Monday, March 4, 2024

Cover Story July 2023

Cover Story July 2023

New Age

Crushing & Screening Equipment

High on Efficiency & Enhancements

Just like every other construction equipment vertical, a wide range of new machines are being introduced in the Indian and global markets in the crushing and screening segment. The objective has been to offer better throughput as well as improved product quality along with meeting sustainability targets for future operations. In addition, issues such as mobility and maximizing uptime through the deployment of smart telematics systems remain high priority for the segment. Armed with technological prowess, globally leading companies have been leading the CHANGE by launching products & attachments that are enhancing the productivity and efficiency of construction & mining activities. Here’s tracking the developmental landscape of crushing & screening machines… writes, PRERNA SHARMA.

The crushing, screening and mineral processing equipment market have witnessed significant growth in recent years, driven by the increasing demand for minerals and aggregates in construction and mining activities and the need for recycled materials. Technological advancements in equipment such as automation, IoT integration, and advanced material handling systems have positively impacted the market, improving productivity, efficiency, and enhanced durability. These innovations have helped reduce downtime, optimize performance, and enhance overall operations performance.

The global crushing, screening, and mineral processing equipment market size reached US$ 21.6 Billion in 2022. Going forward, the market is anticipated to reach US$ 29.48 Billion by 2028, exhibiting a CAGR of 5.16% during 2023-2028. Increasing construction activities, rising investments in various infrastructure projects, and growing product usage in energy production represent some of the key factors driving the market.

Various types of crushers and screener systems such as jaw crushers, impact crushers, cone crushers, hammer crushers, hydraulic crushers, gyratory crushers, vibrating screeners, scalpers, and freeflow screens, play a significant role in the extraction and processing of raw materials. They enable the effective utilization of resources and ensure that the finished product complies with the required quality standards.

The market for mobile crushers is growing rapidly because of the rising cost of operations, along with the lack of skilled labor and increasing requirements of machines with advanced technology that can offer more efficient ways of processing minerals. The mobile crushers can be simply calibrated for accurate output sizes suitable for different applications. These crushers are low on fuel consumption and provide improved safety for the workers because of their ergonomic design, thereby driving the crusher market revenue. The jaw crusher has wide applications in the mining section; it has the capability to crush harder and more abrasive materials like copper and granite with high efficiency. Thus, the demand for jaw crushers is expected to grow due to the rise in the projects of mining to meet the demand for coal, minerals, etc. An imarc market research highlighted that cone crushers generally involve high operating costs for the maintenance of wear components. As a result, market players are introducing liner profiling systems that offer an improved prediction of the mantle and concave liner replacement, identify asymmetric and high wear areas, measure open and closed-side settings and calculate the wear life of cone crushers. They are also launching connected variants with built-in computer intelligence and automation and connectivity systems (ACS). As these crushers allow operators to predict performance, maximize uptime, and provide sustainability, their demand is anticipated to rise in the coming years.

Fueling Productivity & Performance

An optimal crushing process reduces the ore to a desired size more efficiently, economically and safely. The high-capacity, reliable and energy efficient crushing solutions deliver superior performance and maximized throughput also for the most demanding mining applications. The Metso Mining Crushing Stations are made up of 2 solutions: FIT™ Stations and Foresight™ Stations. FIT™ Stations are focused on speed and flexibility for quick installations. The Foresight™ Stations are focused on smart controls and automation for optimal productivity. Both stations come with proven Metso equipment and technology to deliver maximum productivity for even the most demanding mining applications. Developed to crush the hardest ores and rocks, jaw crushers also perform outstandingly with less demanding materials. The core of Nordberg® C Series™ jaw crusher is a pinned and bolted, non-welded frame construction that provides excellent fatigue strength. All the frame components are casted using an alloy developed in-house especially for jaw crushers. In addition to solid casting, the crushers’ frame has a cellular, so called honeycomb structure that, like in nature, has proven to be stronger and more durable. Nordberg® C Series™ jaw crushers are designed modular to save time and installation costs. They can be installed within a few days, minimizing on-site engineering and fabrication.

The new Sandvik 800i series of tough, premium cone crushers are full of smart innovations. Featuring SAM by Sandvik and a range of built-in automation and safety features, they are connected 24/7 to give customers a complete overview of performance, maximizing uptime and productivity. The toughened main shaft and top & bottom shells are much stronger than before. That spells more reliability, higher availability and a low risk of critical failure. Bolted rather than welded top and bottom shell liners reduce maintenance time and are much safer. The improved over-pressure system with dedicated air channel inlets keeps dust out to increase reliability. Replacing individual components or installing overhaul kits is the cost-efficient and sustainable way to a new crusher line. Plug and play installation minimizes disruption and maximizes crusher productivity. Sandvik Automation and Connectivity System (ACS) continuously monitors and optimizes crusher performance and the complete lubrication system. It can automatically adjust crusher settings to compensate for crushing chamber wear – ensuring consistent product size.

Built for high performance and aggressive use, the USP of the wheeled jaw crusher is its miniature size, quick set up time, ease of transport, and easy maintenance. Designed for use in a range of applications, the Terex MPS WJ3042i serves as an ideal machine for quarrying, mining, demolition, and recycling. Being cost-effective due to its simple maintenance requirements, it is designed to give maximum productivity by incorporating a jaw crusher and a heavy-duty vibrating grizzly feeder.

Crushing all that stands in its way, the newly launched Terex® Cedarapids MVP550X is built to pulverize the toughest material that it meets. Manufactured with advanced engineering, the 500-hp machine has enhanced features, including high-speed clearing of jammed material, and quick crusher separation capability for faster manganese changes. Being the best in the line of cone crushers, this product will revolutionize the industry with its hydro-pneumatic tramp iron relief system, high-flow manifold system, and a hydraulic powered threaded upper assembly.

The aggressive yet portable jaw crusher, Evoquip Bison 280, is one of the best for the Indian market in terms of fuel efficiency. It has a direct drive system to accelerate the operations of the crusher in many industries such as recycling, contracting, and quarrying. By providing small to medium operators with a Terex ‘900mm x 600mm’ single toggle jaw crusher, the Bison 280 is the ultimate in time efficiency due to its quick set-up time, ease of transport, and user-friendly control.

Torsa’s Smart IVX series of crushers, with a capacity of 150-200 tph, boasts a compact footprint and a modular design with a combination of jaw-cone and screen mounted on a skid mounted platform. The modular design of the skid mounted plant enables ease of transportation on a flatbed trailer, occupying almost 40% less space, plus, it will require very little civil work during its installation. Torsa’s Smart IVX series of crushers is designed to make the user’s life easier by consuming less steel and concrete, optimizing power and diesel consumption, and minimizing plant breakdowns with smart triggers.

Torsa’s Smart IVX series of crushers is perfect for commercial quarry owners and road contractors looking for a highly robust and efficient machine that can perform well for 15 to 20 years while reducing operating costs. Supported by telematics and IoT-enabled technology, Torsa’s Smart IVX series of crushers provides timely alerts on maintenance, gathers production data, and provides information on idle times, operating loads, running hours, and capacity, enabling plant owners to optimize production and plant uptime. With Torsa’s Smart IVX series of crushers, users can enjoy high productivity, ease of maintenance, and reduced operating costs.

Perfect for on-site crushing of inert materials and the first one of its kind to be introduced on the market, the MB Crusher Bucket is a piece of equipment that works by taking advantage of the hydraulic system of the excavators, skid loader, loader and backhoe loaders to which it is fitted. It has many areas of applications: from building demolitions in general, to the requalification of former industrial and urban areas to the processing of excavation materials, from the earth movement sector to road works, from quarries to mines, from environmental reclamation to applications on rocky soil. The MB-C50 is the smallest crusher bucket in the MB product line, weighing less than one Ton and designed to work on excavators starting from 7 Ton. It is suitable for mini excavators and great for small crushing jobs.

Due to its reduced size and weight, the MB-C50 has proven to be particularly useful in landscaping and restricted areas, ensuring high performance in small size with a production rate of up to 10 m3/h. MB mobile crushers can access any type of job site, without needing specialized vehicles, they are transported with the equipment they’re installed on. They are attached directly to the excavators, loaders, skid steers or backhoes necessary on the job site: all of the materials extracted from the excavation phase can be reduced to the desired output size, without using a recycling plant. The resulting material can then be reused on the same job site, for example as road base, drain or as fill material.

The Hailstone Wheel Mounted Jaw Crusher is engineered for maximum productivity and operator safety. Combined with the mobile Wheel-Mounted Chassis, this crushing unit can be rapidly deployed to maximize production from multiple remote sites. The crusher provides high-capacity primary crushing for aggregate production, recycling, or mining applications. This unit also features a vibrating grizzly feeder for very clean material feed and optimum productivity.

In addition to crushing applications in mining, the company is leading the VSI wheel mounted crushing machines segment as well. They’re designed to maximize operator productivity, performance, mobility and reliability while being easy to use and maintain. Hailstone wheel mounted VSIs have a unique combination of VSI technology and an intuitive user interface. Hailstone wheel mounted vertical shaft impactor is the most convenient solution for the diverse crushing operations in construction, industrial minerals, metallic minerals and recycling applications. Hailstone wheel mounted VSI plant is used as a tertiary stage crusher in a multistage crushing process. It is ideal for fine aggregates production, and is equipped with Hailstone VSI EP7X187 crushing unit especially designed for crushing hard rock types such as granite, basalt and gneiss. It is mounted on wheeled chassis, making it easy to transport between sites with a prime mover. The compact dimensions and agility reduce operational costs.

AVRC SERIES New generation Roll Crusher from Propel Industries has been designed using the latest engineering tools for high reliability. It has premium features like high-efficiency gear drive and hydraulic gap management. Its features and the unique design help manufacture sand at lowest possible power consumption and liner wear cost. High efficiency & low peripheral speed delivers high savings in power & wear cost. It has a robust, reliable and safe design. Hydraulics ensure operating gap is maintained to ensure desired output size & low percentage recycle. Large diameter and extra thick liner design allow larger feed size and high liner change interval.

Etrack Crushers is at the forefront of the deployment of fuel-saving technology such as load-sensing hydraulics as well as offering hybrid diesel/electric drive alternatives. These are two fantastic ways to cut fuel consumption without sacrificing performance. When connected to a mains supply, the company’s electric drive version can achieve savings of up to 70%. Etrack machines are designed to have as little wear as possible. The company employs large pre-screens on the crushers so that shape can be optimized and as a result, it reduces the amount of wear that the crushers experience. These machines are built to be simple to disassemble and reassemble, making it possible to perform maintenance and repairs in a timely manner.

The Powerscreen® Hybrid range has been designed to give customers alternative energy options to operate their range of crushing, screening and conveying equipment. Its Hybrid Machine range has been dramatically enhanced to include more fully electric crushers and screens as well as models powered by innovative combinations of diesel and electricity. These options let you choose which fuel to use, depending upon cost, location and availability.

Hybrid machines can be of special interest if companies operate in an area where electricity is more cost effective than diesel fuel where diesel engine noise is unwanted or on sites where electricity is the preferred energy source. Fitted with an electric hydraulic drive in conjunction with the standard diesel hydraulic drive, the machine can be run as a standard diesel or connected to an external electricity supply once the machine has been set up on site. These wheeled models use onboard electric motors to power the hydraulic drives.

Screen it PERFECTLY!

‘Better screening is free crushing’ is an often-heard statement in the industry, which implies having an efficient screen box that can reduce the burden on a crusher by sizing material correctly. Screening machines and equipment allow for a more efficient production process by separating materials into different sizes, grades, and specifications. This reduces the amount of material that needs to be processed, saving time and resources.

Vibratory screeners are one of the most commonly used types of industrial screening machines. They include high efficiency, low maintenance requirements, and the ability to handle a wide range of materials. Vibrating screens can also be customized to meet specific industry needs, such as high throughput or fine particle separation. However, most traditional vibratory machines cannot size materials down to sizes finer than 44um efficiently. That is where the Hi-Sifter advanced screening technology comes into play. This screener has the ability to screen materials down to as fine as 10um on a large scale where their counterparts such as ultrasonics and traditional shaker screeners cannot even offer sieving down past 44um. Rotary screeners are commonly used in industries such as mining, water treatment, agriculture, food processing and waste management. They are also used in the construction industry to separate aggregates and other materials. The benefits of using rotary screeners include high efficiency, very low maintenance requirements, and the ability to handle a wide range of materials.

The Keestrack K5e screen is one of many machines in the Material Handling department of AM/NS India (ArcelorMittal Nippon Steel India), a joint venture of ArcelorMittal and Nippon Steel in Hazira, Gujarat, India. It extracts 6-60 mm coke by screening 0-80 mm Coke which is used in the Corex plant. Corex is the unique smelting-reduction process which allows a cost-effective and environmentally friendly production of hot metal from iron ore and coal. “The Keestrack K5e scalper is producing up to 50 tons an hour, which is 20 tons an hour more than its predecessor, a competitive brand”, says Suraj Mehta section in charge of the Material Handling.

The goal of AM/NS India is to create smarter and more sustainable steel for India and the world by placing safety, innovation and technology at the heart of the manufacturing operations and product development. “The Keestrack K5e, which can be driven by electric-plug in or via its own diesel/gen set fits perfectly in this vision as it saves a lot of fuel cost and runs very efficiently. The plug in electric and hybrid drive system and the total cost of ownership of the Keestrack scalper were taken in consideration when deciding on the replacement of the previous equipment” Suraj Mehta stated. With a weight of around 30 to 33 tons, the K5 is available in hydraulic, e-version (full electric plug-in backed up with onboard diesel/gen set) and in ZERO drive, meaning there is no combustion engine on board but only electric motors and only functions when powered electric either by mains connection or external diesel alternator. The K5 is in the “mid-range” of Keestrack’s scalper programme. An extensive choice of screen media for the 5000 x 1500 mm double-deck screen box (effective screen area 7.5 / 6.75 m²) and the adjustable screen angle, guarantee a wide range of applications: from highly efficient rock scalping to soil processing with a capacity up to 450 tph, from screening construction waste to the production of marketable end products in three fractions. Like all Keestrack equipment, the K5 series is optimized for transport: all conveyors and other components can be folded for low-bed transport (transport width 2,600 mm) – on site, the unit without support legs is quickly operational.

By providing customers with the flexibility to run the plant from an external power supply or a standard on-board engine, the Finlay 690i mobile inclined screen has opened doors to low emission screening on applications such as quarrying, mining, and recycling. The product has been built to meet the specific needs of users with a high output requirement.

Puzzolana High Speed Screen is the most effective for Fine Screening application with Low Amplitude. High Slope at the feed end enables the material to move faster and fines pass through the sieve meshes quicker to allow stratification by the separation of large particles from fine ones. The inclination is less in the middle and discharge Section, which reduces the transport speed in the sections a good Separation Achieved. Available in single & double deck options and from size 1500x 4200mm to 2400x 6000mm up to 100tph capacity for separation of 1 to 2mm fractions in (-)6mm. It is very efficient screen when there is high Content of fines in the feed. Very Compact Screen is easy to Install. It has improved Efficiency in Sizing Material due to formation of a thin Bed Depth.

The new MOBISCREEN MSS 802i EVO from Wirtgen Group will be presented for the first time in the USA. The powerful mobile screen for coarse elements was designed to meet changing challenges in different application areas. With its clever plant design and flexible conversion options, it guarantees an optimum material flow in natural stone and recycling applications. The large range of screen surfaces and the simple setting of screening parameters make it possible to adapt the MSS 802i EVO easily to new application conditions. If a fine final product is to be screened from particularly coarse feed material, the plant can be quickly converted from three to two final grain sizes. Further advantages of the plant include its simple operability thanks to its intuitive control, ease of physical and visual access to all relevant machine components and its drive concept H-DRIVE with the option of an external power supply for emission-free and therefore environmentally sound work.

The EVO2 line also includes the mobile impact crusher MOBIREX MR 110i EVO2. The plant impresses with flexible application options in both natural stone and recycling. The SPECTIVE operating concept ensures simple, intuitive control. The innovative operating concept SPECTIVE includes various components that are ideally tuned to one another and accompany the machine operator during the entire working day. Apart from the intuitive touch panel and different radio remote controls, the digital application SPECTIVE CONNECT, above all, supports the work site digitalization. The mobile screen for coarse elements MOBISCREEN MSS 802(i) EVO impressed the jury of the German Design Awards and the US Good Design Awards.

Over the next few years, the mining and construction sectors are expected to adopt a larger scale of automation to reduce the dependency on the workforce. Such developments are slated to attract higher investment in crushing & screening equipment that are mobile and offer automated solutions. Overall, the demand is expected to rise in the future.

Fast Facts

  • According to Technavio research, the crushing equipment market is estimated to grow at a CAGR of 4.27% between 2022 and 2027. The size of the market is forecast to increase by US$488.68 million.
  • Mobile Crushers & Screeners Equipment Market size was valued at $3.5 billion in 2021 and is estimated to grow at a CAGR of 5.4% during 2022-2027.
  • The global cone crushers market size reached US$ 1,681.6 Million in 2022. Looking forward, IMARC Group expects the market to reach US$ 2,253.5 Million by 2028, exhibiting a growth rate (CAGR) of 4.9% during 2023-2028.
  • New cone crushers that operate with hydraulic hold-down clamping enable industries to crush at a higher capacity with increased power than ever before. The automatic control of cone crushers has maximized power draw and their throughput, owing to which vendors in the market are focusing on increasing the capacity of their offerings.
  • With the growing concept of recycling, current crushers can separate bitumen and aggregates for reuse as new asphalt. New asphalt stations can create a unique asphalt mix with up to 70% recycled material, and various businesses are deploying cone crushers, along with jaw crushers, to enhance the speed and capacity.

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