Buying stone crushing and screening equipment made easy
Featuring the tips to be considered while buying stone crushing and screening equipment:
Crushing and Screening equipment is the heart of any infrastructure project. The success of the project depends on the design, performance and flexibility of the crushing plant, wherein it is possible to vary the product mix.
Quality of the finished aggregates plays an important role
Moreover, the quality of the finished aggregates also plays an important factor in deciding the crushing and screening system. “Some of the other features that are key-in decision making are the capability of the crushing equipment and the crushing system to be able to adapt to the project requirement, cost of operation and maintenance,“ says RS Raghavan, Managing Director, Proman Infrastructure Services Pvt Ltd.
Proman with their wide configuration and range of crushing and screening equipment and vast experience in the crushing field are in a position to offer total turnkey solution to their customers.
Understanding the application
According to V. Manoj Kumar, Assistant Vice President – PMG, Bevcon Wayors Pvt Ltd, Crushing and screening plays a very important role in the circuit. Bevcon starts with understanding the application of crushing and screening as a first step to pursue a suitable solution to our clients.
• Crusher and screen capacities primarily by calculating the mass flow balance of the system.
• While selecting crushers and screens, the selection is based on the position of equipment in the circuit which is either primary, secondary or tertiary crushing or screening system.
• While designing individual equipment, consideration of the following points plays a very important role.
Tips for selecting the right stone crusher
Ajay Varma, Director, Marsman India Ltd says, “Choosing the right crushing comes down to examining each unique application and the desired output.”
He adds, “A short visit, a couple of questions and a thorough evaluation of a crusher owner can save oneself from the much turmoil that comes with selecting the wrong crusher.”
Few things to consider when it’s time to add a new crusher to the operation.
Evaluate the application
The most critical factor here is the level of hardness of the material being processed. This is typically measured in compressive strength, or the maximum force that material can withstand before breaking.
Primary jaw crushers process hard, abrasive materials such as granite, ores or recycled concrete. Cone crushers are known for their ability to crush hard, abrasive ores and rocks, but they are best suited for secondary crushing applications. Impact crushers are ideal for contaminated materials. They easily handle clay, dirt and metal mixed in with the material. While they can handle hard material, they are ideally suited for soft to medium rock.
Determine the desired output
If an operation can sell 1, 92,000 tonnes per year, its crushers need to produce 1,600 tonnes each month. If a crusher is set up to run five days per week for eight hours per day, the operation will require a machine capable of processing just over 100 TPH.
Proper production capacities are critical to the success of a business. A crusher that is too small fails to produce the desired tonnages, which limits yields and profits and caps the organisation’s growth potential. A machine that’s too large carries extra expense with no added value.
Stationary crushers offer the benefit of a custom, heavy-duty design. However, mobile crushers allow operators to move the unit closer to the face of the crushing activity.
Wheeled mobile crushers can be hooked up to a truck and hauled to different locations or relocated on a jobsite. These units are the need for generator where electricity not available at jobsite.
Attention to detail
A crusher needs to withstand daily abuse. Investing in quality equipment and components upfront will save money in the long run. Before making a purchase, evaluate the quality of some of the crusher’s components.
Be sure the motor or generator and control panel has a good reputation and can meet the operation’s output needs. Note the hopper size. An oversized hopper can accommodate larger equipment used to feed the unit.
A crusher’s discharge chute is under a lot of stress for the majority of a machine’s run time, and, as a result, requires regular maintenance. To eliminate these extra costs, look for the specially designed discharge rock box that reduces the need for wear-liner replacement. The specialised design uses a shelf system with an abrasion-resistant wear bar that allows crushed material to build up and act as a wear liner. The result is zero maintenance, which translates to savings in labour and wears parts.
Abrasion-resistant transfer points will provide the extra strength needed for certain applications, greatly reduce costly replacements and prevent downtime.
Be sure other components such as conveyors, bearings, rollers, shafts and drives are robust and built for high wear.
Compare apples to apples
It’s easy to get caught up in price. While saving money is important, so are the extras that will save time and money in the future. Take, for example, a crusher’s discharge chute. This area of the machine is under a lot of stress for the majority of the machine’s run time, and as a result it requires regular maintenance.
Most machines need wear-liner replacements on a regular basis. Some machines, however, have a specially designed discharge rock box that eliminates wear-liner replacements. The specialised design uses a shelf system with an abrasion-resistant wear bar that allows crushed material to build up and act as a wear liner. The result is dramatic savings in labor and wears parts.
Quality production at a low cost is everyone’s goal. Just be sure to consider all elements of the crusher and the operation’s needs before making the selection. After all, the right machine will make every job easier and more profitable.
Some machines feature a specially designed discharge rock box that eliminates wear-liner replacement.
Study manufacturing unit profile
It is very important to study manufacturing unit profile Infrastructure to purchase high quality equipment.
Technical and financial parameters
Speaking on what is to be considered while buying a stone crushing and screening equipment, Piero Guizzetti, CEO, MB Crusher India Pvt Ltd, says, “The most important aspects of procurement decisions are related to the technical and financial parameters of the client requirements.”
On the technical side, he adds, it is important to understand the type and size of materials which is to be crushed and or screened, the application, the intended use for the crushed material, the level of personnel and machines to be allocated, and the type of site one has at its disposal.
MB crushing and screening attachments are utilisable with any type of material, even the hardest and most abrasive ones. The unparalleled breadth of it’s product portfolio enables to also satisfy any output size requirement. The material can be used directly on site without any need to buy or hire any other resource or equipment. As a matter of fact, they are completely independent and do not require any additional operator as a static crusher would require. Finally, Guizzetti claims, “MB products can be applied at any site, even the hardest to reach and most austere in terms of terrain.”
Life-cycle cost analysis
According to Guizzetti, “On the financial side, CAPEX is one consideration but operational and life cycle costs are increasingly becoming the key factor for purchase decisions in India. This analysis requires one to look at the entire process associated with alternate solutions, as opposed to just the crushing and screening activity. Hence, considerations such as transportation costs of the materials to and from the site, to and from the crusher unit, become important, as well as fuel costs, personnel, maintenance costs, procurement of materials and so forth.”
With MB products, the savings are easily recognisable. Guizzetti added, “Transportation costs are eliminated and fuel costs are reduced. The personnel requirement is also minimised, as a single operator can also easily manage the crushing or screening activities as well as the maintenance requirements of the machine which are easy and economical. Finally, there is no need to procure materials as the output may be directly applied at site and or sold to the market.”
V. Venkataramana, Vice President – Marketing, Puzzolana Machinery Fabricators (Hyderabad) LLP, highlights the points to be considered while buying crushing and screening plant:
• Aggregate requirement for the project and the time scale for the production.
• Availability of quarries and aggregates.
• Depending on duration decide type of plant.
> Mobile or skid or stationary plant.
> Size of plant 200/300 TPH.
> No of stages -2(Jaw + Cone) or 3(Jaw + Cone +VSI) or 4(Jaw +Cone + Sander +VSI) – based on the sizes of aggregates and sand requirement.
> Primary crusher capable of taking bigger feed size- 200 TPH plant feed size 650 mm.
> If sand and fine aggregate required then Jaw + Cone + Sander + VSI to be used.
> To maintain quality sand – classification is required dry or wet type classification.
• If the quarries available are of short quantity and need to move the plant frequently then buy crawler mobile plants.
> The plant should be ease to operate – with electric drive in place of hydraulic drive.
> The secondary crusher should be able to produce product (40, 22, 12, 6 mm).
> Well proven screening station.
Capacity and final product size
Chanchal Sinha, Business Head – SMB India, Thyssenkrupp Industries India Ltd, says, “The major parameters considered by customers are capacity and final product size as these are directly related to customer’s revenue.”
He informs, “Apart from this, quality of machines, wear and tear, ease of maintenance, design and execution capability, service and spare back-up available in close proximity are the factors which customers pay a great deal of attention to before choosing their right partner for their needs. Thyssenkrupp being highly-reliable in all these aspects is the natural choice for it’s customers.”
Kleemann stands for excellent customer benefits
Ramesh Palagiri – Managing Director & CEO – Wirtgen India, claims, “Crushing and screening plants from Kleemann GmbH are characterised by their excellent customer benefits. The decisive elements for success such as technology, innovation, quality and service combine to make Kleemann like no other company.”
He adds, “Its decade-long competence in the construction of stationary plants ensures an excellent position on the market for mobile plants. The plants are distinguished mainly by their sophisticated and detailed solutions which keep constant track of the entire process.”
Solutions for buying stone crushing and screening equipment
Guiding customers to take right decisions
The crushing and screening industry in India is matured and the customer is aware of what he/she wants. Proman has been able to continuously educate the customers and guide them to take the right decision. “A well informed and knowledgeable customer has always appreciated Proman’s professional recommendation and also the superiority of our crushing systems,” says Raghavan from Proman Infrastructure.
“The trend in the crushing industry today is towards reliable, well-designed and flexible crushing plants which can be easily fine-tuned based on the demand of the project,” informs Raghavan
Proman has been in the forefront in providing these requirements of the industry and are in a position to set up the most advanced crushing plant that can produce high quality aggregates, manufacture concrete sand, and plaster sand to the Indian standards specification. “We have solutions for dry and wet process for plaster sand and manufactured sand and also dry mortar mix in bags,” asserts Raghavan.
Bevcon offers screening technologies to mining applications
Bevcon executes project with blend of latest technology with conventional systems in most optimised manner which will enhance the operations reliability. Bevcon core strength lies in use of Innovative Conveying Systems and Equipment which caters present day demands of Indian mining sector.
Kumar informs our highly competent technical team supported by technology partners from US and Europe are in position of supplying the Innovative equipment’s like:
> Vibrating screens
Bevcon offers various types of screening technologies to mining applications. This includes:
• High moisture ore screening in Flip Flow Screens which prevents from clogging of material to screen cloths. These screens are designed with higher G-force. The highest capacity Bevcon can produce screening with 27 sq. metre areas.
• High efficiency linear motion screens which include grizzly screens, dewatering screens etc. These screens will deliver high centrifugal force and fitted with maintenance free unbalanced exciters. The highest range includes up to the capacity of 1500 TPH for coal.
• Conventional high capacity and heavy duty circular motion screens up to 25 sq. metre areas.
Bevcon manufactures various types of crushers especially for coal and lime stone. The crusher range includes:
These crushers cater to the need of coal crushing in major thermal power plants. Bevcon has a product range of crushers from 10 TPH to 1500 TPH for coal application.
For mining sector Bevcon manufactures feeder breakers of 500 TPH. These feeder breakers are very common in coal mining. Bevcon manufactures limestone crushers up to 200 TPH for cement application.
Marsman offers high production at minimum electric power consumption
“Our equipment offer high production at minimum electric power consumption, claims Varma from Marsman. The product catalogue consists of jaw crusher, impact crusher, mobile crushing unit, vibrating screen and vibrating feeders of various capacities ranging from 50 TPH to 1000 TPH.”
“Apart from supplying individual machines, we also cater to projects on turnkey basis. Marsman offers a wide range of mobile crushing solutions for quarrying, recycling, mining applications, aggregate production, coal production, iron ore and cement production. We also offer cone crusher and vertical shaft impactor manufactured in our sister concern company Shakti Mining Pvt. Ltd,” informs Varma.
Marsman crushing and screening plants have been functioning successfully in India and abroad for years. With a strong network globally Marsman have been exporting to more than 30 countries worldwide and are well known entity among major mining companies. Marsman India Ltd also works as an OEM partner for UK Germany, Italy and other European manufacturers for years.
“We are continuing upgrading crushing and screening as per latest technology,” he adds.
The new BF90.3 S4 from MB Crushers
MB has recently launched its new S4 series BF90.3 model, which is the most sold model around the world and also in India. The new series is more compact in dimension that adds stability enhances performance and decreases maintenance and operational costs. “The feedback received in India has exceeded all expectations and we are glad that it has also translated into increased interest level across our entire portfolio,” says Guizzetti from MB Crushers.
MB Crusher machines will be displayed at Excon 2017. This year there will be very interesting news, since MB India will organise a real demonstration area with its machines working: visitors will have the opportunity to understand which kind of solutions MB crusher attachments can bring to their respective construction sites. In fact, compatible as an attachment with any excavator and or loader model and make, MB crusher machines not only provide savings on transportation, but also drastically reduce the amount of other equipment required at site and at the mine or quarry where the materials are sourced.
Meet necessary project requirements
Venkataramana from Puzzolana Machinery, points out few steps to be taken for projects.
• Plants of capacities up to 500 TPH capacities to suit the requirement of mega projects.
• First two stages with single primary Jaw crusher to take a feed up to 1000mm and single secondary cone crusher to produce (-) 55mm product and two tertiary cones and VSI to produce required aggregates and sand.
• Dedicated plants for 100 per cent sand production up to 500tph – for both concrete sand and plaster sand.
• Plants of 200, 250, 300, 350 or 400 TPH plants.
• Cost effective and environment (green) protective solutions in classification both dry and wet.
> Dynamic air separator (dry)
> Bucket type classifier (wet)
> Hydro cyclone classifier (wet)
• Special purpose screens.
Machines to be supplied depending upon customers needs
Thyssenkrupp Industries India has one of the world class design and manufacturing facility to construct machines suitable for aggregate crushing and produce M-sand. These machines based on proven design comprising of jaw crusher, cone crusher and VSI which produce excellent quality sand suitable for construction purposes. Having various sizes of all crusher models suitable for capacities varying from 100 to 300 TPH. “Depending on individual customer needs, machines can be supplied to suit final product size and capacity,” informs Sinha from Thyssenkrupp.
• Recently introduced adjustable bushing with four eccentricities in cone crusher which will enable crusher to change multiple strokes easily without much downtime and to suit their varied capacity requirements. Successfully developed optimum chamber design to achieve higher throughputs and higher per cent of cubical particles at lower power consumption.
• Rotor parts are redesigned with high composite wear resistance material ensuring longer wear life and lower production costs. Unique feature of automatic oil or grease lubrication system for rotor bearings improves working hours. Also high flywheel energy ensures effective crushing of very hard material without affecting the motor power.
Kleemann’s new EVO classifying screen
Offers complete range of track mounted crushers from 150 TPH to 1500 TPH in jaw, cone, impactor and screens. Kleemann has expanded the EVO series overall by four classifying screens.
These screens are manufactured at the Wirtgen Group’s state-of-the-art manufacturing facility near Pune , India since 2015.
The track-driven double-deck classifying screens MS 702 EVO and MS 952 EVO as well as the triple-deck classifying screens MS 703 EVO and MS 953 EVO. The upper deck on both plant sizes has a screening surface area of 7 sq. metre or 9.5 sq. metre. “As with the crushing plants, the favourable transport dimensions and short setup times of the classifying screens meet the demands of contractor crushers. The MS 702/703 EVO achieves a maximum output of 350 t/h and the MS 952/952 EVO an hourly output of up to 500 tonnes,” explains Palagiri.