New Equipment Design - Pitboss S2800 8" Minus Portable Crushing Spread
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ELRUS Aggregate Systems, of Calgary, Alberta, has |
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NEW EQUIPMENT DESIGN! ELRUS DESIGNS A SCREEN CONE PLANT |
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ELRUS has designed a new Screen Cone Plant. The S4800 Gryatory crusher combined 6 by 20 ft. Screen. Contact us for more details. |
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iNDUSTRY PUBLICATIONS / TESTIMONIALS: |
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Al is the Operations Manager of Danford Construction, a family company and well-known member of the Madoc, Ontario business community. With a staff of 24, the company is mostly involved in quarrying work and construction related to road building throughout Eastern Ontario. However, they also do significant amounts of site preparation, excavation, and similar work. Much of Danford's stone comes from its Francis Quarry. About three-quarters of the aggregate is used in specialty concrete and asphalt. tHe pit annually produces up to 150,000 tonnes of high-grade Bobcaygeon Limestone. It's hard and it's dense," says Al, "but it's a very good stone that does extremely well in the Ministry's abrasion tests. It's an excellent stone for aggregate!" Stone of this quality is a challenge for any crusher and Al says he's delighted with the performance of the SANDVIK H3800. "We used to run a 45-inch cone with 5 by 14 screen," he says. "Our new SANDVIK H3800 with 6 by 20 ELRUS screen has a smaller head, but would you believe, it's giving us 40% more production! Our loader sometimes has trouble keeping up." Increased production is a major benefit of the SANDVIK line of crushers. They are designed to work hard and pay big reliability dividends to operators. The Danford machine, for example has a 200 hp computer-controlled power plant that allows maximum crushing all the time.
There is another thing he really likes about the "H" series. "We get a more uniform shape of stone," Al explains. "The Ministry won't accept more than 20 percent flats and longs, but with our SANDVIK H3800 we're delivering under 9 percent right now, and that's about 5 percent better than our old machine." When the SANDVIK H3800 arrived, Danford adjusted their 2442 ELRUS Jaw Crusher down to 2.75 inches and set up the SANDVIK unit with medium coarse liners. "It's a good combination," says Al. "We can feed the cone with smaller stone and it gives us 10 to 15 percent more production than we expected. One risk every operator faces is the chance of getting steel in the load, but this is less of a worry to Al than it used to be with the old set up. "If we get some steel, it's not going to hurt," he said "The cone runs on bushes and it's a lot more forgiving, it really is." After a pause he adds; "This cone was a big investment for us, but it's probably one of the best things we've ever done." |
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A recent crusher change to a portable aggregate spread has delivered improvements in particle shape, product yield, productivity and cost savings for an Ontario producer. |
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By Andy Bateman, Engineering Editor, Aggregates & Roadbuilding Magazine |
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Doug Kelly, Sarjeant's assistant operations manager explains, "About 80 percent of the product from our main pit is used in house by the company's ready mixed concrete plants at Barrie, Midland, Orillia and Brechin, so our main objective is to maximize the output of quality concrete aggregate. Our ten year old VSI made good products and was still in reasonable shape, but the climbing repair costs indicated it was time for a replacement. "We knew that our Timmins operation was obtaining good results with a cone and decided to follow suit. Since installing the new cone a few weeks ago, we have found that it produces well-shaped coarse concrete aggregate. In addition, the overall yield of concrete aggregates has increased, with a corresponding drop in unwanted fines. Further improvements include an increase in overall plant capacity and cost savings in wear parts and energy." Specifically, production of 20 mm b 4.75 mm concrete stone has increased by about 25percent from 80 tonnes/h to 100 tonnes/h, while the capacity of the secondary crushing stage has been increased by 50 percent from 200 tonnes/h to 300 tonnes/h. The cost savings will come from avoiding the replacement of shoes (wear parts) on the VSI every two weeks, together with reduced energy consumption; the new cone is driven by a 200 hp motor, just half the size of the 400 hp motor formerly driving the VSI. The new crusher is a SANDVIK H3800 Hydrocone crusher in the secondary crushing position of an ELRUS portable spread. In typical operating conditions, 152 mm minus bank run is hauled to the plant by two Caterpillar 980G wheel loaders on load and carry duty. The feed material is then reduced to 102 mm minus by an ELRUS 2036 Jaw Crusher and conveyed to a portable load-out bin. From there, a variable speed feeder regulates material flow to twin ELRUS 6 by 20 screens, where all 102 mm by 19 mm material is directed to the H3800. The cone is typically set at a 22 mm close side setting (CSS) and operates in closed circuit with the second screen. Most of the spread's Granular A product is conveyed to the pit's upper level where it is utilized as feedstock for a separate wash plant. Here, a 6 by 16 Dillon screen is teamed with an AEI Ortner 400 plant to produce washed coarse and fine concrete aggregates.
Finally, the system can be set to a multi-CSS function. In this mode, the crusher automatically switches between two different setting to give two product curves. This switching takes place on a time share basis, such that the end product contains the desired proportion of finer and coarser materials. One of the most innovative features of the ASRi is said to be its Process Optimization Tool (POT). To utilize this feature, the results of three laboratory test results on crusher products are keyed into the ASRi. The POT then enables the user to predict the product curves and product qualities that will be produced by different crusher settings. In addition the user can study the effect of a change in set point or anticipate the consequences of switching between different feed materials. ASRi also features an intelligent wear compensation features that means less frequent calibration for the user, while a single press of a button now does metal-to-metal calibration.
As part of ongoing plant improvements, Sarjeant has also recently changed the power supply for both the portable crushing spread and the wash plant. A Detroit Diesel Series 600 generator set, rated at 68 kVA will power the ELRUS crushing spread while the wash plant will be powered by a smaller Detroit Diesel Series 300 generator set rate at 338 kVA. The Sarjeant Co. Ltd. is based in Barrie, Ontario. Its construction materials business interests include the 7th or Oro (Township) and Phelpston sand and gravel operations, four ready mix concrete plants and shared ownership of a hot mix asphalt plant. Non construction interests include fuel oil distribution, 24-hour fuel stations, heating and cooling (supply and installations) and commercial real estate.
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It's phenomenal...just unbelievable what this machine can do!" 
Al points out another advantage is the SANDVIK design. "They are the only one in the industry with a top support for the cone making them very durable, and the chamber has a steep slope so we get a lot better material flow. 
At a time when many aggregate producers have installed vertical shaft impact crushers to meet Superpave (Fracture) specifications, The Sarjeant Co Ltd., has gone in the opposite direction, recently replacing a vertical shaft impactor (VSI) with a new cone crusher.
This H3800 cone features SANDVIK's ASRi crusher control system. There are reportedly only three such systems currently operating in Canada, of which Sarjeant has two. According to the manufacturer, the ASRi intelligent crusher control system allows up to twenty different crushing programs to be stored with the user able to choose between three operating modes for each program. The first mode allows the operator to enter a specific close side setting (CSS) to keep the crusher running at the same setting. Should an overload occur, the crusher opens to relieve the overload and returns the main shaft to the desired position when the load reverts to normal. In Sarjeant's application, the effect of an overload would be a temporary increase in recirculating load until steady throughput was restored. The second mode regulates the crusher load setting (to optimize crusher productivity). If, for instance, the highest load level is selected, the CSS will always be the smallest possible, resulting in maximum reduction for a particular application.
Additional functions include alarm-event log, operating data and historical data. In large operations with multiple crushers the ASRi system on each can communicate with a higher level system by way of an Ethernet connection. The basic requirement for using an automatic regulator like the ASRi system is a crusher with hydraulic adjustment setting that allows for repeated rapid setting adjustment during operation with the crusher under full load. It is therefore suitable for all SANDVIK Hydrocone crushers.
