The Expanding World of Crushing and Screening Equipment
Published: 31/5, 2021
In the prolific world of mobile crushing and screening, many new machines are being rolled out on the market and being put to work in exciting projects all around the globe – from Germany and Cyprus, all the way to Burkina Faso.
Waste management company uses Rotorshredder from BHS-Sonthofen
A challenge for recycling plants is contamination with other materials. A German waste management company turned to BHS-Sonthofen for a new recycling solution for the 30,000t of non-ferrous metals they recycle annually. They opted for the Rotorshredder, which shreds the feed material and breaks up composites. The Rotorshredder type RS 2018 was fitted with reinforcements for aluminum processing, including a hardened housing, double-walled base and new suspension system. The Rotorshredder uses selective shredding. Impact forces deform aluminum, causing impurities to break down. Composites are then separated from the feed material. After classification takes place, the high-purity aluminum is ready for sale.
Arjes shredders in use in Israel
Arjes shredders have been used in a variety of applications in Israel. Recycling company Gal Michsur uses the Impaktor 250 Evo to process materials. Shredded waste wood is mainly used as a substitute fuel in incineration plants and is obtained by an external company for fuel production. Prepared green waste is used for processing in composting plants. All metal contaminants are removed with the over-band magnet and the biomaterial is then screened. The generated commercial waste is shredded to reduce its volume to save transportation costs and landfilling, which are based on the material’s weight and volume, providing double the benefit to customers.
Another example is Carmel Natural Products Ltd., which shreds composted material and green waste on site with the Arjex Titan 950. The material is screened and processed with a high-speed machine to a grain size of less than .8 in (20mm). The Titan 950 also helps separate stones and metal that goes unnoticed during pre-sorting.
The Titan 950 also figures prominently at a large-scale waste collection point in southern Israel, where a large part of the waste is dumped and buried. Using the Titan 950, the volume of household and commercial waste is reduced so that more layers of waste can be deposited, which means more money for the system operator, according to Arjes. The twin shaft can be installed and removed quickly thanks to the quick-change system.
Haas – processing waste wood into biomass fuel
German waste disposal company BWE Balthasar GmbH was looking for a solution to process approximately 40,000t of waste wood annually into fuel for a biomass power plant. In a single-stage shredding process, wood chips of 3.1-4.7 in (80-120mm) with a minimum percentage of fines are to be produced. Haas supplied Tyron pre-shredder and the Alva star screen with oversize recirculation. The Tyron features a twin-shaft system that is suitable for hard wood such as railway sleepers with solid iron plates, as well as a neodym cross-belt magnet. The extra-fine tool configuration (7/6-4) provides BWE with excellent wood chip and high throughput, according to Haas. The Alva star screen separates out oversize material, which is returned to the shredder by the integrated recirculation conveyor. The integrated screw conveyor collects and discharges the usable fraction.
Lindner’s Polaris 2800 fuels one of Europe’s largest cement plants
Enerco – Energy Recovery commissioned a Lindner shredder from the Polaris series to shred high-calorific refuse derived fuels in Cyprus. Vassiliko operates one of the largest cement plants in Europe. To ensure the amount of energy needed to produce approximately 6,000t of clinker per day, they rely on Enerco’s resource-saving alternative fuels. The shredder produces onsite fuel in 2-in (50mm) particles out of end-of-life tires, mixed and bulky waste, and waste wood.
Another novelty from Lindner is their patented SF synchronous fine cutting system. The angle between knives is changed so that they act like scissors, applying force to a smaller area. This, according to Lindner, increases the tools’ impact while maintaining energy consumption. Also, the cutting edges of the shaft are not aligned in parallel. The shafts act like two Archimedean screws rotating in opposite directions. This intake increases throughput and mixes the final fraction for a homogenous output.
New mobile screen, crusher and e-Power range from Metso Outotec
The new Nordtrack S2.5 mobile screen is a small size scalping screen designed for small job sites and a variety of applications. With a compact and light-weight structure, a two-deck screen and a selection of different screening media, it is a solution for construction contractors with frequent changes in site locations or as a rental unit. The Nordtrack I908 mobile impact crusher features a design for smaller-sized material reduction job sites and accepts different kinds of feed material.
The new Lokotrack e-Power range brings the diesel-electric Lokotrack mobile crushing and screening units into one offering. The range includes 15 crushers and 6 screens. Thanks to the development actions to lower fuel consumption, the annual CO2 emissions of the Lokotrack equipment are 20,000t lower today compared to the situation before 2010.
Second Rockster crusher at Tropic Mining & Quarry in Burkina Faso
Tropic Mining & Quarry SASU (TMQ), based in Burkina Faso, has been using a Rockster R900 impact crusher since 2008. To increase limestone processing, a R1100S closed circuit impactor has been added to their fleet. The impactors are used to crush dolomite limestone, which is used for production of cement. The plan is to produce 600,000t of final material per year. TMQ’s R1100S also has a screening system, which consists of a screen box and return belt, to produce perfectly defined final product with an excellent quality.
Diesel-free with RM 120X hybrid
Israeli recycling and waste recovery firm Taha Zahir invested in a Rubblemaster RM 120Go! in 2018. Located in an enclosed hall, which makes low emissions essential, the crusher has been crushing C&D waste to produce road substructure aggregate. Taha Zahir has now added a second low-emission crusher—Rubblemaster’s RM 120X hybrid, which can be diesel-electric and purely electric powered. The feed material with an edge length of up to 800mm is processed electrically to produce cuboid final aggregate of less than 1.26 in (32mm). Taha Zahir also ordered a dust suppression system and installed a wind sifter on both crushers. Every day, approximately 1,000t of C&D waste, mixed with plastic, wood and textiles, are delivered to Kafr Qasim. The RM Go! principle has been developed for Rubblemaster’s new Next machines. With machine communication lights, the user can see the system’s current status. The RM 120X keeps the operator outside the danger zone during crushing. Information on the crushing process is displayed in the RM Go! Smart App.
Powerscreen reveals concept battery-powered screener
Powerscreen’s electrification strategy includes a new concept for crushing and screening – the Eco-Warrior battery-powered screener – designed to combine the company’s famed screening action with a simple, quiet engine with no after-treatment requirements. The required engine size has been cut in half compared with the diesel hydraulic unit, and the battery pack can mean emission-free running or give a power boost.
As part of Powerscreen’s decarbonization challenge, the company has broadened its product range to reduce environmental impact by making its crushing and screening equipment more fuel efficient, using direct drive systems for its crushing range and improving engine capabilities and drive-line design for its screening range. Another tool for fuel efficiency is Powerscreen Pulse telematics that, among many things, helps customers see how and where their machines are being operated. The Hybrid range now features more electric crushers/screeners, as well as models powered by combinations of diesel and electricity.
Komatsu Europe introduces new mobile jaw crusher
The BR380JG-3, powered by a Komatsu emissions-compliant diesel engine, has a power output of 213 hp (159kW) at 2050rpm. The machine incorporates a two-axis type deck vibrator for continuous flow of material to the two stage grizzly separator bars. The semi-automatic feeding system incorporates crusher overload detection and automatic feed control. The BR380JG-3’s expansive 42 x 21.6 in (1,065 x 550mm) jaw opening features tapered side plates and offers a maximum crushing capacity of up to 240 tons per hour. The BR380JG-3 features a one-touch start-and-stop function; a foldable ground-level maintenance access step; and more. The Komtrax telematics and the Komatsu Care maintenance program offer fleet management and support, protect the machine against misuse and, according to Komatsu, guarantee maximum efficiency and uptime.
Cams presents biggest model in the Centauro range
Cams launches the Centauro XL 150.56, the biggest model in their Centauro range of mobile crushing and screening plants for construction and demolition waste, aggregates and asphalt. The Centauro XL 150.56 will increase the series with a machine complete of a bigger primary shredder, screener and secondary shredder with a productivity up to 250 tons per hour. The first machine has been sold in China and will be delivered in May 2021. The dimensions of the crusher are 59x 35 in (1,500 x 900mm), with a hopper capacity is 41 ft2 (3.8m2). Applications include earth and rocks, construction and demolition waste, environmental decontamination and reinforced concrete, to name a few. Optional features include a GPS, recirculation conveyor, dust suppression plant, and more. The series also comprises the Centauro 100.32, Centauro L 120.56, and Centauro L 120.56 APR.
New wheel-mounted screener from Edge Innovate
The Edge SM186 wheeled mounted screener is a solution for applications such as recycling and soils, and incorporates an 18 x 6 ft (5.4 x 1.75m) two deck screen with interchangeable flip flow and scalper bottom decks, and numerous screen media options and configurations. Design features include a low-level feed hopper for loads from all three sides without the need of construction ramps, and 2- or 3-way splitting configuration. The control system features a sequential start/stop functionality.
Fitted with a tri-axle bogie with an ultra-underslung suspension complete with fifth wheel hook-up and air brakes, the Edge SM186 is easy to transport between sites. Operators can choose from different screen boxes including Edge Innovate’s flip flow screen, scalping screen and rinser screen. Optional power sources include diesel/hydraulic, diesel genset or direct electric. The machine is available in a static chassis format. Other features include a modular top deck system, allowing numerous media types to be installed side by side, and screen-box jack up functionality.
New Tana 440 shredders
Customer feedback has spurred a number of improvements to Tana 440 shredders. The model 440DTeco shredder is more versatile, more productive, and easier to use, with a frame structure that allows more space for material flow underneath the rotor. In addition to the 33-knife rotor, there is an option of 44 knives which increases capacity/output in tire shredding by 25%. A variety of cleaning combs are available for different purposes.
In addition, the conveyor system has been redesigned to include transfer and discharge conveyors, both with adjustable speed. The frame of the discharge conveyor is self-supporting enabling angle adjustment that self-calibrates depending on the discharge conveyor angle. An over-band magnet has been repositioned higher, and the space between the magnet conveyor and the discharge conveyor can be adjusted during operation. The Tana Control System helps the user find the most efficient settings for each process. The shredders are available as track, trailer and electric models.
New products from Keestrack announced for 2021
The Keestrack I4e tracked mobile reversible impact crusher can be used in the secondary crushing of rock and recycling building materials. The design with a large variable crushing chamber, rotor and electronically monitored hydraulic gap adjustment allows feed sizes of up to 9.8 in (250mm) and ensures end products of up to -.08 in (-2mm) in closed circuit. Secondary and tertiary crushing can be combined in one mobile solution. The system features a diesel-electric drive concept and weighs 41t. The drive unit with 600-hp (447kW) diesel engine and 300kVa generator is designed as a removable drop-off module.
Other new Keestrack products include the battery-powered S5e track mobile stacker. The 23m stockpile conveyor is equipped with a 22.8kWh lithium-ion battery pack that provides energy for self-sufficient electrical operation of tracks and lifting hydraulics. This enables the 12.7t machine to be independently unloaded and loaded, moved and positioned on site. Finally, the Keestrack F6 is the company’s first production model of new road milling machines, featuring a new milling drum unit with a specific pick design. The working width of the 30t model with 600-hp (447kW) Cummins engine is 78 in (2,000mm), working depth up to 12.6 in (320mm).
Kleemann announces new mobile jaw crushing plant and more
The Mobicat MC 110(i) Evo2 mobile jaw crushing plant has an hourly output of up to 400 tons per hour and can be used in quarry and recycling applications where emphasis is on coarse crushing. The crusher features a two-stage overload system which prevents blockages and material bridging. If uncrushable material enters the crushing process, the CSS opens two times faster than with the predecessor plant or, as an option, up to forty times faster. Other features include the Continuous Feed System and an extra-long articulated crusher jaw.
Kleemann also offers the mobile classifying screens Mobiscreen MS 1202 and MS 1203 with a feed capacity of up to 750 tons per hour. They are available with two or three screen decks and have screening surface areas of 129 ft2 (12m2) in the upper and middle deck and 118 ft2 (11m2) in the lower deck. The feed hopper has a holding volume of 353 ft3 (10m3). Both screens can be combined with crushing plants from the Kleemann Evo and Pro series. They driven by hydraulic power units, and the Dual Power option allows them to be driven by electric power.
Kleemann has also launched new Mobibelt stackers in three sizes and designs. The Mobibelt MBT 20 has a crawler chassis and a belt length of 65.6 ft (20m). With the MBT 24, Kleemann offers a further stacker with a crawler chassis and a length of 78.7 ft (24m). The MBW 15 has a conveyor belt length of 49 ft (15m), and can be moved with a tractor.
Meet Senya Tech’s Micro Crushers
Pioneering a new category in Construction Equipment, Senya Tech is excited to introduce a new revolutionary line of Micro Crushers crushing machinery. Along with parent company, SANME, Senya Tech has been in the rock crushing business for more than 60 years, primarily in the mining and quarry business with its larger machines and custom-designed crushing plants. The new Micro Crusher jaw-crushing machine is designed to be pulled behind a .75t pickup truck and produce up to 30 tons per hour of beautiful finished aggregate product. All this is accomplished with an electric motor and no hydraulics. With the disposal costs of demo product and “buying back” of base aggregate almost reaching at least $1000 per truckload, these machines can pay for themselves very quickly. Small wonder the Micro Crushers generated so much excitement at last year’s Conexpo-Con/Agg show. Comparably sized impact crusher and screen plants are on the way. For now, check out senyacrushers.com for pictures, video, product specs, package deals, and all the Senya Tech has to offer.