CRUSHING IT FINE…

As the Indian construction market graduates, placing demand requirement for high capacity crushers, manufacturers are making their machines equipped with advanced features to enable the users derive optimum output from the equipment. P. P. Basistha & S. A. Faridi find out the details.

The crushing equipment sector is getting acclimatized itself fast to meet the demand of high capacity crushers. Going by the requirement change, the demand is moving towards larger capacity crushers belonging to 300 tonne per hour (TPH) capacity range and above from the present mid size capacity of 150- 200 TPH. The fast track urban development projects and the quarrying areas in major cities are going in for crushers with output ranging from 200-300 TPH. Placed with demand to install high capacity crushers, users are closely looking at the features of the crushers so as to get the best output (and margins) on the large capital expenditure made. Based on the nature of the demand, manufacturers are adding in improvised features to their equipment and in concurrence creating a competitive edge for their products.

Higher Productivity – the Key

Feature advancement in the crushers are being made by the manufacturers by putting in automated features for minimal manual operation and altogether by making their machines more rugged, among other improvements.

In accordance with this, Global industrial construction equipment major, Sandvik have made technical innovations in its crushers in sync with the higher capacity demand requirement on the Indian market. As per Mr. Ramanna Kumar,“ Senior Manager, the Sandvik crushers being a global product are well–acclaimed for its features and output. However, to make our crushers much more well adopted to the Indian market requirements, we are undertaking constant upgradation in the features of the machines.”

Mr. Kumar informs, improvements are being made in the machine’s wear components for their reduced depreciation. Advancements are also being made in the hydraulics of the crushers and also on the structurals. Manganese castings are being provided on to the crushers. The recent innovation made on the crushers is making it equipped with “automatic setting regulator.” With this, the operator can make an automatic adjustment in the setting of the crusher based on his output requirement.

According to Mr. Kumar, Sandvik crushers, both jaw and cone is a product of know how and experience optimized by 3D CAD and Finite Element Analysis (FEA). Each model is tested virtually for stress , strain, shock, deformation, thermal loading, vibration and noise under wide range of load conditions for providing optimum results.

The jaw crushers are of single-toggle type with a deep symmetrical crushing chamber and easy setting adjustments. As per the company, each model has a large feed opening for its size and an ideal nip angle, giving smooth material flow, high reduction efficiency and high capacity.

Sandvik manufactures jaw crushers with a capacity range from 55 TPH - 1160 TPH. While the cone crushers are available with a capacity range of 22- 1050 TPH. Sandvik claims to have cone crushers with high operational efficiency and are much able in providing the right size aggregates.

The element of creating crushers with higher output has also been much kept by Terex Pegson in its crushers. According to Mr. Rajen Khoda, Director Sales South Asia and Middle East, “to provide the desired output in Indian conditions at par with the global requirements, Terex Pegson jaw crushers have been provided with features, consisting optimum crushing geometry, unrestricted feed opening clean crushing chamber among hydraulic setting adjustment.” He says, with advanced provisions in place, our jaw crushers have high reduction ratio.

On the other hand Mr. Khoda highlights, the cone crushers have features consisting, advanced crusher geometry. The machines are able to accept all kinds of feed on most applications. He informs, having all roller bearing design allows the machines to provide high reduction ratio. Besides, provision of attrition crushing enables the machines to provide the desired aggregate product shape. The Pegson cone crushers, claims to have high energy efficiency and high capacity.

Improvisation has been made by Taurian Engineers through making their machine equipped with software for the benefit of the customer.

"With the software in place manual operations can be avoided in our crushers, which in turn cuts down the down time by two to three times," says Mr. Shankarnarayan, General Manager Projects, Taurian Engineers. This as a consequence, improves the overall efficiency of the machines enabling it to provide faster output.” He adds, "the software enables in making change in the programme automatically by the operator from the control panel based on the output requirement of the aggregates.”

The crushers have features comprising, “programme logic control” software for the convenient operation of the machines. The machines have touch screen facilities for programme setting.

He adds, Taurian crushers derive their competitive edge based on their automated control systems. The automated control systems allow smoother operation and consistency of output. For enabling the crushers provide better output, Taurian has entered into a collaboration with the US based Astec to manufacture hydraulics. The company boasts of making its crushers fuel efficient, in terms of lubricants consumption. Taurian crushers claim to consume 68 litres of lubricants as compared to 300 litres consumed by other crushers.

Taurian manufactures crushers and screening plant with a capacity range from 350 TPH to 500 TPH, as based on the market demand for high capacity crushers.

Product Positioning on Finer Details

To make the crushers optimally utilized, manufacturers by making finer technological improvements in their products and in turn are getting their products positioned and promoted. Such has been the approach of Southern India based Proman. Mr. R.S Raghavan, Managing Director, Proman says, “our cone crushers are bush type designed. Besides, they have floating shaft, for higher productivity.” He adds, “ Proman crushers have “multi port rotor technology.” This comprises, different combination of rotors, which can be used based on the application of the aggregates requirement.”

Proman’s crushers come with a smart box. In the smart box diagnostic data of the machine can be stored. This serves to be useful diagnostic tool for preventive maintenance of the crusher. The smart box can be accessed from the web and details of the information in the box can be stored in the computer. Proman claims to have crushers with flexible characteristics.

The jaw crushers of Proman have rugged features consisting, reversible corrugated manganese jaw plate for longer life, replaceable deflector plate for damage prevention. The machines have heavy cast flywheels for smooth operation under momentary over loading condition. They are also equipped with abrasion resistant sideliners for protecting the side frames from wear and tear.

Positioning of product through higher output features by incorporating finer technological improvements has also been done well by Metso Minerals. The Nordberg C series jaw crushers of Metso are based on a revolutionary modular, non welded frame construction. As per Metso, the machine has high-quality cast steel components and durable wear parts. All to ensure high crusher availability, cost efficient crushing and low cost per ton.

Metso’s Nordberg GP Series cone crushers comes with a compact size. According to the company, the low weight of the machine contributes to high crushing performance. The other feature of the machine includes, large feed opening for secondary applications, advanced automation for user friendly automation. The cone crushers come with durable original equipment wear parts.

As per Mr. Dinesh Sharda, Marketing & Communications Manager, Metso Minerals, “to ensure the optimum utilization of the machines, automation at higher levels are being continuously introduced to minimize manual operation.” In accordance with this, he says, “programme logic control” has been introduced in the machines. He tells, Metso, track mounted crushers have intelligent operating systems on board. Besides, they can be operated through remote control systems.

Taking account of every operational part of the crushers and making advancements in the same for higher output has been also done well by Extec Screens. As per Mr. Swapan Das, General Manager India Sales for Extec Screens , “ technological advancements has been made by the company by making improvements in manufacturing , operation and maintenance of the crushers.” He explains, “our machines are manufactured with advanced hydraulic systems and hydraulic motors. The handling systems are made rugged for effective mobility, the tracks of the crushers have additional power packs. In addition, the machines have rarefied cooling systems in place. This makes it easy to operate in high temperature Indian conditions in turn making it more productive.”

Mr. Das adds further, “Extec machines have various stages of filtration and this makes the machine well– protected from dust and allows it to perform effectively without much maintenance.” The other advanced features of the machine consists of direct pressure sensors.

Putting advanced features with finer technological improvements in its crushers has also been carried out by Puzzolana Machinery Fabricators. Puzzolana manufactures crawler, mobile, skid, stationery-crushing and screening plants.

Puzzolana Fabricators' crushers have centralized automated lubrication systems as one of the key advanced features. This allows the machine to perform smoothly with higher productivity in all the three stages of crushing operation. ”Sustained basic improvement is being carried out in the crushers by making them more rugged and heavy. On this, the machines are being made more powerful.” Finite Element Analysis” (FEA) is being carried out to study the ruggedness of the machine. FEA also ensures the rational distribution of load in the machine, says Mr. Prakash Pai, Managing Director Puzzolana Machinery Fabricators.

FEA is also utilized in manufacturing its crushers by Eastern India based Torsa Machines Limited. According to Mr. Manish Bhartia, Joint Managing Director, Torsa Machines, “ the FEA concept of production minimizes the usage of steel during the manufacturing process and at the same time retains its rugged features.” The production concept allows the company to make its products price competitive. Torsa manufactures low and medium capacity crushers.

Making Rugged Machines

While most of crusher manufacturers across the country have positioned their products on the basis of the automated features and other finer technological innovations for better productivity and output, however, crushers and screens manufacturer, Nawa Engineers has been emphasizing on making machines robust for higher productivity.

Nawa’s secondary and tertiary cone crushers have features involving, high speed and roller bearing construction for less frictional resistance, less power consumption and longer life. The machines are also fitted precision machined alloy steel main shaft and perfect dust seal-combined air pressure and mechanical seal protection to all bearings.

In addition to this, the machines have automatic lubrication on all bearings with built-in machine protection controls and they have also high manganese mantle and concave for long life among host of other features. Nawa Engineers is one of the prime high capacity crushers manufacturers in the country.

Getting the Right Productivity

Though manufacturers have put in place all advanced attributes for the higher productivity of the crushers, however they unanimously point out, that to derive the right productivity, the primary operation of the crusher, beginning from the blasting stage has to be much well managed by the users. The process has to be much more streamlined. During the course of operation, continuous back up support of the feed has to be provided. For this, the supply chain has to be well managed. Essential monitoring has to be done for the same. All these and effective fine tuning of the crushing operation would make the operations much effective and go on to ensure higher productivity for the crushers.