July 2002
Four steps help create a positive employee mindset to impact safety
By Mark M. Smith
The aggregate industry has increasingly focused attention on employee training to improve safety and productivity. Great strides have been taken in certain areas, however, the industry can do better.
One area needing improvement is truck haulage. Within this sector, a high number of accidents continue to occur. Expensive equipment is damaged, insurance premiums rise, and productivity is lost. Worst of all, people continue to die or to be injured. All too often, accidents happen because those involved did not know how to avoid a hazardous situation, or they simply grew careless.
Each such incident raises critical safety questions:
• Where were safe practice procedures lost?
• Did the breakdown begin with management?
• Was safety discussed, but treated as expendable when production levels were affected?
• Was the fault a lack of training?
• Was training effective?
• Was the fault that of the individual?
• Did they fail to apply safe methods of operation?
• Could they have failed to understand these methods?
Only by addressing these questions, seriously and honestly, can the industry take steps to decrease the number of accidents. Each statistic is a life. Each life ripples outward and touches other lives.
Management must be the first to develop and display a positive mindset if they expect those under their supervision to display it as well. Their positive actions will then become a catalyst in creating a positive mindset throughout their organizations. Only when management sets a positive example will safety regulations and procedures have real impact.
Creating this predominant mindset takes four basic steps. All employees — from upper management to front-line operations personnel — must believe in the validity of each critical step. Everyone must understand them and use them, no matter how small the task.
Step 1 — Positive Attitude
Attitude affects everyone and everything. In mining, a positive attitude toward safety and productivity requires commitment from everyone. No one can afford to think that some detail of safety or productivity is minor enough to be ignored.
Management has to set the standard for what is and is not a safe practice. They are the front line of a positive mindset for others. From them, this mindset filters downward. Each individual in succession must do their part.
Step 2 — Training
Training equals productivity. Training is empowerment. It gives management, supervisors, and operators alike, a clear understanding of what is and is not the proper way to operate a haul truck.
Training, once in place, generates an ongoing database of information. This database allows accurate assessment of the operation’s commitment to safety and productivity. It also helps in determining to what extent the safety goals are applied and met. Thorough documentation measures the long-term results and achievements of safety and identifies where strengths and weaknesses exist.
Training supervisors in proper truck haulage procedures cannot be overemphasized. A supervisor cannot make solid, well-executed safety and production procedures for a crew if uninformed about the best operating method. Without such information, they will be unable to gauge accurately the actions of others.
Having a clear understanding of truck haulage operations allows supervisors to quickly recognize hazardous or inefficient situations. They then know what steps to take to correct or prevent such situations.
Truck operators benefit as well. Training gives them a clear understanding of the machinery. It enables them to immediately identify safety or operational defects. They can then cease operation at the first sign of trouble, before a hazardous situation develops.
This is why it is so vital to train about safety and production simultaneously. Safety and production should never create conflict within a supervisor or an employee. Training safety and production together enables a company to reinforce its priorities and expectations from employees.
In the long-term, emphasizing safe practices over productivity will always be the most productive way to operate in an intrinsically hazardous industry. Training must drill home the point that tempting fate by cutting a corner to speed a cycle time or keeping damaged equipment in operation to maintain a production schedule is bad business. All it takes is one accident or fatality for an operation to learn the full reality of this fact in the most painful and costly way possible.
Training also gives operators a thorough understanding of what actions must be avoided and what practices must be employed to prevent equipment damage. They will know how to respond correctly in any situation.
A well-rounded training program also teaches operators the consequences of their actions. They must understand that the choices they make, either positive or negative, affect not only their own lives, but the lives of others.
A solid, state-of-the-art truck haulage training program has several facets. Each portion is a tool that ensures that trainees gain a clear understanding of truck operation. Such a program should include classroom instruction, simulation, field training, skills and knowledge measurement, and periodic refresher training.
Classroom Instruction — For classroom instruction, it is important that the training materials offer consistent, comprehensive, and easy-to-understand information. Highlight the lessons with video, graphics, and color. These serve as memory aids to stimulate retention of safety and procedural information. Quality materials help instructors make the learning process stimulating, not intimidating.
Instructor credibility is critical. The most effective instructors are knowledgeable, experienced haul truck operators. Students will have more confidence and respect for an instructor who demonstrates the safety and procedural skills being taught. It is extremely important to take great care when selecting instructors. The success of the training program depends upon it.
Simulation — Simulation is now an established training practice at some surface mining operations. These simulators are used to familiarize new operators with the controls and characteristics of a haul truck prior to actual operation. This reduces the stress levels on the students and enhances the learning process. Student drivers can afford to make mistakes on simulators because the consequences are not catastrophic. Simulation helps the students develop sound driving habits while learning from their mistakes. This reduces the likelihood of mistakes being repeated during actual driving situations.
Field Training — Dedicated field training sites also can play a significant role in well-developed programs. It is here, away from the hustle and bustle of active mining areas, that newcomers begin to put into practice the things they have learned. For the first time, classroom and simulation skills are used on a real machine, in a real situation. Isolating the site away from the production environment allows students to refine the things learned without endangering property or other personnel.
Skills and Knowledge Measurement — Measuring skills and knowledge is crucial in assessing the effectiveness and success of any training program. Without this, there is no way to ensure that operators fully understand the safety, productivity, and procedural training that they have received. Also, there would be no way of knowing if they can apply this knowledge in a field production environment.
Written and field examinations provide organizations with the necessary data to determine successful knowledge and skill transfer. Test results indicate whether operators require additional training or the program needs improvement.
Periodic Refresher Training — Whether a truck operator is relatively new or has many years of experience, all should receive periodic refresher training. This reinforces safety procedures, productivity, and best practices and combats complacency. As in any other job, familiarity can result in carelessness. Refresher training keeps the operators’ skills and knowledge levels sharp.
Step 3 — Accountability
True accountability for the outcome of any truck haulage program requires that each person take responsibility for the consequences of their actions. Managers, supervisors, operators, and others must have a clear understanding of their responsibilities and for what they are held accountable. Everyone must understand precisely what behaviors must and must not be seen and exhibited.
Clear definition of responsibility is critical if individual accountability is to be reinforced. All need to understand the consequences for meeting or failing to meet expectations. It must be understood that accountability applies to everyone. Unless there is a consistent application of the principles of accountability, motivation to operate in the safest manner possible may be lacking.
Step 4 — Consistency
Consistency creates a baseline from which to evaluate safety and operating performance. It enables an operation to take the talents of its work force and forge them into a safe, cohesive unit. It also means that, despite the inconsistencies that arise due to experience levels, personalities, and other factors, safety will remain the number one priority. If safety standards are applied inconsistently, credibility will be lost.
Since individuals react in different ways toward safety, create an environment conducive to compliance. While the standards must remain firm, be willing to do whatever is necessary to assist all to strive for this constant standard. Only then will your safety program succeed.
Summary
These four steps — positive attitude, training, accountability, and consistency — will create a positive safety and productivity mindset within any haul truck program. They allow an operation to measure its commitment to safety and to rate how well programs are being applied. They give added impetus to the strides already taken to improve safety in truck haulage.
The four steps will assist everyone from managers to haul truck operators become experts. Safety statistics will improve. Productivity will increase. Lives will be saved; injuries prevented.
Creating a positive mindset within every truck haulage operation is not an impossibility and can be attained through diligence and effort. Everyone must give safety top priority and complete commitment. Just think, the person saved may be you.
Mark M. Smith is division manager, Mine Training Programs for VISTA Training, Inc.
Your Mine Plan: A Tool for Production
A good mine plan is easy to use and conveys past lessons and information to future operators
By Larry Bolling
Although it is impossible to offer an example of the perfect mine plan for your operation, a good mine plan should be easily understood and comprehensive. It should contain the knowledge gained through thousands of man-hours of mining and convey knowledge of the operation’s past to future producers.
In previous columns, we’ve defined what a mine plan is and described the process of developing a plan. We have talked about realistic reserve estimation and the benefits of quality analysis of geologic reserves. We have discussed the components of both long- and short-term mine plans and the various issues they could address. The one thing this column can’t define is exactly what your mine plan should look like.
A mine plan is a tool that is meant to see a lot of use. A hammer that is not balanced or has a defective handle rarely gets chosen when it’s time to pound nails, just as a plan that is awkward to use and hard to understand will see little use. The following characteristics describe what a “good” mine plan should be:
Easily Understood
A mine plan is a tool for all levels of the organization. Anyone who has a question that is answered in the mine plan should be able to find the information with a minimum of effort. Whether the question is financial, geological, or operational, the answer should consist of clear language — with minimal jargon — and drawings, maps, diagrams, and photographs whenever possible. A summary, index, or table of contents can rapidly direct the reader to the desired section.
Comprehensive
A useful mine plan will address all the mining issues faced by production, quality control, and management personnel for the operation. You already know which issues are critical for your operation. You can ensure that the team or consultant that creates the plan pays proper attention to those items that really matter to your facility.
Just Detailed Enough
If quality or quarry development issues require a shot-by-shot mine plan, then that is what you should have. But if a drawing of how the site will change on an annual basis is sufficient, don’t waste time and money on extra levels of detail. Choose a mine plan interval that represents a logical step for your mining operation, whether it is one month, one year, or one bench level. Difficult production or ramp construction sequences can be clarified with separate drawings or diagrams, and don’t have to conform to any predetermined interval.
A Knowledge Database
As we discussed in previous articles, the mine planning process is an appropriate time to document details about the mining site that might be lost in the future. Much is learned during thousands of cumulative man-hours of experience in any quarry. A few simple notes about what type of material was used to build the berms, or problems with oversize material when blasting in a certain area of the pit could save future operators significant time and money. Consolidating and preserving existing information could well turn out to be the most valuable part of the mine planning process.
Easily Updated
The farther actual mining diverges from the mine plan, the less useful the operating section of the mine plan becomes. If events conspire to render your mine plan ineffectual, it is probably time for an update. The plan must be revised on a regular basis to document quarry development and reflect the changing needs and goals of the operation. Regular updates also provide the opportunity to continue documentation of mining experience on site. Since the base information for the site remains constant, updates usually require only a fraction of the effort of producing the original plan. Choose an update interval that makes sense, according to production levels and site changes for your operation, and make mine plan updates a part of your regular planning and budgeting schedule.
A mine plan is a custom-built product, tailored by you to suit the specific needs of your aggregate production facility. Although the process of developing a comprehensive mine plan may seem daunting, proceeding one step at a time through the development of the plan breaks the process into manageable phases, each one building a firm base for the steps that follow. As anyone who has worked with a fine hand tool or specialized piece of equipment can attest, the right tool can make the job much more enjoyable and efficient.
Larry Bolling, P.G., is a geologist with the Industry & Environment Group of Morris & Ritchie Associates, Inc. He can be contacted at LBolling@mragta.com.
Vulcan Increases Production by Staying on Track
Among the new equipment leased by Vulcan’s Corona quarry is this Komatsu PC1100-6 shovel — the first of its kind in North America.
In North American quarries, a wheel loader is often the norm for truck loading operations. Increases in technology and operator comfort in the 1970s led many quarry supervisors away from traditional cable shovels or excavators to large wheel loaders. But four wheels are not always better than two tracks, as Vulcan Materials Western Division discovered in its Corona, Calif., facility.
The Corona quarry had been in operation for more than 40 years when Vulcan Materials purchased it in 1989. Taking an aging 400-acre operation and turning it into a million-ton-per-year railroad ballast plant was the task charged to Earl Ochs, Vulcan Materials Western Division production supervisor.
“When we started at this site, it was, at best, 50 percent operational,” he said. “That number is now at 94 percent operational readiness at any given time.”
Vulcan’s ability to nearly double production is a direct result of an extensive rebuilding program and a decision to upgrade its equipment fleet, including the addition of a 238,100-lb. hydraulic shovel.
Vulcan found the most cost-effective way to upgrade its fleet was to lease new, fully-maintained equipment from Komatsu distributor SMA Equipment Co. Mike Vinnola, SMA fleet services manager, said SMA’s flexible fleet management program allowed Vulcan to divert its capital from equipment expenditures to on-site upgrades.
“It’s allowed them to have a fixed cost on their equipment,” Vinnola said. “And it freed up some capital expenditure so they could divert their cash to rebuilding plants, rather than spending it on mobile equipment.”
The Corona site operates 12 pieces of Komatsu equipment, including a PC1100-6 shovel, wheel loaders, haul trucks, excavators, and dozers.
The Komatsu PC1100-6 hydraulic shovel used at the Vulcan quarry is the first of its kind in North America. “This is the first PC1100-6 specifically designed to incorporate a shovel,” Vinnola said. “There have been other machines retrofitted for a shovel, but this is the first true PC1100-6 hydraulic shovel.”
The track-mounted shovel provides Vulcan several advantages over a wheel loader, according to Ochs.
“This is a blue granite quarry, so the rock we are loading into the trucks is sharp edged,” Ochs said. “Prior to the shovel, we had to make sure the quarry floor was clean, so as not to puncture or cut the loader or truck tires. The PC1100-6 keeps the floor clean as well but, in the event that some material does fall, we do not have to worry because the shovel is set on tracks.
“The shovel also makes it easier to load trucks in a smaller area. With the loader, there’s always the worry about backing up and turning sufficiently. The shovel pivots on the spot.”
Another benefit the shovel offers Vulcan is a customized high-rise cab outfitted by SMA. It allows the operator to load more quickly with better visibility of the load as he dumps into the haul trucks. “I have a clear view of the bed of the truck as I am approaching it, making it easier for me to see where the load is in the truck and allowing me to keep it as level as possible for the truck driver,” said shovel operator Brian Squires.
Outfitted with an 8.5-cu. yd. bucket, the shovel loads Komatsu HD605, 67-ton haul trucks in four passes. “The shovel is capable of loading the truck in 1.5 minutes,” said Ochs.
The high-rise cab also plays a part in operator safety. “Brian is a bit higher up, putting him above the face in case anything rolls out,” said Ochs. “It just adds to the safety of our quarry and safety is a very important part of our everyday operation.
“We have a credo we live by in our quarries,” Ochs said. “We are creating a quality product at a low price — all while being the safest operation.”
With 10 local competitors, the faster cycle times of a shovel (compared to a wheel loader) give the Corona quarry an advantage.
Moving a Mountain
Vulcan’s goal to increase capacity at the Corona quarry began as a two-phase process. Phase one entailed mining the front of a mountain to make room for a new, technologically-improved processing facility.
“We needed to put up the new production facility at the front of the mountain,” said Ochs. “We subcontracted with a company to perform blasting of faces and then brought in the shovel and the haul trucks to remove the shot rock. The choice to go with the PC1100 was obvious as, again, the resulting shot was sharp and would easily have pierced or cut tires on a (wheel) loader.” Material removed from the front section of the mountain was processed with a portable plant.
The second phase of the project proved more labor intensive. It included mining the backside of the mountain from the top down, creating a haul road and removing more than 30 ft. of overburden.
Vulcan used Komatsu D475 and D275 dozers to rip and move overburden at the top of the mountain. A Komatsu PC400LC-6 excavator and breaker reduced larger blue granite pieces. Vulcan used the shovel in positions that a wheel loader could not work, including the haul road being constructed for truck travel from the face to the new production facility.
“We are constructing a long haul road from the bottom to the top of the mountain,” said Ochs. “In the narrow (75 ft. across) road construction area, a shovel is easier to load the trucks with than a loader because there is no backing up and no dealing with maneuvering in tight spots.”
Another advantage of using a shovel instead of a wheel loader is that road construction is progressing up, rather than down, the mountain. “With a wheel loader it is more difficult to load trucks on an uphill slope,” said Ochs. “The start and stop and gear changes make it more difficult — that slows us down.
“Cycle times are very important in our industry and with the shovel sitting stationary and loading, it remains productive the whole time. The loaders have to back up, scoop, and then make a trek up the slope to the truck. That takes valuable time. With 10 local competitors, we do not always have that extra minute.”
The haul road will be about one mile long and will rise 810 ft. in elevation. Also at work on the road are two Komatsu D475-5 Super Dozers.
“The D475s are spending most of every 10-hour shift ripping,” said Ochs. “There are times when we need to blast because the ground is too solid, but for the most part, these powerful machines are getting ahead of the shovel and keeping it real busy.”
The dozers also play a part in the initial clean up of the road after it is ripped. “There are times that we are unable to get to the shot with the shovel,” said Ochs. “We then use the large blade of the 475s to bring the shot to the shovel. It is a nice system we have going.”
the bottom line...
Vulcan Materials’ Corona quarry transformed an aging quarry that was about 50 percent operational into a highly functional plant through an extensive rebuilding plan. By leasing its mobile equipment, the operation had a fixed cost for its fleet and was able to dedicate more capital expenditures to plant equipment.
Lubricant Trends Uncover Areas for Cost Savings
Matching the correct lubricant to its application is the key to achieving maximum performance
The Berg Corp. chose to spend a little bit more money for a tracked mobile crusher to realize savings due to the unit’s ability to work in tough environments.
According to the U.S. Geological Survey, based on 1999 figures there are more than 14,200 mining operations in the United States that fall into one of the following three categories: nonmetallic minerals (aggregate), coal, and metals. These mining operations purchase in excess of 100 million gallons of lubricants annually, averaging 5,000 gallons per location. Approximately 45 percent of all lubricants purchased by a mining operation are considered industrial lubricants and are used in the plant’s stationary equipment. A large majority of these products fall into three categories: crusher oils, gear lubricants, and greases.
Castrol Heavy Duty Lubricants Inc. has observed the development of some interesting trends that can significantly impact the maintenance and production of a mining operation.
Drew Nagle, a 17-year veteran of Castrol Heavy Duty, notes that mine operators show an increasing trend toward leasing critical resources, specifically mobile equipment.
“The tendency of mining operations to lease mobile equipment reduces their outlay of capital reserves and allows the user to more efficiently control the cost per hour of ownership,” said Nagle. “Many programs have been developed by construction equipment OEMs to guarantee cost of ownership over the life of the lease.”
Leased mobile equipment must be maintained to the extent necessary to prolong component life at the lowest possible cost. According to Nagle, premium quality lubricants are being carefully evaluated as a necessity in this environment.
Conversely, stationary equipment is typically not offered on a lease or lease-to-purchase basis. For this reason, the focus on stationary equipment maintenance has been redirected toward maximizing plant component life. The use of premium quality lubricants and synthetic fluids is encouraged to achieve prolonged component life.
Operators are constantly seeking a balance between improved component life and reduced cost of ownership. Lubricants represent up to 2 percent of the annual maintenance budget. However, industry trends indicate that lubricant quality and performance outweigh product cost. Premium products and synthetic lubricants offer the potential for reduced downtime, lower maintenance costs, decreased wear, extended drain capabilities, and expanded warranty programs, all of which contribute to a lower cost of ownership.
Further increasing the complexity of maintaining equipment is the desire for product consolidation. Operators with a wide variety of equipment seek lubricants that will fit most of their needs with the fewest number of products. This reduces inventory costs and the potential for product misapplication. Castrol Heavy Duty has estimates that approximately 35 percent of stationary machinery used in the plant is lubricated with the wrong product.
“Choosing the correct viscosity grade and lubricant chemistry for a piece of stationary equipment is critical to maintaining it,” explains Nagle. “When a mine is using the incorrect type or viscosity lubricant, the customer becomes dissatisfied with the performance of the machine, not realizing the machine is using the wrong lubricant.
“Plant personnel may be quick to blame a component failure on the machine, rather than improper maintenance practices. This can lead to customer dissatisfaction and an increase in warranty claims.”
Lastly, operators place a high importance on “value added” products and services. On-site technical support coupled with premium-performing products can improve operations and provide significant measurable results. The availability of lubricant recommendations (lube surveys) and technical support can reduce or eliminate incorrect product application and improve component life. These types of services can offer value that far outweigh their costs.
In evaluating a mine’s lubricant line-up, Nagle makes the following recommendations. (Be sure to check your manufacturer’s recommendations.)
Gear Lubricant. A quality EP gear lubricant with premium base oils and stable additive package will offer gear and bushing protection in cone crusher applications. This lubricant should excel in applications requiring U.S. Steel 224 performance.
Synthetic Lubricants. Applications that require oxidation control, thermal stability, and anti-wear performance can benefit from the use of a synthetic lubricant. Non-EP chemistries may be recommended in gear boxes, screens, and speed reducers. The use of a synthetic fluid in these applications offers the potential for extended drains and extended warranty programs.
Gear boxes, screens, and speed reducers that require an AGMA EP gear lubricant can also benefit from the use of a synthetic fluid with EP additives. The synthetic lubricant will offer better low temperature fluidity, enhanced rust and oxidation protection, and improved hydrolytic stability over a mineral-based fluid. As with most synthetic fluids, there is the potential for extended service intervals and extended warranty programs.
Grease. For wet environments requiring a lithium-based NLGI #1 or #2 grease, Nagle recommends a grease that resists softening and washout, but provides excellent stay-in-grade performance and high temperature protection. Lithium complex soap in this type of grease reduces the chances of incompatibility with other greases.
Hydraulic Fluid. A multi-viscosity hydraulic fluid is an excellent choice for hydraulic power units, cavity release, clamp cylinders, and adjusting rams requiring a 140 VI fluid. This lubricant should provide proven anti-wear protection and enhanced performance over a wide temperature range.
Nagle suggests rounding out the lubricants program with regular oil analysis to save money through failure prevention and reduced downtime. With over one-third of mining operations possibly using the incorrect viscosity or lubricant in their stationary equipment, it pays to take a moment to ensure that your most expensive investments are being properly protected.
The Association of Equipment Management Professionals (AEMP) is an individual membership organization comprised of equipment maintenance and management professionals. Its members are responsible for the purchase, maintenance, employee training, shop facilities, and parts management of leading corporations and government entities that utilize heavy, off-road equipment. Its members also represent the major manufacturers and suppliers of the heavy equipment industry. AEMP provides end users with cutting-edge education, and it is the only organization to offer a certification program for the industry, the Certified Equipment Manager (CEM). For more information, contact Stan Orr, CAE, AEMO executive director, at (970) 384-0510, email at ceo@equipment.org or visit AEMP’s web site at www.equipment.org.
Primary Crushing
By Bob Drake
Primary crushing is the critical link between the pit and the plant. The primary crusher — whether an in-pit portable, tracked mobile unit, or mounted on a stationary structure — must be sized to match face loading and hauling operations and to meet the secondary plant’s appetite for stone, measured by gradation as well as by volume.
On the pit side, minimizing idle time on wheel loaders, excavators, and haul trucks and on the primary crusher itself requires not only capacity matching, but also efficient handling of oversized feed. This generally is accomplished through blast design that achieves consistent, appropriate shotrock fragmentation, selective loading at the face to avoid oversize stone, and efficient secondary breaking with excavator- or crusher-mounted hydraulic hammers.
On the plant side, the primary crusher must deliver an adequate volume of the proper gradation of stone to keep crushers and screens in the secondary, tertiary, and finishing plants running efficiently at capacity while minimizing waste, typically fines. The primary plant link can be a direct feed by conveyor or, preferable in most applications, through a surge bin or pile. Surge capacity allows consistent material flow rates and reduces or eliminates operational dependency so downtime in one plant segment does not immediately affect production in the other segment.
Jaw crushers and horizontal-shaft impactors (HSIs) predominate as primary crushers in the aggregate industry. Nevertheless, some primary gyratory crushers remain in action. "We are actively marketing and selling all machines, including the gyratory," said John Stolowski, director of marketing for Metso Minerals. “There is a strong market that requires the use of gyratory crushing.”
However, several factors often favor use of jaws and HSIs. “A jaw or impactor has the range to meet most quarry or contract tonnage requirements — usually from 300 to 750 tons per hour,” Stolowski said. “When it is necessary to yield more than this and the material being crushed is hard like a granite, you probably could consider a primary gyratory.”
Cost is another factor. “The supporting structure to fix a jaw or impactor in place is considerably less than that of placing a gyratory,” Stolowski said. “That’s why you will see more and more jaws and impactors out there.”
Mark Krause, vice president crushing and screening for Cedarapids, a Terex company, noted that more producers are considering use of primary impactors. “I think this is due to newer metallurgy, a better understanding of impactors, trying to minimize fines and overall capital considerations,” he said.
Following is an overview of some of the latest machines and features offered by manufacturers for primary crushing applications in crushed stone and sand and gravel operations.
JAW CRUSHERS
1. Extec Screens and Crushers Tracked Jaw
The C-10 track-mounted primary crusher from Extec Screens and Crushers features a 650- x 1,000-mm (approx. 25- x 40-in.) jaw. A 225-hp engine provides diesel hydraulic power through a clutchless hydraulic transmission. The crusher operates with what Extec calls “high speed and Geo-crush technology to give high production while reducing wear.” Hydraulics power multiple functions: adjusting the jaw’s closed-side setting; raising the entire machine on hydraulic legs to facilitate cleaning and track servicing; and coordinating the flow of material from the vibrating grizzly feeder to the jaw.
2. Kolberg-Pioneer Mobile Jaw Plant
The Pioneer 2649 jaw crusher on Kolberg-Pioneer’s Rocky Trax track-mounted crushing plant is rated at up to 300 tons per hour, according to the company. The jaw features hydraulic dual wedge closed-side setting from 2 to 5 in. On-board power is supplied by a 250-hp diesel engine with full hydraulic controls for the variable-speed feeder, conveyors, tracks, magnet and jaw crusher. The 50-in. x 15-ft. grizzly feeder has a 5-in. step deck and a 11-ft. 5-in. loading height. Total machine weight is 105,000 lb.
3. Komatsu America Tracked Jaw
Komatsu America’s BR550JG-1 track-mounted crusher incorporates a 44-in. x 13.5-ft. grizzly feeder and a 44- x 30-in. jaw crusher driven by hydraulic motor and V-belt. The grizzly feeder, discharge conveyor and track undercarriage also have hydraulic drives. On-board power is provided by a Komatsu six-cylinder, turbocharged 306-hp diesel engine. Crusher discharge setting, ranging from 2.2 to 7.9 in., is changed with a one-touch adjustment. The feed hopper, accessible from three sides, has folding wings to decrease transport height. Minimum loading height with the wings up is 11 ft. Emergency shut-off buttons are installed on the left and right sides of the chassis, on the control panel, and on the optional radio remote control.
4. Lippmann-Milwaukee 3650 Jaw
Lippmann-Milwaukee says its 3650 overhead-eccentric jaw crusher, introduced last year, has a larger throw and a force-feeding action created by the inward and downward movement of the swing jaw. The machine has an oversized heat-treated alloy shaft and tapered roller bearings. An oil lubrication system pump pre-lubes the bearings prior to starting. The 3650’s longer jaw dies help provide a greater reduction ratio and more positive bite on material, according to the company.
5. Telsmith Iron Giant Series
Telsmith’s Iron Giant Series jaw crushers have an improved jaw die design, with increased total weight and re-engineered corrugation design, that reduces the cost-per-ton of replacement manganese, the company says. The crusher has a one-piece mainframe with a hardened replaceable liner between the manganese and the frame, a new clamping arrangement for the stationary jaw die using lateral keys and standard die bolts, and abrasion-resistant steel cheek plates. Telsmith’s overhead eccentric jaw crushers feature spherical roller bearings with combination labyrinth and contact seals and a circulating oil system with spin-on filter, water/oil shell tube heat exchanger, and flow-divider to provide equal flow to all bearings. The Iron Giant Series is available with modular support structures.
GYRATORY CRUSHERS
6. Metso Minerals Superior Super Spider
Metso Minerals continues development of the Superior line of primary gyratory crushers (formerly manufactured under the Svedala name). Its new Super Spider line of crusher models and upgrades incorporates larger feed openings, which minimize bridging and secondary breaking. Production capacity is also increased 15 to 20 percent with the Super Spider liner configurations, Metso says. Internal and external sensors monitor temperatures, pressures, flow rates, and crusher setting. All of the sensor feedback is logged and monitored, allowing remote operation and review. Users of 42-65 or 54-75 Superior crushers of MK-I or MK-II vintage can upgrade to Super Spider 50-65 and 62-75 sizes, respectively. Superior crushers, which are best suited in quarry applications requiring at least 1,000 tons per hour, provide the lowest per-ton operating cost of any style primary crusher, according to Metso. Installation cost is much lower than in the past because a dual counterbalance system allows steel structure mounting, the company says.
HORIZONTAL-SHAFT IMPACTORS
7. Cedarapids 1516 Andreas Primary
Cedarapids, a Terex company, introduced its 1516 Andreas-type primary HSI capable of handling rock up to 34 in. with throughput capacities up to 600 tons per hour. The 55,700-lb. machine has a low-profile design, under 10 ft. tall, allowing its use in stationary or portable applications. The 1516’s 61-in. diameter x 64-in. wide high-inertia rotor is available in three- or four-bar designs. The 5-in. thick single-piece impeller bars allow three-turn wear using Cedarapids’ quick turn wedge system. A cast monoblock manganese primary breaker plate is reversible and adjustable to a 12-in. opening. The secondary breaker plate has interchangeable 3-in. thick tool steel or high chrome white iron liners.
It is adjustable down to 8 in. Hydraulic assist is available for breaker plate adjustments. A standard hydraulically opening upper frame provides access to the crushing chamber.
8. Eagle Crusher UltraMax 69
Eagle Crusher Co.’s UltraMax 69 primary impactor has a 69-in.-wide feed opening and a solid steel three-bar rotor. The company rates the machine at 400 to 600 tons per hour. The crusher has a gravity-hung, reversible manganese primary curtain and a hydraulically adjustable secondary curtain with bolt-on replaceable liners. The UltraMax 69 can be mounted stationary or as an in-pit portable. The portable system features gasoline-powered hydraulic lift and leveling to assist in relocation. Eagle Crusher says its new UltraChrome titanium blow bars can decrease wear costs to as low as 7 cents per ton in applications ranging from hard rock to heavily reinforced concrete.
9. Grasan KRH1515 Portable
Grasan’s largest road-portable primary crushing plant uses a Hazemag APPH1515QL impactor to process up to 650 tons per hour of concrete and asphalt or up to 800 tons per hour of limestone, according to the company. The 46- x 60-in. crusher inlet opening accepts up to 32-in. feed and a hydraulically moveable inlet base helps clear jamming and bridging. Hazemag’s APPH 1515QL HSI features automatic curtain adjustment with hydraulic cylinders. The unit has a 18,000 lb., 60- x 60-in. rotor powered by a 400-hp electric motor or optional Cat 3412C diesel engine. Crusher side liners are in three standardized shapes to reduce spare parts inventories. A 16 cubic yard skid-on hopper and grizzly feeder has a bypass chute to reject or retain undersize material. Six hydraulic legs allow set up and tear down without a crane.
10. Irock Magnum Series
Irock’s Magnum Series offers three sizes of portable primary impactor plants. Production capacities of the Magnum 4043, 4056, and 5060 range from 275 to 800 tons per hour of up to 36-in. material, according to the company. Irock impactors use only two blow bars, which develop 800,000 to more than 1 million ft-lbs force, the company says. An external key bar wedge locking system eliminates weak spots common to Andreas-style blow bars, which allows use of higher chrome alloys that decrease wear costs, according to Irock. Magnum plants have standard variable-speed vibrating grizzly feeders with a beveled grizzly design that removes fines without clogging.
11. Komatsu America Tracked Impactor
Built on the undercarriage of its PC200 excavator, Komatsu America’s BR480RG-1 track-mounted impactor crushes up to 330 tons per hour, according to the manufacturer. The machine has a 49-in. diameter x 51-in. wide rotor and a 52- x 40-in. feed opening. The two-stage grizzly is controlled by an auto-feeder system that senses crusher load. The unit also has an automatic gap-setting system.
12. Lippmann-Milwaukee 5165LP and 5860
The Lippmann 5165LP and 5860LP are primary impactor plants intended for recycle or aggregate applications. Rated capacities are 250 to 380 tons per hour and 350 to 600 tons per hour, respectively. The crushers feature semi-closed rotors attached to high alloy steel shafts with keyless locking assemblies and four reversible and flippable blow bars with vertical-lift replacement. Frame and apron liners are drilled and tapped to use standard hex head cap screws and lock washers. The bolted design keeps the plates tight longer as the liner wears, according to the company. A standard electric/hydraulic power unit and hydraulic cylinders open the crusher hood for maintenance access. The portable plants use 10-ft-wide quad-axle suspensions and have a 14-ft travel height. Various lengths of grizzly feeder are available.
13. Stedman Mega-Slam Series
Stedman offers five models in its Mega-Slam Series of primary impactors. The largest, MS6460, has a 61- x 46-in. feed opening and produces 500 to 700 tons per hour, the company says. Mega-Slam models have contoured solid rotors and use a breaker bar holding device with buried wedges to minimize wear, installation, removal, and indexing time, according to Stedman. The crushers have reversible manganese monoblock aprons and optional 3-in. thick replaceable secondary apron breaker plates. Interchangeable housing liners are made of 2-in. thick high-chrome or alloy steel. Maintenance and inspection access is provided by side and rear doors, a roof hatch, and a hydraulically opened hinged rear housing. The MS6460 weighs 83,000 lb.
FEEDER/BREAKERS
14. DBT Mineral Processing Roll Impactor
DBT Mineral Processing’s primary roll impactor (feeder/breaker style) is intended for low silica stone, such as limestone and gypsum. The units do not require feed hoppers or ramps. Material is dumped directly on a flighted chain feeder using wheel loaders or haul trucks as large as 100 ton capacity. The material is fed in a straight line all the way through the crusher and a rotor with impact heads mounted above the chain feeder crushes the rock. The chain feeder reverses to free oversize or wedged material. DBT’s smallest primary accepts 40- x 40-in. feed and produces as much as 450 tons per hour; its largest primary accepts 6- x 6-ft rock and can produce as much as 1,500 tons per hour, the company says. The units can be skid- or track-mounted and feature low overall height, making them suitable for underground operations.