December 1, 2013
Whether focusing on production basics or new engine emission requirements, this year’s new equipment offers opportunities to upgrade operations.
by Therese Dunphy, Editor-in-Chief
and Kerry Clines, Contributing Editor
How we made our choices
When we ask readers how we can best help them keep track of changes in the products and services they use to produce aggregates, almost everyone wants an annual short list of the really important stuff.
No wonder. The sheer volume of introductions is overwhelming. Aggregates Manager covers numerous products each year in its RollOuts departments and Supply Lines features and offers even more product coverage through its website and newsletters.
So each year, our staff reviews all the product introductions we’ve covered for the past year to pick out 25 that we believe are worth further review. Our priorities are new concept products, which are rare; new series/new generation products in categories that relate to the aggregates industry; and other rollouts which serve our readers’ interests by increasing competition in a product category.
Inevitably, we omit deserving products, either because we just didn’t understand the significance of the product or because the announcing company didn’t communicate what was special about the product, or both. In either case, we apologize in advance for these omissions.
Atlas Copco’s line of bucket crushers joins its silent demolition tool range of hydraulic attachments. Said to reduce the overall cost of a job by reducing the amount of equipment needed on site, the four new buckets were engineered with a wide aperture bucket and large capacity. The output size adjusts from 0.5 to 4.75 inches, with a slightly smaller output size in the smallest model. The bucket jaws, which receive the most wear, can be inverted. The top and bottom jaws can be replaced or single jaws can be rotated by 180 degrees to extend wear and service life.
Upgraded simulation software
Three years in development, Bedrock Software, LLC’s newest program is said to represent a completely new generation of simulation software to manage and optimize an aggregates operation. AggFlow Design and Manage is a hybrid program that allows users to work on-line or off-line and to share projects with other users at will. The sharing capability is intended to allow process engineers, consultants, and equipment dealers to work more effectively and efficiently when developing a plant optimization strategy. Simulation can be used to determine optimal production capacity for a particular equipment configuration; then users can input field sample data to compare what the operation is actually producing to its theoretical capability. This information can then be used to identify and eliminate bottlenecks and inefficiencies. BedRock | www.aggflow.com Text INFO to 205-289-3782 or visit aggman.com/info
World’s largest rockbreaker
BTI introduces the TRX64 stationary rock breaking system. Said to be the world’s largest rockbreaker, the unit weighs more than 110,000 pounds. Booms for the TRX series range from 48 to 64 feet carrying breakers in the 8,500- to 20,000 foot-pound class, depending on reach.
BTI | www.rockbreaker.com
Text INFO to 205-289-3782 or visit aggman.com/info
Innovative screen options
Deister’s exciter vibrating mechanism is designed for use with large, linear-stroke screens and feeders. The company says multiple units can be positioned in series and linked by flexible shaft couplings to provide exceptional B-10 bearing life in conjunction with aggressive G-force. Innovative seal, shaft, and bearing designs are said to make the unit rugged and easy to maintain. The exciter mechanism can be driven by V-belts or a direct-drive flexible shaft.
Powerful dust suppression
Dust Control Technology says its DustBoss DB-100 dust-suppression unit is engineered for use in large quarries. With a range of more than 100 meters, the machine is able to reach stockpiles 200 to 300 feet high. The atomized misting unit stands nearly 10 feet tall and can cover an area of 280,000 square feet from a single location. The machine is fed by a manifold of 30 brass nozzles; features simple, user-defined 359-degree oscillation with an adjustable elevation from -7 to 45 degrees; and can be outfitted with a dosing pump to meter in surfactants or tackifiers to enhance the binding of dust particles.
Elrus says its new compact 6- by 12-foot three-deck screen plant was designed with an emphasis on increasing plant efficiency, reducing size and weight, and reducing the overall cost of ownership. It incorporates two screening sections on each deck, offering the benefits of both horizontal and inclined screening. The primary high-angle panel at the feed end results in rapid fines removal, while the secondary lower-angle panel results in accurate sizing and stratification.
Fully automated drill rig
Flanders says its new Ardvarc 4.0 is the world’s first fully automated multi-pass drill rig that also features the first autonomous angle drill implementation. The machine features multi-pass and semi-pass automation, drill-hole and hole-angle accuracy, automatic drill string adding and racking, new human/machine interface (HMI), new data collection, and more modular hardware. It can align itself to within +/-1 degree of the design heading of the hole and automatically set the proper mast angle, according to the company. Flanders | www.flandersinc.com | Text INFO to 205-289-3782 or visit aggman.com/info
Belt training solution
Flexco says its easy-to-install PT smart belt trainer is made of durable materials and works with both mechanical and vulcanized belts. The item features pivot-and-tilt technology that corrects tracking problems on medium-tension belts. A fully enclosed stainless-steel pivot bearing located downstream from the roller creates an almost immediate tracking result. The bearing requires no lubrication and is guaranteed not to seize.
The Instantel Third Party Access for Series IV software application allows users to control, upload, and download data directly from Instantel Minimate Pro4 or Minimate Pro6 seismographs without using the Instantel Blastware Compliance Module. Event data can be exported into the XML, CSV, or ASCII file formats. Exported data can be further analyzed within a spreadsheet or leveraged using the Internet, automating the process of transferring vibration data directly from the Series IV unit to a website for viewing by approved stakeholders. The program also maintains the proprietary Instantel Event format and security features and the same functionality as the Blastware Compliance Module. Instantel | www.instantel.com | Text INFO to 205-289-3782 or visit aggman.com/info
John Deere’s 644K hybrid wheel loader uses diesel and electric power and captures regenerated energy as it is created to use in powering the machine. The loader features a 229-horsepower John Deere PowerTech 6.8-liter Tier 4 Interim engine that runs at an operator-selected constant speed from 900 to 1,800 rpm. The company says the engine’s constant operating speed maintains continuous hydraulic flow at all times to deliver crisp hydraulic responsiveness and reduce cycle times; the electric motor delivers torque resulting in fluid operation and a smooth ride. The machine has four operating speed ranges, but no reverse gear or clutches as direction changes are performed by the electric motor. Deere & Co. | www.johndeere.com | Text INFO to 205-289-3782 or visit aggman.com/info
Takes measurements in the field
Laser Technology, Inc. released the 200X TruPulse laser rangefinder to measure slope distances and degree of inclination. The unit can then calculate horizontal and vertical distances, height, and 2D missing line values. Suitable for applications requiring a high degree of accuracy, such as rock face profiling for blast design or stockpile measurements for volume and tonnage calculations, it produces measurements with a +/- 2-inch range of accuracy.
Intelligent machine control dozer
Komatsu America Corp. rolled out the D61EXi/PXi-23, its first intelligent machine control model in North America. While crawler dozers have been able to perform high-precision finish grading after installing an add-on machine control system, the unit’s fully automatic blade control allows it to perform rough dozing, as well as finish grading in automatic mode. Customer selectable dozing modes allow system response to be tailored to the current machine operation for optimized performance. A factory-installed cab top Global Navigation Satellite System (GNSS) antenna, inertial measuring unit, and stroke-sensing hydraulic cylinders replace the typical add-on machine control system components. Komatsu America Corp. | www.komatsuamerica.com | Text INFO to 205-289-3782 or visit aggman.com/info
KPI-JCI and Astec Mobile Screens showcase the Kodiak Plus K500+, a new 500-horsepower, remote-adjust cone crusher. The unit is the latest addition to the Kodiak Plus Cone Crusher family and fills a demand for larger secondary and tertiary cone crushers that are used by high production aggregate producers and mining companies. Some of the refinements implemented into the Kodiak Plus product line include a new hybrid cast/fabricated base frame design, the ‘MILO’ automated control system, a new patented liner retention system, patented thread locking ring, and anti-spin cone brake.
Produces high-spec aggregates
The McCloskey V80 vertical shaft impactor is now available around the world. The company says it is designed to produce high-specification sealing aggregates, with a high proportion of fines required for main roads, road base, or manufactured sand. The plant features a Cemco crusher, a heavy-duty feeder with hardox steel hopper, a 350-horsepower Cat C9 engine, and four possible crusher combinations for higher efficiency and less wear.
McCloskey International Ltd. | www.mccloskeyinternational.com
Text INFO to 205-289-3782 or visit aggman.com/info
High reduction ratio
Metso’s HP3 cone crusher is said to provide the highest reduction ratios of any cone crusher in its class, produce finer products using fewer crushing stages, and save customers energy and operating costs. Its high-cavity density is said to improve inter-particle crushing action for end products with consistent gradation and superior shape. Major enhancements include dual-acting hydraulic tramp release cylinders that enable the crusher to pass tramp iron without stalling or damaging internal components. If the crusher does stop under load, the dual-acting cylinders provide a large clearing stroke to quickly and safely clear the crushing cavity. An advanced fastening system for the mantle and bowl liner eliminates the need for backing material, making liner changes fast and easy. The crusher features an IC700 automation system for optimum operating parameters.
Mobile leachate and wastewater system
The Neptune Evaporator System, from Neptune Systems, offers a low-cost method for environmentally sound leachate, storm water, and wastewater disposal. It offers on-site disposal at a cost of less than 1 cent per gallon by converting a liquid stream into an aerosol, which allows the water to evaporate while contaminants settle back in a narrow alley at the front of the evaporator. Mounted on a trailer for easy transport on site or to multiple locations, the unit processes an average of 4,000 gallons per hour and up to 9,000 gallons per hour in optimal conditions.
Aggregate truck body
Philippi-Hagenbuch, Inc. introduced a new design for its Aggregate HiVol Body. The new body, developed for use in quarry environments, fits all brands of off-highway, rigid-frame haul trucks. Designed to match the life of the truck, the new body is said to decrease carryback of sticky material. Engineers gather information on height and width restrictions, as well as loading tools and hopper/loadout, to create a body tailored for maximum productivity and minimum maintenance according to site-specific needs. The body’s design also incorporates the tailgate, allowing for maximum payload.
Fully independent pre-screen
Powerscreen says its XH320X impact crusher was developed with a fully independent, hydraulically driven pre-screen, which improves fines removal and reduces chamber wear costs for the customer. A hydraulically folding extended side conveyor with a stockpile height of about 12 feet has been added to the machine. The hopper capacity has been increased by the addition of hopper extensions, which also can be hydraulically folded for transport. The new hopper design incorporates hydraulic locking pins for rapid set-up time and removes the need for manual wedges. The unit has a full-length product conveyor with optional under-pan feeder for recycling applications. An optional extended, hydraulically folding product conveyor increases stockpile height to slightly more than 13 feet.
RMT Equipment’s upgraded VEI Millennium 5 and Helper X loader scales are now equipped with new high-definition color displays to improve visibility in any angle and light condition. A new, removable Vprint ultra-fast thermal printer can be located underneath the monitor or anywhere in the cab. Customers can start with the entry level VEI Millennium 5 and upgrade to the advanced Helper X model as their needs grow in the future.
RMT Equipment Inc. | www.rmtequip.com | Text INFO to 205-289-3782 or visit aggman.com/info
Low capital cost
Sandvik’s CI521 impact crusher is part of the Prisec CI5xx series of horizontal shaft impact crushers, which the company says provides customers with a low capital cost solution, optimum performance, good cubical shape, and the lowest operating cost per ton. The patented crusher range was developed in response to customer demands, combining the ability to configure one stationary crusher into either a primary or secondary configuration, which makes it adaptable to a variety of applications.
Reduced setup time
Superior Industries’ Swing Axle XTP TeleStacker conveyor shifts from road to radial mode in just five to 10 minutes, drastically reducing the 45- to 60-minute setup time required by the original model. The conveyor’s new power travel system is engaged by a pre-installed t-handle mechanism that takes just seconds to engage and needs no maintenance or guarding. Its new axle design requires fewer link arms during transport and while in operational modes. The addition of a pivoting walking beam allows for true wheel alignment during radial travel.
Superior Industries, North America | www.superior-ind.com
Text INFO to 205-289-3782 or visit aggman.com/info
Crushing capabilities coupled with easy maintenance
Telsmith says it engineered the T300 Cone Crusher for maximum uptime and productivity while delivering 300-horsepower performance and a crushing capacity of 125 to 400 metric tons per hour in abrasive quarry applications. The unit is designed with six cylinders — fewer than conventional units — but offers large crushing force avail¬ability. A patent-pending anti-spin feature (mounted on top of the machine for ease of maintenance) prevents head spin to extend manganese life. Also patent-pending are the unit’s hybrid bearings that offer both static and dynamic lift, which results in greater lift to efficiently carry the crushing forces.
High weight-to-power ratio
Screen Machine says its patent-pending, track-mounted CST cone crusher features a 50-inch quarry-duty cone crusher that offers the highest weight-to-power ratio of any tracked cone plant in the industry. It is uniquely designed with a vibratory shaker screen located between the feeder and crushing chamber.
Screen Machine Industries, Inc. | www.screenmachine.com
Text INFO to 205-289-3782 or visit aggman.com/info
Modular washing and screening
Terex Washing Systems’s AggreSand incorporates Terex washing systems in a modular design that is pre-wired and pre-plumbed to allow for quick and easy set-up, as well as ease of maintenance. A 12-cubic-meter hopper is available with an automatic tipping grid and a 12-foot, two-deck vibrating grid complete with variable-speed belt feeder, all controlled from the main operator interface and radio control unit. A wide-feed conveyor sports a direct-drive electric motor and gearbox arrangement and will work at a 19-degree angle when feeding the system. The three-deck, two-bearing rinsing screen has riveted construction to reduce stress associated with welds. Each deck has eight individually controlled spray bars, which are isolated from vibration. A split sump tank receives rinsed fines from the bottom deck of the screen while two centrifugal slurry pumps move material from the sump tank into two hydrocyclones. Underflow from the hydrocyclones goes to a dewatering screen fitted with two counter rotating vibratory motors. The unit also has the option of three aggregate and two sand conveyors, which are powered by direct-drive electric motors and gearbox arrangements.