November 1, 2008
Mobility can sometimes be a key factor for running a profitable operation. Here’s a selection of portable plants that are on the market today.
by Kerry Clines, Senior Editor
Metso Minerals Industries, Inc.
New generation mobile jaw
Metso Minerals Industries, Inc. says its Lokotrack LT3054 is operator friendly, combining constant high crushing capacity, a broad range of process options, and the newest dust and noise reduction options. The C Series jaw crushers have a non-welded, pinned and bolted design and can crush hard rock types such as basalt, as well as rock-based recycled materials. The crusher can be equipped with a high-capacity grizzly feeder, a pan feeder/scalper combination, or a pan feeder/roller grizzly combination. Optional two-deck screen and product conveyors are available. Transport dimensions are 57 feet long; 11 feet, 6 inches wide; 12 feet, 6 inches high; and a weight of 145,500 pounds. A side conveyor, transported separately, allows for increased discharge capacity and stockpile volume.
Kleemann Inc. USA
Two-deck, independent pre-screen
Kleemann Inc. USA’s Mobicat MC 120 Z mobile crusher has a two-deck, fully independent pre-screen which can be fitted with punch sheet, grizzly, and wire mesh. The crusher is fitted with a lined, heavy-duty vibrating feeder below the crusher to eliminate belt wear by impact when crushing. All of the company’s plants use an onboard diesel-electric generator to drive conveyor belts, vibrating chutes, and screens. The generator’s water-cooled diesel engine is enclosed in a sound-suppressing housing. Special heating and cooling systems are available for extreme climates.
Eagle Crusher Co.
The Hybrid Traxx is Eagle Crusher Co.’s first track-mounted impactor plant. The new design features diesel electrical power for both the impactor and the plant, with hydraulic operation powering the tracks. The machine features a compact design and can work in tandem with other stationary or mobile equipment. The plant is equipped with the new, three-stage UltraMax II Impactor and features a large 18-inch under-crusher clearance. Other features include a 5/8-inch steel hopper, 42- by 32-inch feed opening, and a 25-horsepower variable-speed feeder control. The 42-inch by 40-foot conveyor is fixed at a 10-foot discharge height, allowing direct loading of trucks. The plant also features a wireless handheld remote control with 30-foot tether backup. Options include hydraulic hopper side extensions, grizzly cross conveyor, and a magnetic separator for steel recovery.
Sandvik Mining & Construction USA LLC
Mobile secondary crushing unit
Sandvik says its UH440i and US440i mobile secondary crushing units provide a quick return on investment. The “i” stands for built-in intelligence that the company says ensures smart and trouble-free operation. The units come with Sandvik’s CH440 and CS440 cone crushers, respectively, and many added features. The units can operate independently or in a system incorporating other units and can be used under any climatic conditions. The crushers are equipped with ASRi, an automatic setting system that the company says optimizes cone crusher efficiency and automatically adapts the crusher to variations in feed conditions.
Versatile, mobile screen
The Fast Trax Series Mobile Processing Plants from KPI-JCI offer the ultimate in productivity, mobility, versatility, and adaptability, according to the company. The unit offers numerous value-added standard features, a hopper with performance enhancing options, and the versatility of unit-to-unit compatibility. The company says the unit represents the only line of track-mounted plants designed, manufactured, and supported in the United States that is backed by authorized dealers worldwide.
Mobile crushing system
Terex Cedarapids says it designed its new Mobile Aggregate Crushing System to be a highly mobile, high-capacity, complete crushing system, not just a collection of individual processing units. The company says MACS uses larger crushers and screens than what are typically used in track-mounted or wheeled plants. Trailer designs permit travel throughout most of the continental United States. The crushing and screening units travel under 13 feet, 6 inches high and under 12 feet wide. Interplant conveyors are designed into the units; folding conveyors and walkways are set up using on-board hydraulics, eliminating the need for cranes or lifts. The system uses industrial electric drives so that it can be powered by either generators or line power. System layout provides visibility of the entire circuit from a central pop-up control house. Belt wipers and skirted conveyors help minimize spillage.
Tracked primary impact crusher
Telsmith, an Astec company, says its new QuarryTrax Model TI6060 track-mounted primary impact crushing plant is designed for high-capacity production of up to 800 tons per hour. According to the company, the plant’s PA6060 impact crusher incorporates innovative technologies that prevent damage from any uncrushable materials, while reducing maintenance, providing greater uptime, and lowering operating costs. The hydraulic system provides fingertip control of apron adjustments. A hydraulic tilting feed plate clears bridging. Easy-access inspection doors and a hydraulic upper frame allow quick maintenance access. The Trax-Max control system monitors and controls plant operations. A handheld wireless remote maneuvers the plant and provides crusher, feeder, engine, and conveyor control from a safe distance. Available options include a hydraulic hammer, 18-cubic-yard hopper extensions, a folding conveyor extension, scrap metal magnet, and more.
Portable jaw crusher
Grasan road-portable and pit-portable jaw crusher plants are available in a range of sizes with various crusher brands and diesel or electric power. Plants can be customized to meet each customer’s needs or specifications. Chassis frames are built with high-strength, wide-flange steel beams. Hoppers use 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. Bypass chutes have steep valley angles, wear liners, and large clean-out doors. Discharge conveyors feature heavy-duty construction with impact bed sections under the crusher. Most plants can be equipped with a skid-on, skid-off hopper-feeder module for over-the-road weight reduction and fast plant setup without a crane. Six independent hydraulic legs further enable fast setup. Complete electrical packages are available with starter panel, wiring, quick disconnects, and remote operator control station.
FLSmidth Excel LLC
Mobile/portable cone plants
Raptor XL300 and XL400 cone crushers by FLSmidth Excel LLC can be custom designed as portable wheel-mounted or mobile track-mounted plants. Wheel-mounted plant options include rear discharge and rear-feed side discharge for both the XL300 and XL400. When combined with a horizontal 6- by 20-foot two- or three-deck screen, the SL 300 can be configured into a closed-circuit crushing and screening plant. Both crusher models can be configured with two- or three-deck horizontal screens that are 6, 7, or 8 by 20 feet to provide open-circuit crushing and screening plants. Optional hydraulic run-on jacks are available to quickly level the plant into operating position after pulling onsite. Both models feature a high pivot point and large crushing stroke for excellent crushing action throughout the crushing chamber.
Heavy-duty crawler undercarriage
The new Terex Pegson XV350 vertical shaft impact crusher features the Terex Canica 2050 GD VSI crusher on the Terex Pegson I-Beam chassis with heavy-duty crawler undercarriage. The company says the plant crushes up to 350 tons per hour, produces an excellent product shape, and is ideal for the manufacture of sand. The Hardox fixed-feed hopper with crash bars has a lowering rear door that allows the plant to be fed by any of the company’s crushers on flat ground. A touch-screen control panel operates the crusher/engine speed, oil pump, discharge and feed conveyors, and crusher level controls. Other features include a wide variable-speed feed belt with hydraulic raise/lower and spray bars with atomizer nozzles for dust suppression at the crusher mouth, product conveyor feed, and discharge end.
Single-toggle jaw crusher
Terex Finlay says its compact, track-mounted J-1175 single-toggle jaw crusher boasts easy transport, fast setup, and on site mobility. The crusher is fitted with a heavy-duty vibrating grizzly feeder with integrated pre-screen and automatic control to regulate the feed into the crusher, plus hydrostatic drive and reverse crushing action to assist in clearing blockages. The unit features a hydrostatic transmission for its crusher drive and two-speed tracks with “soft start.” The 11.7-cubic-yard hopper has hydraulically folding sides for fast setup. Transport dimensions are approximately 47 feet, 8 inches long; 9 feet, 6 inches wide; and 116 inches high. Available options include a full-function radio remote-control unit, bypass conveyor, over-band magnet, belt weigher, and independent pre-screen.
Four-row cage mill
Stedman says its four-row Cage Mill is efficient and reliable and allows aglime producers to produce aglime to any specification and meet most state specifications in open circuit. According to the company, the mill produces consistent product quality with little change in product throughout the life of the wear components, even with high-moisture feed. Feed does not have to be dry. Material is loaded into the feed hopper, conveyed to the cage mill, crushed, and then discharged out the side. Discharge is completely open and requires no screens or grate bars. Mill capacities range from 5 to 100 tons per hour.
Custom-designed portable plants
Universal Engineering provides custom-designed and built portable plants to meet each of its customer’s needs. Design emphasis is placed on optimum control of the material flow for flexibility, safety, and efficiency. According to the company, the plants are easy to set up on the jobsite and reduce downtime between production runs.
Extec Screens & Crushers Ltd.
Track-mounted compact crusher
Extec’s new C-10+ track-mounted mobile crusher is designed for small quarry, recycling, or demolition applications. The crusher is carried on a sturdy, angled superstructure that gives it a more sturdy appearance and adds 2 tons to its weight, taking it to 32.1 tons. A wide door provides easy access to all the engine’s key maintenance points. A vibrating feeder ensures a consistent flow of material to the machine’s jaw, which operates at 300 rpm. Its jaws can be quickly and easily operated in reverse to free any blockages. The machine’s engine, hydraulics, feeder, crusher, and conveyors can be controlled from the control panel located safely within reach of an operator beside the unit. A separate “umbilical” control offers some limited stop/start and travel controls.
Fintec Crushing & Screening Ltd.
Fintec says its 542 track-mounted mobile screen is robust and highly durable. The machine is carried on a heavy-duty tracked undercarriage with 20-inch-wide tracks that provide maneuverability and stability. The screen incorporates a large-capacity 12- by 5-foot two-bearing screenbox with increased screening angle built into the bottom deck. The unit’s belt feeder has a large capacity and is fitted with a radio-controlled tipping reject grid. A folding access walkway around the screenbox provides easy maintenance access. Other features include a quick-release screen section on the high impact zone of the top deck, pendant track control, heavy-duty belts on all conveyors, and Engine Shut Down Protection System.
Mobile jaw crusher
Komatsu’s BR580JG-1 Mobile Jaw Crusher has a newly designed vibrating grizzly feeder and an all-hydraulic drive system. The crusher has an EPA Tier 3-certified electronically controlled high-pressure common rail fuel-injection system. The machine is equipped with the latest Komtrax technology, which sends machine operating information to a secure Web site using wireless technology. Data such as operating hours, location, cautions, and maintenance alerts are relayed to the Web application for analysis. The automatic discharge system makes it easy to change the opening of the discharge port. All operation switches are located at ground level on the main control panel. A one-touch start button sequentially starts the operation of the magnetic separator, belt conveyor, jaw crusher, and feeder.
Rubble Master Systems Inc.
New class mobile processing
Rubble Master says its compact RM100 recycler is versatile, powerful, and stable, and can be transported without special permits. Transport weight is just 31 short tons. Features include a crushing capacity up to 220 short tons per hour with 1 1/2-inch minus final product; radio-controlled release system that clears blockages at the push of a button; and high-performance, wear-resistant crushing tools. The company says the machine has the ability to handle any material in any environment.
Continuous-flow crushing plant
Lippman-Milwaukee says its new Lippmann 6500LP Crushing Plant offers a revolutionary flow design and other features that can result in twice the production of competitive plants. A larger feeder, larger impact crusher, and larger screen deck combine to make the machine the highest producing plant for its size in recycle crushing, says the company. A continuous-flow design allows material to discharge smoothly with the rotation of the rotor for uninterrupted production. A heavy-duty pan feeder under the crusher prevents conveyor belt damage. On-board return conveyors mean that only two pieces of equipment, instead of four, need to be moved to the jobsite. Setup and tear down are fast and easy.
Vertical shaft crusher
The Remco SandMax 500-ST crusher is an autogenous vertical-shaft crushing machine designed to operate as a third or fourth stage crusher in the processing of all types of rock, ore, and minerals. The crusher can be operated in either open- or closed-circuit (closed-circuit is recommended for lowest net operating cost and highest production rate of any given size below 1/2 inch). The 400-horsepower machine has a feed size of 1 1/2-inch by #4 mesh and a production rate of 130 tons per hour.
Astec Mobile Screens
Astec Mobile Screens says its PEP Duo-Vibe, high-frequency screen is incorporated into the heavy-duty Fold ‘n Go Series of mobile screening plants via the Fold ‘n Go 2612D. The unit offers a double-deck PEP scalper/high-frequency combination screen for processing coarse and fine material separations. The machine gives maximum production and efficiency in crushed stone, RAP, sand and gravel, and more, according to the company. The company says the wheel-mounted plant is able to move around to multiple jobsites with a quick setup time of under 15 minutes.
The Powerscreen Warrior is a machine capable of dry screening, three-way splitting, and stockpiling. The screen box can be raised/lowered hydraulically for easy maintenance. Several sizes of screens and wires can be bolted in easily. The side conveyor can be removed to allow the unit to be converted to a two-way split machine with two products on the tail conveyor. The radial fines conveyor can move up to 180 degrees for greater stockpiling capabilities. The incline/horizontal belt-feed hopper discharges onto the screen box from above, spreading the material on impact and allowing it to flow more equally over the screen. Other features include hydraulic folding conveyors, hydraulic screen angle adjustment, hydraulic retractable oversize conveyor for ease of mesh change, hydraulic folding hopper sides, a screen walkway, engine protection shut-down system, and integrated variable-speed belt feeder. The machine sets up in about 20 minutes and can screen up to 550 tons per hour, according to the company.
Company Reader Service #
Astec Mobile Screens 20
Eagle Crusher Co. 3
Extec Screens & Crushers Ltd. 14
Fintec Crushing & Screening Ltd. 15
FLSmidth Excel LLC 9
Kleeman Inc. USA 2
Lippmann-Milwaukee, Inc. 18
Metso Minerals Industries, Inc. 1
Rubble Master Systems Inc. 17
Sandvik Mining & Construction USA LLC 4
Terex Cedarapids 6
Terex Finlay 11
Terex Pegson 10
Universal Engineering 13