Primary Possibilities

With plenty of options for stationary and portable primaries, producers can find a crusher that fits their needs.

by Therese Dunphy, Executive Editor

Universal Engineering
Hydraulically adjustable feed plate

Universal Engineering Corp.’s MaxCap Series of crushers offer the capacity of a New Holland style crusher with the ease of operation and maintenance of an Andreas style machine, the company says. The crushers feature a hydraulically adjustable feed plate, interchangeable back and top wall castings, a hydraulically adjustable breaker plate that automatically maintains its position, and a heavy-duty disc style rotor with quick-change hammers.

The crusher series, which is available in a variety of dimensions with capacities up to 1,400 tons per hour, has a heavy-duty fabricated steel construction with an upper section of the housing that retracts hydraulically for easy access to the interior of the impactor. Other features of this series include the following: a rotor lock pinned from the crusher housing into the rotor body; top-loading, reversible hammers protruding leading edges; interchangeable abrasion-resistant alloy steel liners to protect the interior walls of the crushing chamber; and large access doors on the side and back of the crusher.

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Sandvik Rock Processing
High strength, low weight

Sandvik Rock Processing’s Jawmaster single-toggle crusher is high in strength and  low in weight. It has a deep, symmetrical crushing chamber that optimizes the nip angle and crushing motion, according to the manufacturer. The crusher also features an active feed opening that increases material volume and allows for maximum capacity. Hydraulic on-the-fly adjustment is available for some models, as well as a complete range of sizes for stationary and portable applications. The crusher also has four roller bearings that are grease-lubricated and has grease-filled labyrinth seals. An almost-square feed opening is designed to accept large material without blockage, while a thick, replaceable wearing plate protects the top of the moving jaw from being damaged by the impact of feed material. The jaw crusher is available in capacities ranging from 75 to 110 short tons per hour up to 885 to 1,160 short tons per hour, with feed openings from 22 by 32 inches to 52 by 60 inches.

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Telsmith
Long crushing chamber

Telsmith Inc.’s Iron Giant jaw crushers boast a long crushing chamber that delivers higher performance in quarried stone, the company says. Shallow nip angles that result from the long chamber create an aggressive stroke that nips stone quickly while the long chamber holds a higher volume of stone, processing more with each stroke. The end result is greater productivity in even the hardest stone, according to manufacturer claims. Available in models 4448 and 5060, the jaw crushers are said to be ruggedly built for decades of service and include unique, simplified maintenance features designed to yield optimum up-time availability.

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Stedman
Crunches cubical product

Designed to increase profits by maximizing production, Stedman’s Mega-Slam Primary/Secondary Horizontal Shaft Impactor is said to handle feed sizes beyond the range of conventional secondary impactors. The company builds five models in the line, each of which produces a cubical product and — in some cases — eliminates the need for primary reduction equipment. The largest model, the 6460, features a 61- by 46-inch feed opening and produces up to 700 tons per hour when handling limestone, sand and gravel, or asphalt. The line features a solid rotor that is contoured and computer designed for maximum efficiency. A positive breaker bar holding device with buried wedges minimizes wear, as well as breaker bar installation, removal, and indexing time. Designed for durability, the models are available with optional 3-inch-thick replaceable secondary breaker plates, a standard rear apron spring bridge assembly, and interchangeable housing liners made of 2-inch-thick high-chrome or alloy steel.

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Hazemag
Rugged and reliable

The Hazemag APP Series Primary Impact Crusher is ideally suited to crush run of quarry, medium-hard materials down to a product size of 0 to 8 inches (with 90 percent at minus-4 inches) in a single pass, the company says. This machine is normally offered within a plant/system where secondary crushing is also present. Due to its high-reduction ratio; however, the need for multiple secondary units is normally eliminated.

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McLanahan Corp.
Reduces fines production

McLanahan Corp. has introduced its DDC-Sizer series as an efficient means of primary and secondary crushing of low silica materials such as limestone. The DDC-Sizer is an evolution of the double roll crusher and is ideally suited to handle wet, sticky feeds contaminated with clay while producing a cubical product size due to the intermeshing teeth and slow rotational speeds of the rolls. According to the company, the primary advantage of this style of crusher is the significant reduction of undesirable fines in comparison to other primary and secondary crushers on the market, maximizing product yields.?With a low-profile, low-headroom design, the DDC-Sizer is supplied with retractable wheels at each corner so that it can be rolled out from under hoppers or chutes for easier access during normal maintenance. Capacities range from 500 to 5,000 tons per hour with each unit designed for the application.

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Excel Crusher Technologies
Customer-driven design

 Designed with input from aggregate producers, Excel Crusher Technologies’ new Raptor cone crusher is said to deliver high-performance crushing in a rugged, dependable, automated machine. The cone crusher features heavy-duty design for extended life, a two-speed electric adjustment drive system, and an innovative hydraulic tramp release system. Two units, the XL300 and XL400, can be run via a PLC-based crusher automation package that includes an AB Compact Logix L32E PLC; a 10-inch display screen; 24-volt power supply; Ethernet switch 4-port, input, and output modules; and a Hoffman electrical enclosure.

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Metso Minerals
Meets demanding applications

The LT1315 and LT1415 new generation Lokotrack mobile crushers from Metso Minerals combine high crushing capacity, a broad range of process options, and operator friendliness with the latest dust- and noise-reduction options, according to the company.

The LT1315 has a low transport height. When equipped with the optional overband magnetic separator and pan feeder below the crusher, recyclable materials containing rebar may be processed without any problems, the manufacturer says. The LT1415 features a capacity range of up to 1,000 short tons per hour. Both primary crushers are built around the company’s Nordberg NP Series impact crushers, have Tier 3-approved engines, and can be equipped with a pan feeder/scalper or a roller grizzly. They also can be equipped with a two-deck screen and product conveyors. The LT1315 and LT1415 have a quarrying setting range of 60 to 150 mm and 60 to 200 mm, respectively. Both have rotor speeds of 450 to 560 rpm and have feed hoppers 8-cubic-meters in volume and 108 inches in width. An optional rubber lining is available for reduced wear and noise level, and optional feed hopper extensions enable loading by a wheel loader. The standard hopper is suitable for excavator loading.

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Kolberg-Pioneer
Maximum-performance rotor

The Pioneer Horizontal Shaft Impact Crushers from Kolberg-Pioneer, Inc. (KPI) — the 4233, 4240, 4250, and 5260 models — provide adaptability, reliability, accessibility, and versatility in primary, secondary, tertiary, and recycling operations, according to the company. The units feature a maximum-performance rotor with access characteristics of a segmented rotor in two-, three-, and four-bar configurations. A sequentially welded, fabricated base provides maximum strength for extended base life, and heavy-duty crusher shaft and bearing assembly and rotor retention system allow the crushers to withstand the day-to-day harsh environment and severe impact applications, the manufacturer says.

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Eagle Crusher
Industry’s heaviest solid-steel rotor

The UM 1600-69 HSI crushing and recycling plant from Eagle Crusher is portable and self-contained with a 69-inch feed opening. The crusher features a sculptured three-bar rotor made of solid steel and contains a 61,000-pound impactor with a 68-inch by 20-foot vibrating grizzly feeder. With its 13-ton sculptured solid-steel rotor, the shock of huge, slabby concrete and asphalt is easily absorbed.

The plant weighs 77,800 pounds in transport mode and 170,000 pounds when it’s complete. Travel width is 11-feet, 11 inches, and travel height is 13 feet, 5 inches. Feed hopper capacity is 27 cubic yards, and the discharge system is 54 inches by 40 feet. A road-portable discharge conveyor is optional. The standard on-plant power supply is 500 horsepower (electric) with an optional 800 horsepower (electric) or 521 horsepower (diesel) engine.

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Grasan
Independent hydraulic legs

Grasan’s road-portable and pit-portable jaw crushing plants are available in a full range of sizes with various crusher brands and diesel or electric power. Chassis frames are built with high-strength, wide-flange steel beams. Hoppers for the plants use a 3/4-inch plate wall construction with heavy angle reinforcing and are available with 3/8-inch wear liners. Grizzly feeders come standard with hydraulic hydrostatic drive for variable speed control. Discharge conveyors feature heavy-duty construction with impact bed sections under the crusher. A variety of axle configurations also are available to meet state-specific loading requirements, and most plants can be equipped with a skid-on, skid-off hopper feeder module for over-the-road weight reduction and fast plant setup. Complete electrical packages are available with a starter panel, wiring, quick disconnects, and remote operator control station.

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Terex Finlay
Large-reduction ratio

The new I-1312 impact crusher plant from Terex Finlay is a multiple-speed impactor, which is designed for primary and secondary crushing of concrete/asphalt rubble and limestone. It features high throughput, a large reduction ratio, and quick set-up, according to the company. The plant’s crusher has a large discharge opening and has a standard three-bar or optional four-bar configuration. The hopper capacity is 11.7 cubic yards, with hydraulically folding sides, 5/8-inch hardox sidewalls, and tapered grizzly apertures. The system features an advanced compliant control system with large display screen, a detachable doglead control for tracking or optional full-function radio remote, and five operating modes — track, manual, automatic, configuration, and language — with a menu-driven graphic user interface. Other options on the crusher include a bypass conveyor, overband magnet, belt weigher, extra dust cover for discharge conveyor, hydraulic water pump, re-circulation conveyor, tracked or wheeled undercarriage, and a Caterpillar Tier 3 engine.

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Terex Cedarapids
High-production tonnages

The horizontal shaft impact crushers from Terex Cedarapids have an extra-large feed opening that accepts feed sizes from 6 inches to a maximum 22 inches to process most types of material including gravel, shot rock, and recycle feed. They come in two sizes with two crushing chamber configurations and offer high-production tonnages, improved particle shape, and reduced wear costs, according to the manufacturer. Three or four bar rotors are available for either 4- or 5-inch thick, four-turn blow bars, made from chrome or tool steel with optional ceramic inlays. The 50-inch open rotor design with 5-1/4-inch thick backer bars results in a high-rotor inertia, allowing it to operate at large reduction ratios for higher capacity.

The primary apron is configured as either a one-piece cast manganese configuration that can be turned to increase wear life or a high-strength fabrication with bolt-on, 3-inch-thick cast chrome liners. The crushers also feature large, spherical roller bearings with taconite-type labyrinth seals, large inspection access doors, and hydraulically opening body halves, which results in quicker blow bar and liner changes, according to the company.

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Lippmann
Produces cubical aggregate

Lippmann’s 4800 Series Impact Crushing Plants features a large crusher feed opening that the company says is able to devour concrete full of rebar and ripped asphalt, as well as many other tough materials filled with debris. The self-contained unit contains the company’s 4248LP Impactor with a 34-inch feed height and has a 48-inch rear-discharge conveyor, 20-inch-wide return conveyor, and two 20-inch-wide cross conveyors. The unit’s 425-horsepower diesel motor and 100-kilowatt generator, as well as the heavy-duty rotor of the system’s crusher, provide the portable plant with the power to offer a greater reduction ratio and to produce a high-quality, uniform cubical product, including Superpave aggregate, according to the manufacturer. Other features include an abrasion-resistant hopper, hydraulic legs, a 62-inch by 10-foot double-deck screen with an underscreen hopper, a 48- by 72-inch pan feeder under the impactor, the company’s 4716 feeder with 4-foot grizzly, and an optional 36-inch permanent magnet.

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DBT Mineral Processing
Handles bigger feed size

The newest addition to DBT Mineral Processing’s line of primary crushers is the 1521 with processing capabilities of 1,500 to 2,000 tons per hour. It boasts a 7- by 7-foot feed opening, with 60 to 70 percent of passing material reduced to 4- to 5-inch sizes with minimal fines production. The totally mobile plant is available in skid-mount, non-powered, or powered-track configurations. Installation time for the unit is three to four days, with no concrete pads or steel structure requirements. The PLC-regulated plant can be run via remote control.

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Irock Crushers
Closed-circuit crushing and screening

Irock Crushers offers the RDS 15 Closed Circuit Crushing and Screening Plant, which combines quick set-up, high output, Cat power, and the Irock 15 impactor. A PT Tech clutch provides increased efficiency for better fuel economy and improved reliability. The crusher is 40 by 43 inches, with a 5- by 16-foot, two-deck screen. Production ratings range from 150 to 300 tons per hour, depending on the application.

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Construction Equipment Co.
Dual crushing and screening

Construction Equipment Co.’s Crush-It-Screen-It Combination Unit combines two tandem plants. The crushing plant can handle recycled concrete, recycled asphalt, limestone, decomposed granite, shale, basalt, and other materials. Meanwhile, the screening portion of the plant separates and sizes material to produce in-spec stockpiles. The combination works together as a closed-circuit package, but each plant can also work separately, the manufacturer reports. Production capacity ranges form 125 to 300 tons per hour, depending on material type. The plant is driven by a Caterpillar engine package that features a push-button, self-adjusting, hydraulically actuated clutch that will not start when the engine speed exceeds 800 rpm.

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Terex Pegson
New generation jaw

The 1100 by 650 track XR400 is Terex Pegson’s new generation hydraulic-release jaw plant and features the “M” Series single-toggle design. According to the company, it provides hydraulic overload protection, high throughput, excellent reduction capability, and greater protection against damage from tramp iron and rebar in the feed. The aggressive, high-swing jaw can accept large feed and processes up to 400 tons per hour. With typical fuel consumption of less than 6 gallons per hour, the portable plant features a highly efficient HFO direct drive system.

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Crushtek, LLC
All-around crushing

The Supertrack 1140j from Crushtek, LLC, is an all-around crusher, suitable for virgin aggregates or mineral recycling. With crushing capacities of up to 220 tons per hour, the unit features ease of operation with feed sensors in the crushing chamber that automatically control the material flow to the crusher. A 12-channel remote control option eliminates the need for additional operating personnel at the crusher itself.

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