupp are available in two sidewall and rotor variants: the sidewalls can be equipped either with anvils or with a material bed. For the rotor there is a choice of open or closed configuration. The optimum design is selected on the basis of the feed material and the specific customer requirements.
thyssenkrupp offers its Multirok vertical shaft impactors in three sizes: Multirok 7 for throughputs of up to 200 tph; Multirok 9 for throughputs of up to 300 tph; and Multirok 9 Duo – which has two drive motors – for throughputs of up to 400 tph. The product size is mainly influenced by the rotational speed of the rotor. The Multirok can be equipped with a variable frequency drive to adjust the rotor speed. This ensures quick and easy product changes during operation.
Maintenance is a key issue in the operation of vertical shaft impactors. Multiroks from thyssenkrupp are of robust design and offer a long service life while ensuring easy access to key components. The rotor liners and liner plates on the rotor and the anvils in the anvil ring can be accessed and replaced simply via a hydraulically removable housing cover. All wear parts are made of highly wear-resistant materials.
thyssenkrupp, www.thyssenkrupp-industrial-solutions.com
Metso Superior MKIII Primary Gyratory Crusher
The Metso Superior MKIII provides a significant performance leap in gyratory crushing. Based on Metso’s industry leading crushing technology, the MKIII is the first high-speed primary gyratory crusher to deliver up to 30 percent higher capacity and 70 percent lower downtime in a comminution circuit.
Designed for the most demanding primary crushing conditions and with the new, patented SmartStation for optimized production, the Metso Superior MKIII brings whole new level of cost-effectiveness and reliability to operations. The MKIII is the first high speed primary gyratory crusher on the market, surpassing traditional primary gyratory crushers by up to 30 percent in speed, thus having a 30 percent higher capacity.
The rotable top shell ensures safe maintenance and reduces downtime by up to 70 percent. In addition, the MKIII can be paired with the Metso Metrics solution for predictive maintenance and online asset management.
Metso, www.metso.com
Superior Primary Crusher; VSI
Superior Industries Inc. offers a 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.
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.
The company has 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. Thirdly, 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).
Superior Industries Inc., www.superior-ind.com
EvoQuip Cobra 290R
EvoQuip exhibited for the first time at bauma, showcasing the Cobra 290R – the newest addition to its “compact with impact” crushing range. The Cobra 290R is a closed-circuit version of the Cobra 290 that incorporates a 2.74- x 1.5-m post screen that ensures the required product specification is achieved with oversize material either being recirculated back to the crusher or stockpiled.
The ability to quickly detach the complete afterscreen system including the oversize conveyor provides the option of either running the machine in standard mode or transporting separately.
The compact Cobra 290R closed-circuit impact crusher is versatile, easy to use and has the ability to operate in the most demanding of applications making it the perfect solution for many industries. The track and crush feature comes as standard providing the operator the ability to move the machine using the optional remote control from the excavator cab without shutting down the crusher.
Ground level access to the engine, hydraulics, service and refueling points also ensures ease of use and serviceability for the operator. The rapid set up from ground level combined with the intuitive two button start up sequence ensures the customer can be crushing in minutes.
EvoQuip, www.terex.com/evoquip
Weir Minerals’ Trio TP Cone Crusher Range
The Trio TP cone crusher range delivers high performance, safe and mechanically reliable crushing. Whether your needs are stationary, wheel mounted or track mounted, these compact, robust, high performance crushers are suitable for heavy duty crushing in both the mining and aggregate industries.
Rugged and reliable, and designed to achieve outstanding results, all TP series cone crushers feature a steep crushing chamber angle, a large crushing stroke, and optimum speed to deliver a finer product through increased inter-particle comminution. The TP series cone crushers are designed to allow for maximum mobility without sacrificing versatility or crushing force.
Other design features:
- Adjustment: Threaded bowl with hydraulic gear drive for precision. Closed Side Setting (CSS) adjustment and easy integration with a remotely controlled system.
- Operating Controls: Fully integrated hydraulic console with push button controls for clamping, clearing and adjustment.
- Bearings: Bronze bearings designed for extended life under maximum load.
- Lubrication: Self-contained, climate controlled oil lubrication skid with integrated Programmable Logic Controller (PLC) monitoring condition sensors.
- Gearing: Spiral cut bevel gear set with hardened teeth and pinions to ensure quiet, smooth and efficient horsepower transmission.
- Frame: Cast high strength alloy steel with an optimized design to deliver maximum strength and durability.
Weir Minerals, www.global.weir/products/product-catalogue/trio-t-series-cone-crushers
Stedman Cage Mills
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
McLanahan MSP Cone Crushers
The technology that makes a McLanahan MSP Cone Crusher outperform competitive cones on the market is the combination of all of the factors of performance i.e. balanced eccentric, higher speeds, fulcrum point position, and stroke. By using sound engineering with years of field testing a truly tried and tested new cone crusher has emerged.
A balanced eccentric coupled with a fulcrum point ideally placed over the crushing chamber yields highly effective compression crushing. This allows higher eccentric speeds to maximize performance without disruptive forces. The eccentric stroke is designed to work with the eccentric speed and fulcrum position to produce higher yields and minimize recirculating loads. The torque and resultant crushing forces are as effective as virtually any cone crusher on the market.
Spiral bevel gears provide the turning force to the eccentric. The spiral gear is mounted on a sturdy countershaft of the cone crusher, which rides in bronze bushings. The gears are precision cut for quiet operation. Misalignment problems are eliminated.
The MSP Cone Crusher features one of the largest volume displacements by a crusher head. When there is a large volume of material displaced this way, it means that more material is crushed in each cycle, more material can be fed to fill the larger void left when the crushing head recedes, and more material flows through the crusher due to the larger throughput and gyrating cycles allowing material to drop further. The benefits of high efficiency, greater crushing force and high capacity coupled with the durability the market expects are the reasons why this design is the best way to increase your productivity and profitability.
MSP Cone Crushers are built to make operations run smoother and easier. It’s simple control panel provides users with the necessary information to properly run the crusher. For example, the MSP Cone Crusher shows the exact cone setting to allow the operator to stay on top of a critical set point.
McLanahan Corp., www.mclanahan.com