Rock to Road

Features Aggregates Technology
Focus on Crushers

A roundup of the latest crusher models available


August 12, 2008
By


Topics

Focus on Crushers

Two new Raptor cones unveiled
by FL Smidth Excel

24The XL600 and the XL 900 have joined the Raptor cone crusher
line of FL Smidth Excel LLC.

The XL600 is designed for medium-to-high tonnage aggregate operations needing a large secondary cone with a maximum throughput
capacity that approaches 907 tonnes/h. The XL600 handles feed sizes
up to 360 mm with, claims the manufacturer, the most active feed
opening on any competitive model for better product shape and higher
yields of saleable product.

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While the machine has a 600 hp motor, the crusher speed can be
selected to optimize throughput, size reduction, product shape and
product yield. The large 1.65 m crushing head uses the same eccentric motion as the other Raptor series cones, with a high pivot point
and large crushing stroke for improved crushing action throughout the
crushing chamber.

The XL600 can be installed to replace cone crushers with a 1.5 m
head diameter or larger without major modifications to foundations or
feed arrangements.

The XL900 is a 900 hp cone that delivers a throughput capacity of
nearly 1270 tonnes/h in a quarry’s secondary position. The high pivot
point and large crushing stroke is claimed to produce more crushing
action from the first nip at the feed opening and through the chamber
until the material exists the parallel zone.
Featuring a large 1.8 m crushing head, the unit handles feed sizes
up to 313 mm. It easily allows a reduction ratio of up to 6:4, according
to the manufacturer.
Both the XL600 and the XL900 are built with a rigid four-arm
frame and integral countershaft mounted inside one of the four arms.
This provides a stronger frame design and avoids pitfalls associated
with an external countershaft box, claims the manufacturer.
www.excelcrushers.com

Fintec adds track-mounted cone

24b

Fintec Crushing and Screening Ltd. has introduced the new Fintec
1080 cone crusher to its line of track-mounted crushing plants. Designed to generate excellent particle shape products, the 385 hp cone
combines high strength and high capacity with high-reduction performance, all-in-feed and direct hydraulic drive. Its hydraulic closed-side
setting and tramp iron relief system makes the 1080 well suited for
recycle and contract crushing operations.

The 1080 features a Sandvik H3800 cone crusher, developed with
the Sandvik CSC (cubical shape crushing) technology for meeting
tight spec standards. Equipped with a 5 m3 capacity feed hopper and a
maximum feed opening of 191 mm, the hydraulic-adjust cone allows
a coarse closed side-setting (CSS) of 13 mm to 38 mm and a medium
CSS of 8 mm to 25 mm. Crushing chambers are available for extra-
coarse to extra-fine applications.

Among the 1080’s automated features is a level monitor that controls the feed rate to ensure choke feeding, while a semi-automatic
setting regulation system optimizes production and tracks liner wear.
A 1000 mm wide hydraulic folding conveyor allows easy access from
above the crusher maintenance. The hydrostatic crusher drive is con-
trolled by a remote radio console.

The compact design of the 1080 track-mounted plant enables it
to be transported from site to site on a lowboy trailer. Plant setup and
operation is carried out in a matter of minutes. Onsite mobility is
achieved by simple controls, rugged 508 mm wide tracks and a Cat
Tier III-compliant engine.


KPI-JCI adds automation to jaw, cone crushers

25

A new automated setting system has been introduced by KPI-JCI,
a member company of the Astec Aggregate and Mining Group, for its
existing line of Vanguard Jaw crushers. The standard version of this
new feature offers single hydraulic control that will modify the toggle
and spring tension adjustments simultaneously.

According to the manufacturer, the new setting system increases
functionality, reduces labour and increases jaw output. This feature
allows for adjustments while the crusher is in operation.

An optional version of the setting system offers a
single hydraulic control that will modify the
toggle and spring tension assembly plus in-
corporates a relief function as well. The major
benefit of the optional version is its ability to
automatically relieve itself from a non-crushable
condition without causing potential damage to the
crusher.

Also available from KPI-JCI is a new automation systems package for its Kodiak cone crusher line. The pack-
age includes a user-friendly touch screen PC which provides more
intuitive controls and monitoring. The PLC controls all machine
functions for higher operational reliability while monitoring hydraulic
pressures, temperature, flows and levels. Options for data logging and
access of operational parameters, production data and error condition
are available with the new automation systems package.

On the mobile track mounted plant side, KPI-JCI has launched its
largest Fast Track jaw plant to date. The new FT 3055 Fast Track is
built around a 30×55 jaw that offers production rates of up to 635
tonnes/h. The plant is aimed at the quarry, recycle and contractor markets. Among it notable features is an overload protection system which
optimizes production by regulating the crusher feed to prevent
overloading and possible plugging.

www.kpijci.com


Komatsu launches new mobile crusher

Komatsu has announced its new BR580JG-1 mobile jaw crusher
that features a newly designed vibrating grizzly feeder and an all-hydraulic drive system.

With an operating weight of 48 988 to 50 984 kg, the BR580JG-1 is
powered by a fuel-effi cient Komatsu SAA6D125E-5 engine that EPA
Tier III emissions certifi ed.

The new crushing plant is equipped with the latest Komtrax technology (Level 2), which sends machine operating information to a secure
website utilizing wireless technology. Special features of the new plant
include Komatsu’s patented HydrauMind fully hydraulic drive system,
a newly-designed vibrating grizzly feeder and a new KC4430 jaw.

By delivering the optimal amount of oil through load-sensing and
pressure-compensated valves, the HydraMind hydraulic system senses
overloads and automatically slows the feeder down.

In operation, the new grizzly feeder moves the material elliptically
to effectively separate and feed it evenly into the KC4430 jaw which is
equipped with a load-presetting semiautomatic feeder system.

The plant is also equipped with a fully-automatic discharge adjustment system and crusher protection.

According to the manufacturer, this system makes it easy to change
the opening of the discharge port. Even with routine wear on both
plates, the discharge setting can be changed with a simple one-touch
operation. The jaw protects itself by allowing the locking cylinders to
fully open the discharge port which makes it easier to remove clogged
material from the crusher.

All operation switches are located at ground level on the main control panel, allowing the operator to easily reach and control the operations. With a one-touch start button that sequentially starts the operation of the magnetic separator, belt conveyors, jaw crusher and feeder,
the operator can have the unit up and running in a matter of minutes.
www.komatsu.ca

McCloskey teams with Telsmith

A new heavy-duty, track-mounted crushing plant has been launched
by McCloskey International. The C50 jaw plant is the first of a completely new range of track-mounted jaw, cone and impact crushers that
McCloskey International plans on bringing to the market.

At the core of the new C50 mobile plant is a 50×26 single toggle
jaw developed in partnership with Telsmith Inc. In addition to its own
lines of aggregate production equipment, Telsmith is a major manufacturer and supplier of specialized components to other companies
such as McCloskey International. The C50 is designed for fast set up
times and easy transport. The open chassis design facilitates maintenance.

Powered by a 350 hp Cat C9 Tier III diesel engine, the main components of the C50 include an integrated hydraulic folding hopper and
hydraulic folding stockpile conveyors, a 6.8 m3 feed hopper, an 1180
mm x 4.3 grizzly feeder with adjust speed up to 975 rpm, a 650 mm
x 2.23 m side conveyor and a 1050 mm x 4.21 m product discharge
conveyor.
www.mccloskeyinternational.com

 
High capacity crushing system from Terex

A new mobile aggregate crushing system, called MACS, is the
latest development from Terex/Cedarapids.
MACS is designed to be a highly portable,
high capacity, completely integrated system
to optimize production and minimize set up
time.

The MACS utilizes larger crushers and
screens than what are typically used in track
mounted or wheeled plants. For crushing the
MACS incorporates the new rugged JS3054
primary jaw, an ElJay MVP 450 Rollercone
secondary cone and an ElJay 450 Roller-cone teritiary cone. Screening is accomplished using an ElJay TSH
8203 triple-deck scalping screening and an ElJay TSH 8203 triple-deck finishing screen. Numerous configurations of these components
are possible to produce a wide range of specification products.

The unique trailer designs can be permitted for travel in most jurisdictions. The crushing and screening units travel under 4.1 m high and
under 3.6 m wide. Interplant conveyors are designed into the units so
that separate transfer conveyors are not required. Folding conveyors
and walkways set up using on-board hydraulics, thus eliminating the
need for cranes or lifts. Also large hydraulic support legs level and
stabilize the units to speed set up.

According to the manufacturer, low cost operation is another feature of the new system. The entire system utilizes industrial electric drives so that the MACS
can be powered by either high efficiency generators or line power when available. The unique
layout of the system provides the operator visibility of the entire circuit from a central pop-up
control house. High quality belt cleaners and
skirted conveyors are used throughout to minimize spillage. Maintenance is minimized since
all components such as gear boxes, belt idlers,
pulley bearing, are selected for long life and low
maintenance.

Common components are employed wherever possible to simplify
support and minimize the number of different parts. The control trailer is stocked with frequently used parts and is organized in a visual
inventory management system.
www.cedarapids.com

New mobile plants launched by Metso Minerals

27The new Metso LT7150 is the company’s first Lokotrack mobile plant built with a Barmac VSI crusher on board. The Barmac
B-series vertical shaft impact crusher, featuring rock-on-rock crush-
ing, is designed to produce high-quality cubical aggregate, road base
and premium-grade manufactured sand. The VSI’s 840 DTR rotor ac-
cepts feed sizes up to 66 mm, accelerates material and continuously
discharges it into the crushing chamber. Its particle velocities range
between 45-75 m/s. The crusher runs on a direct hydraulic motor,
eliminating the need for V-belts and enabling a fully adjustable tip
speed using the automated control panel.

The feed from the rotor and the cascading material recombine us-
ing the rock-on-rock action into a continuous cloud of airborne par-
ticles moving around the crusher. Excess material is prevented from
fl owing through the rotor overfl ows via the cascade ports.

The LT7150 is powered by 415 hp Cat C13 Tier III diesel engine.
The plant is equipped with Metso’s IC400 process automation system
that features complete automatic crushing process controls, single-
button startup and advanced fault diagnostics. The IC controls allows
the LT7150 to be interlocked with other LT crushers and ST mobile
screens for balanced processing circuits and lower operator require-
ments.

The unit weighs 30 000 kg and has a transport width of 3 m and
height of 3.4 m.

The LT116 and the LT106 jaw crusher plants are two more addi-
tions to Metso’s Lokotrack range of mobile track plants.

The 50 000 kg LT116 is equipped with Metso’s new C116 jaw and
a state-of-the-art crusher automation system. The C116 jaw features a
new cavity design for better grip and maximum inter-cavity crushing.
Together with automatically adjustable feeder spread, the new crusher
design ensures effi cient, continuous choke feeding. The 1150 mm x
800 mm feed opening provides a maximum feed size of 640 mm.
The jaw plates of the C116 are interchangeable between the fi xed and
moveable sides for longer service life, improved operational perfor-
mance and simpler logistics.

Depending on the feeding system, the LT116 can be equipped with
the standard 6 m3 or optional 9 m3 feed hopper. For faster setup times,
the hopper fl anks can be folded hydraulically.

The 45 000 kg LT106 is built around Metso’s C106 jaw crusher
that delivers 10 per cent more production effi ciency due its new cavity
design, longer stroke and slower optimized rpm speed. Features of the
new jaw include a new frame and pitman structure that is designed to
minimize the stress levels within the machine while increasing crush-
ing forces. Bigger and heavier fl ywheels back the increased perfor-
mance up by storing suffi cient energy for each crushing cycle.

The C106 has a feed opening of 1060 mm x 700 mm, providing a
a maximum feed size of 600 mm.

The LT106 is powered by a 300 hp Cat C9 Tier III diesel engine.
The plant can be fed by conveyor, excavator or wheel loader and, ac-
cording to the equipment used, a feed hopper size of 6 m3 or 9 m3 can
be selected.

Another new crushed introduced by Metso is the HP5, a rugged,
energy-effi cient cone that accepts feed material up to 330 mm. Weigh-
ing 33 112 kg and offering the highest reduction ratios of any cone
crusher currently on the market, the HP5 can hold tighter settings than
previous HP range machines. Dual-acting hydraulic release cylinders
enable the HP5 to pass tramp iron that would normally stall or dam-
age other cones. Should the crusher stop under load, these dual-acting
cylinders provide a large clearing stroke, independent of liner wear, to
quickly clear the crushing cavity.

The HP5 requires no backing material between the head and the
mantle allowing for faster liner changeouts. The crusher is also fi tted
with a new dust containment system for improved air quality. www.metsominerals.com

Sandvik introduces retrofi ttable VSI rotor

The new Sandvik Hurricane rotor for vertical shaft impact crushers
is described as a major breakthrough in VSI autogenous rotor design.
With four new rotor and wear parts patents pending, the revolution-
ary design is said to weigh 25 per cent less than competitive rotors
as well as producing signifi cantly reduced vibration levels inside the
crusher. The new rotor design is also claimed to require less servicing
and fewer wear parts than competitive VSI rotors thus lowering oper-
ating costs per tonne.

In 2002, Sandvik introduced its line of autogenous crushers that
use a rock lined rotor to accelerate material, which is then impacted
in a highly energized rock lined crushing chamber. Included among
the main advantages claimed by the manufacturer is increased prod-
uct throughput of up to 30 per cent for the same power draw due to
the technologically-advanced rotor design. The streamlined design
increases the discharge height to allow the material to exit the rotor
more effi ciently.

With the Sandvik rotor retrofi t program, the manufacturer says
it is extending the benefi ts of the patented Hurricane rotor design to
other makes of autogenous VSI crushers. Only 39 different parts are
required for all retrofi ts including rotors which reduced the need for
replacement stocking.
www.sandvik.com


Telsmith expands product line

28

Three new Telsmith crushers have been added to company’s range
of portable and stationary crushing systems. Telsmith is a member
company of the Astec Aggregate and Mining Group.

The recently launched Quarry-Trax model TJ3538 is a mobile
track-mounted primary jaw plant that is designed for both quarry and
recycle work. The plant’s jaw crusher features a larger gap and a 1473
mm wide crushing chamber, boosting capacity by up to 15 per cent, ac-
cording to the manufacturer. Additionally, the jaw crusher’s hydraulic
systems are said to provide three key benefi ts for operation and up-
time production: Hydraulic Adjustment reduces maintenance time and
maintains crusher output; Hydraulic Tramp Iron Relief protects parts
and components against overload damage and subsequent downtime
and, Hydraulic Chamber Clearing allows the operator to safely clear
the crusher and return to production in a matter of minutes.

The total weight of the TJ3258, including the 1.5 m x 4.57 m VGF
module and 1371 mm x 13.7 m discharge conveyor is a hefty 77 122
kg. The plant is carried on a 3.7 m long track undercarriage composed
of 508 mm wide triple grousers on 203 mm chain pitch. The inde-
pendent hydraulic drive motors are capable of propelling the machine
at speeds of to 1 km/h. Power is supplied by a Cat C9 Tier III diesel
engine rated at 350 hp.

The Quarry-Trax utilizes PLC controls for all key machine func-
tions. In the automatic mode, the crusher feed is maintained and maxi-
mized by monitoring engine load, crusher load and feed bin level. The
crusher setting is displayed on an on-board colour LCD monitor and
adjustments are enabled through push button controls. Handheld wire
remote manoeuvres the plant and provides crusher, feeder, engine and
conveyor controls from a safe distance.
Another new crusher introduced by Telsmith is the SBX cone that
is engineered with new internal components and crushing chamber
profi les that allow it to accept larger feed material. The cone is suitable
for secondary crushing circuits that previously required larger crushers.

The advanced features of the new cone crusher include a Dynamic
Adjust system that enables remote adjustment under load, a mainte-
nance-free hydraulic anti-spin system that extends manganese life, a
large stroke chamber clearing system that delivers safe and quick re-
covery from a shutdown and heavy duty components for rugged duty
cycles.

Although the SBX is built for compatibility with any fully auto-
mated plant, the cone can be combined with TRAC 10, a stand-alone
crusher control system that allows operators to monitor crusher opera-
tions, make adjustments to crusher settings and collect operational and
maintenance data without the costs of having to rework existing plant
controls.

The SBX is available in three models – the 300 hp 44SBX, the 400
hp 52SSBX and the 500 hp 57SBX.

Telsmith has also introduced its new PA6060 primary impact crush-
er which features a large 1500 mm x 1500 mm rotor set on oversized
220 mm wide series roller bearings to tackle shot rock or concrete
recycle feed material up to 1016 mm in size. A motor rated at 400-500
hp is recommended to power the machine which can produce 315 to
545 tonnes/h, depending on the crusher setting.

The 27 700 kg PA6060 utilizes a state-of-the-art hydraulic system
to provide fi nger-tip control of apron adjustments. A PLC allows op-
eration in an AUTO mode that will automatically return the apron to
preset spacing and track wear parts consumption. The manufacturer
claims these technologies prevent damage from uncrushable materials,
while reducing maintenance.

Additional features include a hydraulic tilting plate to safely and
quickly clear bridging; interchangeable and reversible mono-block
aprons to reduce maintenance costs; easy access inspection doors and
a hydraulic upper frame for quick access to maintenance areas.

The PA6060 is available in wheeled, track mobile or modular plant
arrangements.
www.telsmith.com