Loads of new crushers, screeners and shreddersPublished 10/5 at 14:16
In the prolific world of mobile shredding, crushing and screening, many new machines are being rolled out to 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 aluminium recycling plants is contamination from other materials such as wood, plastic and other metals which stick to aluminium, thus requiring separating. A German waste management company turned to BHS-Sonthofen for a new recycling solution for the 30,000t of non-ferrous metals that they recycle annually. The company opted for the Rotorshredder, which shreds the feed material and breaks up composites. The Rotorshredder RS 2018 was fitted with reinforcements for aluminium processing in accordance with the customer’s requirements. After receiving a hardened housing, double walled base and new suspension system it was commissioned in December 2019. The recycling of raw materials contributes to a recycling plant’s profitability which often hinges on high purity levels. BHS-Sonthofen therefore considers each application individually and chooses a shredding solution appropriate to the situation. The Rotorshredder itself uses selective shredding, with the impact forces ‘deforming’ the aluminium, causing impurities to break down. Composites are then separated from the feed material and following classification, the high purity aluminium is ready for sale.
Arjes shredders in use in Israel
Arjes shredders are now in use in Israel by such company’s as Gal Michsur, which uses the ‘Impaktor 250 Evo’ to process materials including shredded waste wood, which is mainly used as a substitute fuel in incineration plants. Prepared green waste is also used for processing in composting plants, with all metal contaminants removed with an over band magnet. The material is then screened, with the generated commercial waste then shredded to reduce its volume to save transportation and landfilling costs. In Israel, these costs are based on the material’s weight and volume, with reduction benefitting the customer twice over. The second example of Arjes shredders in Israel is Carmel Natural Products Ltd., where there is a composting area and a collection point for green waste that is shredded on site with the ‘Titan 950’. The material is screened and processed to a grain size of 0mm-20mm, as required in Israel. Using the Titan 950, stones and metal that went unnoticed during pre-sorting can be pre-shredded and sorted. The third example of Arjes shredders in Israel is a large scale waste collection point in southern Israel. A large part of the waste generated there is dumped and buried, but through using the Titan 950, the volume of household and commercial waste is reduced so that more layers of waste can be deposited. Further improving efficiency, the twin shaft on the shredder can be installed and removed quickly thanks to its quick change system.
Haas processing waste wood into biomass fuel
BWE Balthasar GmbH is a German waste disposal company that operates a waste sorting plant. The company was looking for a solution to process approximately 40,000t of waste wood annually into fuel for thermal utilisation in a biomass power plant, producing wood chips of 80mm-120mm with a minimum percentage of fines. To do this, Haas supplied a ‘Tyron’ pre-shredder and ‘Alva’ star screen with oversize recirculation. The Tyron features a twin shaft system and ‘neodym’ cross belt magnet making it suitable for hard wood railway sleepers with solid iron plates. An extra fine tool configuration provides BWE with excellent wood chip and high throughput. The Alva star screen separates the usable fraction (-120 mm) from the oversize 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 in Cyprus (an associated company of Vassiliko Cement Works) commissioned a Lindner shredder from the Polaris series to shred high calorific refuse derived fuels. Vassiliko operates one of the largest cement plants in Europe and to ensure the amount of energy needed to produce approximately 6,000t of clinker per day, it relies on Enerco’s resource saving alternative fuels. The shredder produces fuel with a particle size of approximately 50mm out of ‘end of life’ tyres mixed and bulky waste and waste wood. “We are delighted to report that since we commissioned Lindner’s new Polaris 2800, it’s been possible to increase our waste treatment capacity for the production of alternative fuels suitable for Vassiliko’s calciner,” says George Americanos, general manager at Enerco.
Another development from Lindner is the patented ‘SF’ synchronous fine cutting system which changes the angle between knives 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, with the shafts acting 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 scalping screen designed for compact 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 designed as a solution for construction contractors who experience frequent changes in site locations, or as use as a rental unit. Also new is the Nordtrack I908 mobile impact crusher which features a design for smaller sized material reduction job sites accepting different kinds of feed material. “Nordtrack sales have been developing very well despite the pandemic; in fact, we have exceeded sales targets in some areas,” says Vesa Tuloisela who heads the Nordtrack product offering at Metso Outotec. “However, we are always listening carefully to customer feedback. These two new products represent a concrete outcome of those discussions.”
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 six screens. The development has led to lower fuel consumption, with the annual CO2 emissions of Lokotrack equipment being 20,000t lower today than it was before 2010. “Lokotrack design principles are simple: optimise the operating costs, capacity, and end product quality of the customer application,” says Kimmo Anttila, VP Lokotrack solutions at Metso Outotec. “Lokotrack is robust, energy efficient, and highly mobile – and it meets the versatile needs of customers today and tomorrow.”
Second Rockster crusher for 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 its limestone processing, a R1100S closed circuit impactor has been added to the fleet. The impactors are used to crush dolomite limestone which is used for production of cement, with the plan being to produce 600,000t of final material annually. “The R900 was exactly the right crusher to start the processing business,” says Al Hassane Sienou, managing director of TMQ. “We are convinced in the robustness and longevity of these impact crushers and have therefore this time invested in a larger impactor from Rockster. Our new R1100S also has a screening system, which consists of a screen box and return belt so we can produce perfectly defined final product with an excellent quality.”
Diesel free with the ‘RM 120X’ hybrid
Taha Zahir from Kafr Qasim, Israel, invested in a RM 120Go! in 2018. The crusher has been crushing C&D waste to produce road substructure aggregate. Processing takes place inside an enclosed hall, meaning it was essential that emissions are kept low. Taha Zahir was interested in a second low emission crusher choosing a RM 120X hybrid, which can be diesel-electric and purely electric powered. Daily, up to 1,000t of feed material, with an edge length of up to 800mm is processed to produce cuboid final aggregate (0-32mm). As the C&D waste is mixed with plastic, wood and textiles, Taha Zahir also ordered a dust suppression system and installed a wind sifter on both crushers. The RM Go! has been developed for RM’s new ‘Next’ machines, with communication lights enabling the user to view the system’s current status, and to operate the crusher from outside the danger zone with information on the crushing process displayed on the ‘RM Go! Smart App’.
Powerscreen reveals battery powered concept screener
Powerscreen’s electrification strategy includes a new concept for crushing and screening: the ‘Eco-Warrior’ battery powered screener. This has been designed to deliver the screening action the company says its machines are famous for, whilst also being a self-charging, or plug in model that features 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 produce emission free running or give a power boost. As part of Powerscreen’s decarbonisation challenge, the product range has evolved to reduce environmental impact by making crushing and screening equipment more fuel efficient. This is done by using direct drive systems for the crushing range and improving engine capabilities and drive line design for the 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 new BR380JG-3 is powered by a Komatsu EU Stage V emissions compliant diesel engine, and comes with a CO2 off setting scheme. “The new BR380JG-3 is Komatsu’s first diesel powered machine in Europe with net zero CO2 emissions,” says Vince Porteous, product manager at Komatsu Europe. “Komatsu believes that solving environmental, social and governance (ESG) issues are key to the future.” Operating weight ranges from 33,500kg to 35,310kg, engine power output is159kW at 2,050rpm. The machine incorporates a two axis type deck vibrator for continuous flow of material to the two stage grizzly separator bars and a semi-automatic feeding system incorporates crusher overload detection and automatic feed control. The machine has a 1,065mm x 550m jaw opening with tapered side plates, a maximum crushing capacity of up to 240t/h and a 1,050mm wide main conveyor (with a 120m/min top speed), which can produce a stock pile of 37t. The BR380JG-3 features a one touch start and stop function; a foldable ground level maintenance access step and other features including ‘Komtrax’ telematics and the ‘Komatsu Care' maintenance programme. The latter two 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 has launched the Centauro XL 150.56, the biggest model in its Centauro range of mobile crushing and screening plants for construction and demolition waste, aggregates and asphalt. The Centauro XL 150.56 provides a bigger primary shredder, screener and secondary shredder with productivity up to 250t/h. The first machine has been sold in China and will be delivered in May 2021. The dimensions of the crusher are 1,500mm x 900mm, hopper surface is 3.50m x 2m and the hopper capacity is 3.8m2. Applications include earth and rocks, construction and demolition waste, environmental decontamination and reinforced concrete, to name but a few. Optional features include GPS, recirculation conveyor and dust control. The series also comprises of 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 a 5.4m x1.75m two deck screen with interchangeable flip flow and scalper bottom decks. This is available with 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; two or three way split configuration and a control system that features sequential start/stop functionality. The machine is fitted with a triaxle bogie with an ‘ultra’ underslung suspension complete with fifth wheel coupling and air brakes making it 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. As well as wheeled, 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
Tana 440 shredders have been improved in response to feedback, with the first new model being the Tana ‘440DTeco’ shredder, which according to Tana, is more versatile, more productive, and easier to use. Its frame structure allows more space for material flow underneath the rotor and in addition to the 33 knife rotor, there is an option of 44 knives which Tana states increases capacity/output in tyre shredding by 25%. The cleaning combs are also bolted on, with different cleaning combs being available for different purposes. Furthermore, the conveyor system has been redesigned, with the transfer and discharge conveyors both having adjustable speed. The frame of the discharge conveyor is self-supporting enabling angle adjustment, with the scale system calibrating itself depending on the discharge conveyor angle. The over band magnet has been repositioned higher with the space between the magnet conveyor and the discharge conveyor being adjustable during operation. The new shredder also come with the ‘Tana Control System’ (TCS) which features a touchscreen display for a user interface that helps the user find the most efficient settings for each process. The shredders are available as track, trailer and electric models.
New ‘I4C’ compact impact crusher from McCloskey
The I4C the latest addition to McCloskey International’s impact crusher line, with the power and productivity of a 1,125mm impactor in a compact format, with an impact crusher having a deeper chamber, creating greater tramp release space. With an aggressive blow bar and apron design, a four bar variable speed rotor and three crush zones with an optional fourth strike, the I4C can be set up as a primary or secondary crusher. An asymmetric feeder reduces bridging and, combined with the single unit feeder-hopper construction, delivers motion and vibration for the material as it moves into the impact chamber. The I4C features a curved belt on the main conveyor that manages material delivered to its 4m high stockpile. The I4C is equipped with a chamber door safety sensor, built in safety shutdown functions, chamber safety arm and a platform for changing blow bars. McCloskey states that the IC4 is, size for size, it’s most powerful impact crusher. “We are bringing the I4C to market to respond to the demand for a heavy duty, high production impact crusher with high mobility and enriched safety features,” says Toni Laaksonen, senior vice president, McCloskey International.
New products from Keestrack for 2021
Keestrack’s new ‘I4e’ tracked mobile reversible impact crusher can be used for secondary crushing of rock and recycling building materials. The design has a large, variable crushing chamber, rotor and electronically monitored hydraulic gap adjustment that allows feed sizes of up to 250mm ensuring end products of up to -2mm in closed circuit with secondary and tertiary crushing being able to be combined in one mobile solution. The system features a diesel-electric drive concept and weighs 41t. The drive unit has a 447kW diesel engine and its 300kVa generator is designed as a removable drop off module. Also new is the Keestrack F6, which is the first production model of new road milling machine line, featuring a new milling drum unit with a specific pick design. The working width of the 30t model with a 447kW Cummins engine is 2,000mm, and a working depth of up to 320mm. Prototypes and pre series models have undergone tests in Asia where the series is produced, whilst parallel to their introduction there, introduction strategies in other regions are being worked on.
Kleemann announces new mobile jaw crushing plant and more
Kleemann’s ‘Mobicat MC 110(i) Evo2’ is a development of its predecessor. It has output of up to 400t/h and can be used in quarrying 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 (close side setting) opens twice as fast as its predecessor, or, as an option, up to forty times faster. Other features include the ‘Continuous Feed System’ and an extra-long articulated crusher jaw. Kleemann has also introduced mobile classifying screens, the ‘MobiscreenMS 1202 and MS 1203’, with a feed capacity of up to 750t/h. They are available with two or three screen decks and have screening surface areas of 12m² in the upper and middle deck, and 11m² in the lower deck. The feed hopper has a holding volume of 10m³. Both screens can be combined with crushing plants from the Kleemann ‘Evo’ and ‘Pro’ series. They are driven by hydraulic power units, with a ‘Dual Power’ option allowing them to be driven by electric power.