The Big Boys of Crushing
These extra-large crushers, with production capacities of 700 tons per hour or greater, are not for the faint of heart.
By Kerry Clines, Senior Editor
Cemco says its Turbo 128 V-Twin VSI crusher is ideally suited for the production of 1 1/2-inch aggregate rock commonly used in concrete and is customizable for the production of several types of aggregate materials. The crusher is driven by a dual-drive V-Twin motor available with up to 900 horsepower. It weighs approximately 42,000 pounds and offers production capabilities of up to 1,000 tons per hour.
Williams Patent Crusher’s Willpactor impact crusher, with a capacity of up to 2,500 tons per hour, was totally redesigned in 2004 with input from quarry operators. Medium chrome or manganese blow bars are indexable and easily replaced. The crusher’s adjustable, solid impact block allows product gradation control and reduces problems resulting from bridging. Moving the hydraulic breaker plate adjustment allows bridged material to fall into the path of the blow bars without interrupting operation.
McLanahan’s Universal MaxCap impact crusher is available in three different primary impact crushing models with capacities of up to 2,000 tons per hour. It offers the large expansion crushing chamber of a New Holland-style impact, while using the replaceable hammer technology of the Andreas-style crusher to break rock. It is said to deliver a high-quality, cubical product at a lower cost per ton.
Hazemag says its primary impactors incorporate the latest designs and control technologies, ensuring consistent performance, economical operation, easy and safe maintenance, and extended service life. The crushers are fitted with the HAZtronic system that puts the operator in control. Production capacities range from 100 to 2,800 short tons per hour.
Eagle Crusher’s large UltraMax 1600-69 has a production capacity of up to 800 tons per hour. The portable plant features a 13-ton sculptured solid-steel, three-bar rotor that is said to absorb the shock of large, aggregate materials and reduce down time. It includes the UM69 impactor with a 68-inch by 20-foot feeder, 69-inch feed opening, and fully lined hopper. The self-contained plant comes in standard 500-horsepower electric, optional 800-horsepower electric, and 521-horsepower diesel.
FLSmidth’s versatile 1500 x 134 Raptor 500 cone crusher provides secondary crushing capabilities of up to 850 tons per hour. It is a stationary unit with multi-site flexibility. The company says its Raptor crushers offer more crushing force with a high pivot point and large crushing stroke for better end-product shape. The company says the crusher’s new design offers maximum productivity and maintenance benefits.
Trio’s TC-84 cone crusher features a 500-horsepower electric motor, an 84-inch head diameter, a push-button hydraulic console that controls clearing and adjustment, and a crushing capacity of up to 1,430 short tons per hour. Its self-contained, skid-mounted oil lubrication system is PLC integrated with automatic shutdown sensors for out-of-tolerance oil temperature, pressure, or flow. Electric in-tank heaters and an electric air-to-oil heat exchanger for cooling provide a climate-controlled lubrication system.
Metso says its C145 jaw crusher, one of the largest models in the company’s C Series, can reach capacities of more than 1,000 tons per hour, depending on the closed-side setting. Like all of the C Series jaw crushers, the C145 has a large eccentric throw coupled with a steep toggle-plate angle that magnifies the effective stroke at discharge. The company says the large stroke, combined with the right speed, flywheel inertia, and high crusher power, results in high crushing performance.
The Telsmith J3858 jaw crusher is capable of processing up to 950 short tons per hour. The crusher’s hydraulic chamber clearing allows stone to be passed through the crusher with the push of a button, increasing uptime and eliminating a potentially unsafe situation for employees. Hydraulic overload protection allows cylinders to release and free tramp metal, then return to the normal operating position, lowering operating costs by not damaging toggles.
The new Terex Cedarapids JS4552 jaw crusher features durable construction and an aggressive crushing motion. The company says it handles large feed sizes and is easy to operate and maintain. The jaw die retention system and hydraulic-assist shim system allow more uptime. The jaw die wedges are accessible from the sides of the crusher and are easily removed. The hydraulic-assist shim system allows jaw setting adjustments to be made easily without tools.
Kleemann’s Mobicat MC 160 track-mounted jaw crusher employs a 77-ton, single-toggle jaw crusher that weighs approximately 15 tons. Powered by a 422-horsepower electric motor, the plant has a crushing capacity of up to 1,000 tons per hour for hard stone and up to 1,500 tons per hour for limestone. Features include a feeder capacity of up to 55 x 43 inches, a 3,178-cubic-foot capacity hopper that can accommodate two 41-ton-capacity dump trucks, and an inclined apron feeder with a double wobbler feeder. Weight is distributed over two hydraulically operated crawler tracks.
Joy Global’s BF23D-22-475 feeder breaker reduces run of mine limestone up to 36 inches in size down to minus 9 inches at a rate of 1,000 tons per hour. The 550-horsepower unit is skid mounted, allowing it to be kept close to the face to minimize haul distance. The company says the 50-inch-diameter machine delivers consistent product size with minimal fines generation.