06 June 2020

Industry Focus- Crushing & Screening Equipment

Good demand Aggregates

The three major sectors driving demand for construction aggregates are; real estate, infrastructure, and mining, and all three are on the upswing. While fast track rollout of infra projects in the transport and power sectors will generate major demand, so will the real estate sector. The other major demand driver for crushing and screening equipment is the mining sector, which was opened up majorly by the Mining Ordinance last year. All this adds up to a significant demand for aggregates across size and types. Satish P Chavan reports.

 

Fast Facts
  • 135 billion tons of crushed aggregates required during 12th Plan period
  • CSE sales in first two quarters 2016-17 up 25 per cent compared to last year
  • CSE share in overall CE projected at 13 per cent, to touch $ 30 billion end 2017
  • Shift in preference to mobile units, CAGR projected at 30-35 per cent next five years
  • Demand for ‘Total Solutions,’ comprising 'equipment+training+aftermarket services'
  • APAC region to clock highest CAGR at 8.5 per cent
  • Global CSE market projected at $ 2.55 billion by 2022

 

Now that India’s trillion $ juggernaut to modernise its infrastructure has rolled out, there are all kinds of EPC and realty projects being launched. As this gathers steam there’s going to be huge demand generated for all types of aggregates. Concomitantly this will generate huge demand for crushing and screening equipment (CSE), across the wide spectrum of product verticals, ranging from all kinds of crushers to screening equipment sifting out aggregates ranging from coarse to fine grain sand. Big-ticket programmes like 24x7 Power, Affordable Housing and Housing for All, 100 Smart Cities, 30 km of roads per day, different highway projects and dedicated freight corridors, and a target of a billion tons of coal from Coal India Limited (CIL), by 2019, etc, will generate huge demand for aggregates. The government has increased spending on road and infrastructure development to the tune of around Rs.1 lakh crore for projects announced in 2016-17, hence the requirement of aggregates is bound to increase. In fact overall CSE businesses in the first two quarters of 2016-17 have already shown an increase of more than 25 per cent compared to last year.

According to market research firm Freedonia Group, at an estimated demand of 3.3 billion tons, India accounts for roughly 7 per cent of the 48.3 billion metric ton global market for aggregates. Non-building construction activity comprises 70 per cent of aggregates demand by volume. This sector is expected to hold onto its lead through 2020. Consequently, demand for CSE is going to be huge in India considering the demand for aggregates across all sectors.

 

Green Trends
In keeping with the new trend of CSE, OEMs now offer green machines and remanufacturing. CSE is now becoming more fuel efficient with a minimum carbon footprint. The new trend is telematics and SCADA for ease of repair and maintenance. CSE machines are hard on wear-and-tare and with proper MRO procedures a client can enhance total productivity in the long run. OEMs are also offering safety features like dust suppression systems. With pollution control issues arising out of dust emissions, manufacturers design products which can be retrofitted to control such kinds of pollution effectively. Mostly, water suppression systems are used to minimise the amount of dust created at the crushing and transfer points. With regular maintenance procedures these systems reduce mineral and silica dusts, which are abrasive, but can be controlled.

 

DEMAND DRIVERS

The biggest demand drivers for CSE are; EPC projects in the infra sector, including transport (roads/rail/airports/ports), real estate projects ranging from government housing schemes to projects launched by builders and developers, and urban infra projects ranging from transport to utilities like power and water etc. The other major demand driver is the mining sector, which will need CSE machines across all capacities and types to process all kinds of aggregates. A study conducted by Central Pollution Control Board of India (CPCB), estimates that 135 billion tons of crushed aggregates will be required during the 12th Plan period. When translated to equipment needed, this adds up to a huge 26,500 CSE units by end-FY17, as compared to around 12,000-15,000 operational units currently. India’s ECE market is valued at $230 billion in 2017. Of this total the share for the CSE segment is projected at 13 per cent and projected to touch $30 billion (Rs.1,350 billion) end 2017. And the new trend of using artificial sand will fuel this growth even further. According to available data the global CSE market is projected at $2.55 billion by 2022, by when, mobile crushers are expected to dominate demand. In the local market, Indian and foreign OEMs are competing intensely for maximum market share in this segment.

 

 

Terex Powerscreen has been an International brand and hails from N Ireland, UK, it produces a world class range of products catering to all corner of globe. Manufacturing centers are located in UK, USA, and in India.
Vadiraj Pappu, Sales Head - Terex Powerscreen Business, Voltas Ltd (Mining & Construction Equipment Division)

 

 

OLI has been credited as a global leader in vibration technology and in the vibration industry. OLI engages itself continuously in the Research and Development activities by bringing innovative ideas in the vibration industry. The ongoing improvements in our products bring immediate and concrete advantages for our customers in terms of increased efficiency and diminished Total Cost of Ownership and we give Guarantee of one year from the date our product is supplied. Our products are available in all ranges and at the most competitive prices.
Sundaram .S. Iyer, Managing Director, Oli Vibrators India

 

 

“NORD develops its own motors and supplies them to all the major markets throughout the world. Our own developments ensure a high level of independence from external suppliers and therefore provide our customers with the key advantage of short and highly dependable delivery times. These products helped us develop a strong customer base all across the globe.”
P L Muthusekkar, Managing Director, Nord Drivesystems

 

 

STRESS ON MOBILITY

While big mines and captive mines with a long operational life prefer stationary CSE, there’s now a noticeable shift to mobile CSE units, especially in the EPC sector and more so in the road and rail sectors. The major demand for mobile crushing and screening plants in India is being generated by road contractors and commercial aggregate suppliers. A stationary plant has the crushers and screens mounted on fixed structures. Work is required on the foundation and it typically takes around 2-3 months to start production. Whereas, because in a mobile plant, crushers and screens are mounted on a crawler-driven chassis, it affords great intra-site and inter-site mobility, and production can start almost immediately. Therefore, revenue generation is also immediate for a customer using mobile crushing and screening plant. Prohibitive transportation costs, irrecoverable stationary plant installation expenses and environmental protection restrictions imposed by CPCB, have caused a shift in preference to mobile units. With track-mounted crushers and screens, there are less environmental restrictions or clearances required compared to stationary plants.

 

With the shift in preference the CSE industry innovated and developed mobile solutions for delivering high quality crushed and screened aggregates meeting the most stringent requirements in terms of elongation and flaky index, shapes and sizes, at affordable costs and production requirements of the customers. A significant market driver is competition amongst CSE suppliers to deliver innovative products like trailer mounted primary jaw crushers, secondary and tertiary hydraulic cone crushers, vertical and horizontal shaft impactors, coupled with in-stage multi-deck vibrating screens and aftermarket solution support to entice more customers. The demand for mobile CSE is projected to grow at a rate of 25 per cent every year, according to OEM sources. Currently the share of mobile crushing and screening plants is approximately 15 to 20 per cent, which is projected to go up to 30-35 per cent next five years. The industry turnover can be pegged at $1 billion. Also mobile units will provide gainful employment to nearly 500,000 people across rural India, where there is a dearth of employment opportunities.

 

OEM OFFERINGS

German major Wirtgen has a major presence in India with its Kleeman integrated range of CSE machines. Kleemann crushing plants have several innovations like the CFS - Continuous crusher feed system, diesel-electric drive, crusher de-blocking system etc. Kleeman’s range comprises six jaw crusher models of various sizes, a variety of impact crushers of different sizes, as well as cone crushers and screening plants. They have a broad performance range extending from 100 tph to 1000 tph. The delivery range includes tracked mobile plants suitable for low-loader transport, with 150 different customer-specific plant configurations. The entire product portfolio is a closed aggregates material manufacturing cycle.

MOBICAT crushing plant uses a jaw crusher and comes in capacities ranging from 200 up to 1,500 tph. This mobile plant comes in seven variants of different types and capacities, in two line models. Contractor Line and Quarry Line.

MOBIREX are mobile impact crushers available in five variants in two product lines; Contractor Line and Quarry Line.

MOBISCREEN is a range of tracked screens of 11 models and extends from 7 – 18.4 m² screening area. Available either in double or triple-deck screen with or without feed hopper, as a banana screen, with finger screening surface, with rubberised perforated panels, etc. It has two line models;. Contractor Line and Quarry Line.

MOBIFOX products is the impact crusher in the SNH series and are equipped with a third impact apron, a so called 'grinding path,' which is not responsible for crushing the material, but ensures the ever so important cubicity of the grain size, making it possible to obtain high-quality aggregate for manufacturing concrete or asphalt.

MOBICONE is a mobile secondary/tertiary cone crusher with integrated screening units. Its plants are available in different sizes and configurations. The series is specially designed for secondary and tertiary crushing in hard-stone applications.

 

thyssenkrupp is another German major that offers a wide range of CSE products. Its crushers are specially designed for different types of materials – from soft coal to very hard iron ore. Each type of crusher is available in various sizes, the selection being based on the requirement of particular capacity, feed and crushed product size. They can be offered for both stationary and mobile applications. These include: Roll Crushers, Hammer Crushers, Impact Crushers,

Ring Granulators, Rotary Breakers, Jaw Crushers, Hammer Mills, Gyratory Crushers, Cone Crushers, and Feeder Breakers.

 It also offers a range of screens in matching capacities for wherever screening before or after crushing is required. Special purpose screens like eccentric disk roller screens are offered for handling sticky materials. Their screens include: Vibrating Screens (circular, linear and elliptical motion), Grizzly Screens, Banana Screens, Roller Screens, and Wobbler Feeders (Screen)

Feeders include: Apron Feeders, Reciprocating Feeders, and Vibrating Feeders.

Sandvik from Sweden is also a major player in the CSE space in India. Its product line of CSE provides advanced, proven solutions for any size-reduction and classification challenges. Their application expertise covers greenfield, expansion, and individual or multi-equipment replacement projects. Sandvik screens for scalping and classifying minerals and coal come in a wide range of sizes and in several types – both individual units and complete systems. Their wide range of feeders for crushers and other applications include robust, impact-resistant grizzly feeders, reciprocating plate feeders, and pan, belt, and apron feeders to swiftly and economically transfer material.

Terex from USA offers a range of CSE in India, which includes a range of Jaw, Cone, and Impact crushers. Its Powerscreen brand includes Chieftain Screen Range, Warrior Screen Range, and H Screen Range. Additional range includes; Powerscreen® MKII, Powerscreen® Commander 1400, Powerscreen® Phoenix 2100, Powerscreen® Phoenix 3300, Powerscreen® Mobile Conveyors, and Powerscreen® Dual Power.

Puzzolana, another entrenched CSE OEM in the Indian market -- is focused on environmentally friendly technology. That is why it introduced dual power crushers which can run either on board DG set or external electric power. Using electrical motors for crusher and conveyor drives, it managed to eliminate over 90 per cent of the hydraulics. Consequently its O&M cost is approximately 30 per cent lower compared to conventional hydraulic drive crushers.

Voltas Limited’s Mining & Construction Equipment Division (M&CE), offers Powerscreen (a Terex brand), range comprising a product portfolio for the quarrying, mining, and aggregate industries. Known for market -leading productivity rates and excellent reliability, the Powerscreen product line includes: Tracked Jaw Range- Metrotrak. XA400S, and 1180 Preimertrak, XA750; Tracked Cone Range- 1000 Maxtrak, 1000SR, 1300 Maxtrak, 1500 Maxtrak; Tracked Horizontal Screen Range- H5163. H6203; and Tracked Vertical Shaft Impact Crusher--XV 350. For iron ore crushing: Metrotrak 900x600 + 1000 SR, 150 - 200 TPH capacity; XA 400 S + 1300 Maxtrak + CH210030, 250 - 300 TPH capacity. Iron Ore Screening - H6203 upto 600 TPH; Warrrior Range upto 600 TPH. Aggregate Crushing: XA400 S +1000 Maxtrak + CH1700 3D, 200 TPH capacity; and XA 400 S + 1300 Maxtrak + CH21 00 3D, 250 - 300 TPH .

Proman offers world class crushing and screening equipment which includes a complete range comprising; LIPPMANN range of heavy duty jaw crushers, PROcone – cone crushers, REMco Vertical Shaft Impact (VSI) crushers, ORTNER sand washing systems, and Finedoor screens and feeders. The brand also offers flexibility in the form of PROMO series mobile crushers and PROMAN-Striker range of tracked machines.

Other major OEM companies in the CSE market include; Rockster Recycler India, Gujarat Apollo, Terex (Powerscreen), Kingson Crusher, Propel Industries, etc.

 

Aftermarket Services will be a major differentiator among OEMs competing for market share in a very robust Indian market for CSE. With plenty of Indian OEMs and global companies setting shop here, the Indian market for CSE has become very competitive, in terms of both – cost and product quality. The resulting paradigm shift is towards seeking total crushing and screening solutions with relevant guarantees, instead of only equipment from the vendors. As such, completion is in a dimension, making the suppliers work on new business strategies. End users of CSE are now demanding ‘Total Solutions,’ which are customised and client specific, and comprise of 'equipment+training+aftermarket service’. For example Finnish major Metso, who is a major entrenched player in India offers value added services like: Health Audit (allows checking, observing equipment during operations, inspection of internal components and recommendations of spare and wears). Metso Repair Facilities (bears replacements to complete refurbishment), Parts support contracts (value based proposition, wherein parts for the equipment are agreed to be supplied over a period of time). The Service support Contracts (ensures the optimal health of the equipment, helps avoid downtimes, maintenance and plant audits are done on a routine basis). Metso also offers optimisation and upgradation contracts (systems are upgraded to incorporate latest features, process optimisation to reduce costs, Retrofits enhances life-times of the equipment).

 

Metso’s Annual Maintenance Contracts aims to achieve optimum availability of the equipment by deploying highly skilled personnel with the latest technology for equipment monitoring and maintaining equipment to achieve optimal utilisation. In operational and maintenance contracts, Metso Provides an operational crew for executing production and maintenance related activities comprehensive offering which shows benefits of AMC and accountability for overall plant performance. Customer Training is also an integral part of Metso services, upgrading the customers knowledge about the product to increase its efficiency and productivity.

 

 

Crushing and screening plants from  Kleemann 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. 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.
Ramesh Palagiri, MD&CEO, Wirtgen India

 

 

Sandvik has always been synonymous with high quality and reliable equipment. We deliver what we commit. Excellent technical solution combined with high speed delivery is one of the biggest strength of ours.  The focussed solution with reduced cost per ton of production really gives us an edge. We understand that the future is going to be automation in mining and Sandvik has crushers featuring the latest generation of automation, thereby making the products safer and maximising their utilisation.
Ashoktaru Chattopadhyay, Business Head - Crushing & Screening, Sandvik Mining And Rock Technology

 

 

LONG-TERM OUTLOOK

Now with ongoing projects to modernise India’s infrastructure, and with opening up of the mining sector, there is going to be demand for all sorts of CSE products across the spectrum. The biggest demand will be for stationary multi-stage plants of bigger capacities which seamlessly integrate the entire process of manufacturing aggregates in various grades of fines. From coal to iron ore to mining other metals and minerals, with demand for these commodities growing leaps and bounds from the manufacturing, power, and construction sector, they are going to generate huge demand for CSE machines.  As with other construction equipment, India’s CSE industry has global prospects of exporting to emerging markets in Asia and Africa. But the only real competitor in these markets are the Chinese, who practice predatory price strategies. But with proper government support like duty drawback etc, Indian OEMs are playing successfully in emerging markets. The competition in India and emerging markets will force OEMs make it to the finer aggregate grades to thrive in a tough market.

 

 

GLOBAL TRENDS

The market for mobile CSE is estimated to grow at a CAGR of 5.57 per cent for the period 2015-2020. The Asia-Pacific region is projected to register a growth of around 8.5 per cent, and the European region is estimated to register CAGR of less than 1 per cent. The shift of preference of quarry operators from setting of a stationary plant to employing mobile crusher and screeners can be prominently seen in most of the geographical regions with Asia-Pacific regions adapting very quickly to the mobile technology because of high transport costs.




Leave a Comment

Name  
Email Address
(will not be published)    
Website
Comment