May 8, 2011
Your complete guide to new and updated equipment and supplies in the aggregates industry.
By Aggregates Manager Staff
ConExpo-Con/Agg 2011 was the staging ground for the introduction of many new products and equipment for the aggregate industry. In fact, there were so many introduced at the show that we couldn’t fit them all into this one issue. So we have broken them up into categories and will run one or two categories at a time in this and the next several issues. We decided to lead off with crushers, the bad boys of the processing plant.
FLSmidth Pekin, LLC, recently merged into FLSmidth Salt Lake City, Inc., debuted three new models of its Raptor line of cone crushers at ConExpo-Con/Agg. The new models include the XL500, XL1300, and XL2000 cone crushers. The 500-horsepower XL500 is designed for secondary crushing with features such as a large feed opening, high pivot-point crushing action, and wide crushing stroke. With a head diameter of 59.06 inches, it can accept feed up to 25 percent larger than a crusher with less throw or a similar head diameter. The XL1300 is a 1,300-horsepower machine. With 2,000 horsepower, the XL2000 offers an extra-heavy-duty, high-grade steel mainframe; an automated control package; and a hydraulic tramp release cylinder and clearing system. These new features are based on customer input.
Durable construction, high production
The new Terex Cedarapids JS4552 jaw crusher, on display at the show, features durable construction and an aggressive crushing motion for high productivity. The company says the crusher is easy to operate and maintain, and offers new levels of reliability and convenience. The jaw die retention system and hydraulic assist shim system allow more uptime, as well as fast and easy jaw setting adjustments without the use of tools. Jaw die wedges, which are accessible from the sides of the crusher, are easy to remove and can be changed quickly, reducing downtime.
Highly versatile crusher
Powerscreen, a Terex company, showcased its latest XH500 horizontal shaft impact crusher at the show. Representing the latest generation of highly versatile track crushers, the company says it is designed for maximum throughput of up to 500 tons per hour and is ideally suited for contract crushing due to its high productivity and ease of set-up, operation, and maintenance. Key features include a vibrating pan feeder, a double-deck live pre-screen, a feeder load management system, an under pan feeder, an efficient crusher direct-drive system, crusher hydraulic overload protection, a hydraulic raise/lower product conveyor, a new PLC control system, and large stockpiling capacities.
Telsmith’s new Tel-Trax Model TC52 high-capacity, track-mounted cone crushing plant made a big impact on show goers. Built around the 400-horsepower model 52SBS cone crusher, Telsmith says the TC52 boosts tonnage output in secondary and tertiary applications, while accepting larger feed (up to 12-inch topsize) than 300-horsepower units. The unit is outfitted with automation controls that automatically adjust the feed rate and reduce the need for operator oversight by monitoring parameters such as crusher overload, feed bin levels, diesel power supply, and the discharge conveyor. The automated controls package also allows a soft link to additional Tel-Trax crushing and screening plants to provide a completely linked and integrated processing solution.
Kleemann debuted its MC 110 Z track-mounted jaw crusher at ConExpo-Con/Agg. The unit boasts a high-torque reversible hydraulic jaw and fully hydraulic gap adjustment that makes it friendly for the contractor market. The R version has an integrated grizzly, while the Z version has a fully independent, double-deck pre-screen. The unit can be fitted with an optional final screen and oversize discharge, which allows the operator to produce a final graded product with a single machine. The fuel-efficient crusher uses a Cat C9 engine and is configured for operation by a single person who can feed raw material into the crusher while using a wireless remote-control unit in the cab of an excavator or loader. Crusher dimensions are 44 by 28 inches; transport weight is 99,200 pounds; length is 47 feet, 5 inches; and width is 9 feet, 10 inches.
Quattro movement for increased feeding capacity
Atlas Copco showcased its new line of Powercrusher track-mounted mobile crushers and screeners, including jaw crushers, impact crushers, and cone crushers with a crushing capacity from 242 to 606 tons per hour, and screeners with a capacity of 242 to 485 tons per hour. The four jaw crushers incorporate “Quattro Movement” made possible by an up-thrust toggle plate position. This causes a figure-eight motion in the moving jaw, which increases the feeding capacity and produces a post-crush at the crusher outlet. The six impact crusher models use optimized geometry in the crusher box with hydraulically adjustable swing beams, resulting in a minimal percentage of oversized material and high reduction ratios and throughputs. The PC 1000 cone crusher is designed to accept an “all-in” feed that increases particle-on-particle crushing, which improves the quality of the end material shape, decreases wear, and may eliminate the need for pre-screening.
Sandvik’s new QH440 track-mounted cone crusher was on display at the show. It is designed for mobility, ease of transporting, and quick set-up time. The unit features a CH440 cone crusher capable of producing up to 388 tons per hour. Features include a heavy-duty, wear-resistant, hydraulically folding feed conveyor; a dual-coil metal detector; automated material level feed control; four jacking legs for stability; and a wide selection of optional extras. The unit comes with a choice of six crushing chambers ranging from fine to extra course. Product shape and grading can be easily adjusted by changing the throw.
Mobile impact crushing
The new MR 110 Z EVO unit from Kleemann made its first appearance in North America at ConExpo-Con/Agg. The impact crusher features a new material flow concept — the discharge chute under the crusher is 4 inches wider than the inner width of the crusher, and the subsequent discharge belt is another 4 inches wider than the discharge chute. Rapid flow of the material keeps it away from the critical area under the crusher and reduces wear. An independent vibrating double-decker pre-screen is said to improve the cost efficiency of EVO units. A newly designed crusher bypass includes changes to its geometry and form to boost performance and reduce wear. Optional new and improved screening units are available and are more than 44 percent larger in size than those on previous units, allowing for tonnages of between 350 and 450 tons per hour.
Sandvik displayed its QI440 track-mounted impact crusher, which features a fuel-efficient, 330kW, Tier 3-compliant, C-13 diesel engine and a Sandvik CI322 impactor. Fed via a two-deck, pre-screen, the crusher is a four-hammer, open-style rotor that discharges onto a secondary pan feeder. The unit has an operating weight of 54.9 tons and is 50.9 feet in length when in transport configuration. Additional features include a variable-speed primary pan feeder for controlled and continuous feed, an independent grizzly and underpan feeder for reduced blockages, and an optional recirculation conveyor.
Tracked HSI primary
Inertia Machine Corp. rolled out its 5066 Tracker Primary HSI Crusher at the big show. The track-mounted model is designed to deliver up to 700 tons per hour while offering trailer-free transport due to a design that includes the unit’s own removable axle. The crusher features a large 14-cubic-yard, non-heaping hopper and boasts a 60-inch by 18-foot variable-speed drive, vibrating grizzly feeder. Combined with a 42- by 64-inch feed opening, the impactor allows the handling of oversize material while preventing bridging. The 42-inch by 38-foot discharge conveyor with motorized head pulley is rated up to 1,500 tons per hour. The unit is powered by a John Deere 400-horsepower, Tier III diesel engine and a 125 kW generator.