Safety features, cost efficiency, among other factors play a pivotal role in determining the desired output.

Mining is one of the core sectors driving growth in the economy. Besides contributing to the GDP, it also acts as a catalyst for the growth of industries like power, steel, cement, etc., which in-turn is critical for the economy’s overall development. Every 1 per cent increment in the growth rate of mining and quarrying results in 1.2 – 1.4 per cent increment in that of industrial growth.

The crushing and screening equipment play a significant role in the above sectors given that the two are largely complementary. During the crushing and screening process, ore is sized and separated from ROM (run of mine) stage to end usage stage.

Ensuring safety, stable operations and high yields.

Safe, orderly and efficient
Bevcon selects the crusher and screen capacities primarily by calculating the mass flow balance of the system. The selection is based on the position of equipment in the circuit which is either primary, secondary or tertiary crushing or screening system.

The company experts are ready to help customers during commissioning of new circuits or upgrading old circuits, and have extensive experience commissioning, operations of crushing and screening circuits. V. Manoj Kumar, Assistant Vice President – PMG, Bevcon Wayors Pvt Ltd., says, “Bevcon ensures that start-up activities on assigned systems is conducted in a safe, orderly and efficient manner. Provide technical assistance to the customer operating personnel during initial operation of equipment and systems. Ensure the completion of system performance tests and handing over formalities.”

Crucial safety commitment
According to Piero Guizzetti, CEO, MB India, MB crushing and screening equipment are able to perform directly at site, they are innovative and compact buckets that represent the cost-effective solution. On site there are always excavators or other heavy machinery and MB units work with any brand. The advantage is that equipping the excavator with these attachments with only one machine and one operator, material available can be treated. He adds, “Transport cost and procurement costs are drastically reduced. Not only logistics is facilitated but many operational costs are also reduced, thereby increasing revenue. And, even in site where job schedules are tight with MB units, commitment to safety is crucial, in fact one operator manages the entire chain of crushing and screening safely from the excavator cab.”

Chamber combination results high yield
Rock on rock to rock on metal version can be easily converted by offering anvil rings and rocks. Ajay Varma, Director, Marsman India Ltd informs, “Chamber combination results in higher production yield. This simplified retro fit can be easily and quickly installed on existing rock on rock model without changing the complete machine resulting in differing product’s needs.”

Safe and stable operation is the priority
Ensuring safety, stable operations and high yields is a part of the curriculum. Puzzolana Machinery Fabricators have added new range of jaw crushers for higher productivity utilising the same drive motor. Also to meet the increasing demand for bigger secondary crushers of +400 TPH the company have added a new cone crusher into the range. Also the bigger machines will reduce the number of machines and accessories which in turn will reduce the cost of operation. In other words, the overall cost or tonne of production will come down dramatically and also efficiency of the system will improve.

Rajender Khoda, Group Business Development Advisor, Puzzolana Machinery Fabricators (Hyderabad) LLP asserts, “To cater to the increasing need for crushed aggregates, we are launching bigger, high productive crushing and screening equipment to our already existing wide product range, keeping in view safe and stable operation as a priority.”

Following quality standards and safety norms
Viraj Parthi, Country Manager, Terex Finlay says, “There is a need for road construction industry to stand up and courageously transform the process through innovative engineering approach and equipment. More than 70 per cent of contractors are still not prepared to adopt technology for faster execution of projects. To ensure time bound completions of infra projects we are prepared and have proven and robust machines that is actually giving upper edge to our existing customers. Safety has been among the core values for us. We follow the most stringent quality standards and safety norms.”

The Terex Finlay machine is in conformity with the EC Machinery Directive 06/42/EC together with appropriate EN harmonised standards and national BS standards and specifications. To ensure stable operations, the company has a dedicated and experienced aftermarket support. Terex Finlay machines are the most robust and reliable machine thus provide maximum availability and has higher production capacities. These unique features have helped Terex Finlay in establishing as the most trusted brand.

Achieving reliable productivity
Crushing and screening is the most important part of any process unit. It should be selected based upon the safety features available in the crusher and screen, which in turn provide maximum productivity. Swarbhanu Banerjee, Sales Manager – Surface OE, Komatsu Mining Corp. Group suggests, “A primary crusher must have safety features to protect the machine from uncrushable metal parts that could potentially damage the equipment. Additionally, this will also help reduce downtime and ensure consistent productivity.”

Cost effective but efficient

Considering capex while RoI
The materials used in the production of equipment are important since heavy toll absorbed by crushing and screening equipment is a significant consideration. Also, owing to the heavy duty of the operations, it is imperative that the supplier has an adequate infrastructure for servicing the machines, with consumables and spares readily available.

Guizzetti from MB India said, “When considering the return on investment (RoI), capex is only one of the many elements to be considered. A decision should be made considering capex along with productivity, maintenance cost, product lifecycle, etc. Of course, one must be sensitive to the varying investment capacities out there in the market.”

Right synchronising
Varma from Marsman India asserts, “Marsman’s crushing and screening equipment produces high productivity at low power. We provide solutions to customers to suit their requirement while also suggesting various ways to lower their cost of production.” Right synchronisation of crusher, feeder, vibrating screen and conveyors are also equally important factors in achieving cost effectiveness.

Prime consideration
Khoda from Puzzolana recommends the following points to be considered while buying crushing and screening equipment
• Aggregate requirement for the project and the time scale for the production.
• Production required per year and duration of quarrying lease it will decide type of plant mobile, skid or stationary plant.
• Number of stages of the plant depending on the end product requirement.
• Feed size availability and production requirement will be decided on primary crusher size.

Factors driving cost effectiveness
To start a project, proper planning is necessary and one should keep the variable Indian conditions in mind. The right equipment selection is the key to success. Parthi from Terex says, “We have a dedicated rock test laboratory to understand the needs and deliver accordingly. Our machines are capable of producing high quality aggregates with greater capacity thus enabling our customer to claim bonus on early completion of projects and also save overhead charges. Also, owning a track mounted crusher enables our customer to mobilise the complete crushing plant quickly near the required sites thus saving huge haulage cost of aggregates.”

He adds, “Apart from the capital cost two important factors drive the overall cost effectiveness. Firstly, the product support and availability of equipment and secondly, operating team expertise to get maximum output. Terex Finlay focuses on both these aspects by providing best and swift aftermarket service and training programs.” The company has vast network of experienced service engineers for continuous product support. A unique training centre has also been set up to provide advance training to the crusher operators and plant supervisors. Recently, Terex India has been accredited as training partner of Infrastructure Equipment Skill Council (IESC) under the banner of Skill India and NSDC program of the government.

Reducing maintenance time
Banerjee from Komatsu advices, “There are various types of crushing and screening technologies available in the market that is cost effective, but to ensure the greatest return, mines need to consider the best fit for their specific application. Additionally, I would also recommend high capacity crushing and reclaiming equipment reduce maintenance time.” It is very important to be mindful of the TCO (Total Cost of Operation) over the life of the machine. Remember, capital expenditure is only a fraction of the actual cost of the machine and choosing a cheaper option may cost one in the long run.

Optimum productivity till life of the equipment
The key is to analyse the problems together and refer them to dedicated specialists. This approach will lead to improved productivity, lower cost, improved energy efficiency and eventually better profitability. The challenge to lower the cost per ton of finished products requires a thorough knowledge of the whole quarrying process, combined with the best equipment, service, support and consumables. Ashoktaru Chattopadhyaya, Business Line Manager – Crushing and Screening (Sandvik Mining and Rock Technology), Sandvik Asia Pvt Ltd. says, “Our newly introduced ‘lifecycle approach’ together with innovative ‘Opti-Agg’ software solution has enabled us to maximise the production with required gradation and quality. This has ensured the optimum productivity and customer’s peace of mind till the life of the equipment.”

Sandvik VSI unit is unique and has made sand processing possible in three stages of crushing with the introduction of Sandvik CH550 in stationary and mobile applications. There are several integrated strategies which can improve efficiencies and reduce energy use. Selective blast design, ore sorting, waste removal, advances in modelling and new grinding technologies are just some of the approaches companies are adopting to improve ore grades and cut energy costs. Thus, the collective usage of the modern mechanised techniques will be of great help to the crushing and screening segment thereby achieving cost and energy efficiency.

Board holistic perspective
One needs to look at screen and crushing equipment holistically in four broad perspectives viz. productivity, reliability, easy maintenance, safety.

The company’s engineering team uses latest 3D modelling software tools to standardise the equipment. Kumar from Bevcon says, “Most of the critical components of the equipment shall be undergone with ‘Finite Element Analysis’ to ensure the optimisation and added value engineering aspect. Apart from 3D and analysis software, the company also often uses ‘discrete element methods’ to ensure the life and performance of the internal components of crusher and screens.” After engineering, manufacturing process should be taken care right from raw material stage to the finished product stage. Stringent quality norms are imposed to ensure the quality of raw materials, stage wise inspection and test trials are met with the customer specifications.

Crushing and Screening – Latest offering

MB Crusher drum cutter range
MB has recently launched drum cutter line of products in the Indian market. The portfolio is composed of 4 models that may be attached on the smallest of excavators up to 35 tonnes class excavators. Guizzetti says, “Our drum cutters distinguish themselves not only in terms of productivity but also in terms of technology. Our direct drive twin motor system ensures that the force is distributed to the drum which is encountering the most resistance. This takes into consideration the fact that in no digging, trenching or tunneling the material will never be uniform across the area to be worked upon. This feature has been highly appreciated across the world for its uniqueness and pertinence considering the main application areas.”

Quarry skid: technology by Marsman
“Quarry skid is not our latest offering per sale, but a technology we have been offering to European market for years. Although for India it can be considered as a latest technology since the trend of recycling rubble stage in India,” says Varma.

Quarry Skid is a machine used for recycling or crushing rock, concrete, rubble on site of the actual project and not for off in the mines. It comes fitted with a silent DG set powered by diesel for smooth on site operation. It is ready to use crusher with a vibrating feeder and small discharge conveyor. Quarry skid can be plat formed on truck transported wherever required. After the completion of crushing, it can be easily loaded back on the truck.

Puzzolana offers diesel electric system
Khoda says, “We are now offering track crushing and screening plants with diesel electric system instead of diesel hydraulic system.”

The Kleemann EVO series
Kleemann is extending the EVO series by a total of four new classifying screens viz. 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.m or 9.5 sq.m. As with the crushing plants, the favourable transport dimensions and short setup times of the classifying screens meet the demands of contractor crushers.

According to Wirtgen India, “The MS 702 or 703 EVO achieves a maximum output of 350 t/h and the MS 952 or 953 EVO an hourly output of up to 500 tonnes. This high output is achieved, above all, thanks to the good material stream through the plant. This starts with the in-feed which, thanks to the generously-sized feed hopper, is possible by means of a wheel loader or an upstream crushing plant.” The material is conveyed to the screen casing on the extra-wide feeding conveyor of 1,200 mm. Its screening angle can be adapted to the application. An impact plate on the conveyor discharge spreads the material evenly on the screen surface.

MOBISCREEN EVO screening plants
With the MOBISCREEN EVO screening plants, Kleemann also places an emphasis on the subject of safety. Operation of the screening plant is via a mobile control panel that can be attached at three different points on the plant. This guarantees the best viewing positions of the executed plant functions. All plant functions are started automatically without each side discharge conveyor having to be activated individually. Data on machine operation can also be read off at the control panel. Plant movement is without jolts due to proportionally activated hydraulic valves. The plants operate particularly efficiently and produce a high output when interlinked with crushing plants of the EVO series, whose size and output are tuned to the EVO screening plants. A further bonus for safe plant operation is the emergency-off function, which, in the case of an interlinked combination of plants, works across all screening and crushing stages.

Terex Finlay C-1540 Cone crusher
Terex Finlay C-1540 Cone crusher features number of major benefits including hydrostatic drive, rapid setup time, higher reduction ratio and output capacity. The company offers pre-screen option with the cone crushers that helps in increasing the cone efficiency significantly. Also, the Terex Finlay J-1175 jaw crusher comes with reversible operation for clearing blockages and a fully hydraulic adjustable CSS option. Terex Finlay machines have an advanced electronic control system that helps not only in quick diagnosis of any problem but also providing information for optimal plant maintenance. Parthi added, “For material handling we are now offering our track conveyors. Smooth mobility and high stockpiling capacity ensures significant cost saving in material handling.”

Joy feeder breakers
Joy feeder-breakers from Komatsu are designed to reduce operating costs and increase productivity. The company’s feeder-breakers can be designed for a variety of industrial applications and materials, including coal, phosphate, cement, limestone, petroleum coke and gypsum board, among other materials. By custom-designing and building the feeder-breaker for specific haulage and conveyor systems, the operation will realise optimum availability and reliability. The company offers mobile, semi-mobile, skid, fixed mounted feeder-breaker, which provide flexibility to customer to shift the crusher easily as and when required.
According to Banerjee, “Our underground feeder-breakers are designed for low-to-high seam applications to provide high productivity and reliability in the most rigorous of conditions.” The MVT-II is a secondary and tertiary sizer that reduces fines generation through matched velocity technology, while optimising throughput capacity. Roll speeds are set to match the speed of incoming material, reducing excess fines created with other designs. Additionally, segmented roll design allows operators to replace the worn segments individually and adjust the gap between two rolls to optimise productivity.

Sandvik crushers and screeners
Sandvik crushing and screening equipment offers one of the most advanced range of products with solution-based approach. This contributes to increased performance and productivity for its customers.

Chattopadhyaya says, “We provide full plant solution of various ranges (200 TPH to 500 TPH). Furthermore, the gyratory crushers, medium and bigger cone crushers, PriSec range of crusher, sizers have been appreciated in the market. Capacity range starts with 100 TPH and can go up to 3500 TPH.”

He says, “Our VSI crushers can produce 100 per cent down <2.36 mm sand known as plaster sand. Our HSI called PriSec can produce from 1,000 -m feed size to 100-mm product in single stage for soft rock minerals like coal, Bauxite, etc. It can covert the primary into secondary within three to four hours on site without additional expenditure.”

The company has a wide range of crushers for versatile crushing needs in both mining and aggregate sector, and has already developed and started manufacturing the track mounted crushing units in India.

One of the key contributions in sustainability and advancement, is the state-of-the-art solutions for sand manufacturing and iron ore fines (beneficiation / palletisation application). The company has introduced the latest state-of-the-art technology and 500 series crusher models like CH550, CH540, etc.

Bevcon

Vibrating screens
Bevcon offers various types of screening technologies to mining applications. 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.m area. High-efficiency linear motion screens 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.m area.

Crushers
Bevcon manufactures various types of crushers especially for coal and lime stone. The crusher range includes
• Hammer mills – Crushing ratio 35:1
• Impactors – Crushing ratio 35:1
• Double roll crushers-Crushing ratio 5:1

Kumar says, “These crushers cater to the need of coal crushing in major thermal power plants. Bevcon has a product range of crushers from 10 – 1500 TPH for coal application. For mining sector, the company manufactures feeder breakers of 500 TPH. These feeder breakers are very common in coal mining. It manufactures limestone crushers up to 200 TPH for cement application.”

Bevcon ensures that start up activities on assigned systems is conducted in a safe, orderly and efficient manner.
V. Manoj Kumar, Assistant Vice President – PMG, Bevcon Wayors Pvt Ltd.

Our drum cutters distinguish themselves not only in terms of productivity but also in terms of technology.
Piero Guizzetti, CEO, MB India

Marsman’s crushing and screening equipment produce high productivity at low power.”
Ajay Varma, Director, Marsman India Ltd

We are now offering track crushing and screening plants with diesel electric system instead of diesel hydraulic system.
Rajender Khoda, Group Business Development Advisor, Puzzolana Machinery Fabricators (Hyderabad) LLP

Safety has been among the core values for us. We follow the most stringent quality standards and safety norms.
Viraj Parthi, Country Manager, Terex Finlay

Our underground feeder-breakers are designed for low-to-high seam applications to provide high productivity and reliability in the most rigorous of conditions.
Swarbhanu Banerjee, Sales Manager – Surface OE, Komatsu Mining Corp. Group

Our ‘lifecycle approach’ together with innovative ‘Opti-Agg’ software solution has enabled us to maximise the production with required gradation and quality.
Ashoktaru Chattopadhyaya, Business Line Manager – Crushing and Screening (Sandvik Mining and Rock Technology), Sandvik Asia Pvt Ltd.