Keestrack

Swapan Das and Topor Basu
Swapan Das, MD & Topor Basu, GM

"At bauma CONEXPO INDIA (Booth O.C03), Keestrack will highlight Etrack’s revolutionary full hybrid technology in the Keestrack B4e jaw crusher and H4e cone crusher. Both track-mobile models represent the latest generation of diesel-electric Keestrack plants and provide plug-in operation without starting the onboard diesel."

Etrack Crushers offer advanced electric drive concepts, with huge savings for contractors and operational advantages for larger multi-stage mobile plant lay-outs.

Etrack Crushers was established in 2017 as part of the Keestrack Group to promote their comprehensive programme of track-mobile crushers, screeners and related equipment in the Indian sub-continent. Local Indian experts, supported by the group’s experts in application-engineering and after-sales resources, work on projects in the Indian mining sector and mineral aggregates and recycling industry. Keestrack is on the way to establish local assembling and manufacturing.

From early 2019, Etrack’s new assembly plant in Neemrana will produce Keestrack hybrid crushers for Indian and South Asian markets.

Etrack’s new 10,000 m² manufacturing facility accommodates modern offices and extensive parts storage facilities, with scope for further expansion. The production programme includes the full hybrid crushing plants Keestrack B4e (jaw) and H4e (cone) which have been identified to meet the demands of Indian contractors in terms of productivity, transport, and on-site mobility.

Etrack’s assembly is based on core OEM modules (crushers, frames, chassis etc) delivered from the group’s European factories. The local staff of production engineers and qualified technicians will assemble all plants with components (engines, drives etc) of international technology partners or local suppliers. This will guarantee shorter lead times and allow full flexibility to comply with technical specifications or individual customer requirements.

80% of the 24 Keestrack models in 7 product lines are optionally available as diesel-electric hybrids.

Entering the Indian market with Etrack Crushers, Keestrack decided to promote its advanced range of hybrid and plug-in processing solutions. The company had recognized the advantages of diesel-electric drives for highly mobile track-mounted plants from 15 to 70 ton transport weight, most typical for application in the mineral aggregates and recycling industries.

Starting with partially electrified models, Keestrack added e-versions to all its ranges of mobile crushers (jaws, cones, impactors), scalpers, classifiers, and stackers. Today, 80% of the 24 Keestrack models in seven product lines are optionally available as diesel-electric hybrids, with 75% providing full-electric “plug-in”-operation. All the latest innovations - such as the cone crushers H4e/H6e, jaw crushers B4e/B7e, and impact crusher R3e – provide electric drives as key design characteristics, thereby, optimising the effect of the zero-emission and low noise technology.

Keestrack

Another highly productive hybrid solution is the classifier Keestrack C6e. First introduced in 2012, this machine has proved to be very successful in the final screening of iron ore.

Up to 80% savings can be obtained with diesel-electric operations.

Up to 80% savings can be obtained when operating diesel-electric – with constant low engine revs – or opting for full electric plug-in-operation via external gen sets or accessible mains. In diesel-electric operation, hybrids offer additional savings by supplying electricity to secondary e-plants (screeners, stackers) through their external plug-out functionality.

Keestrack’s concept of using powerful electric motors for the crusher/screener units and the necessary plant hydraulics (lifting cylinders, tracks etc) combined with several smaller e-drives for conveyors and ancillary equipment (water pumps, compressor etc) provide many other benefits in terms of safety, ease of operation and maintenance, availability and long-term total cost of ownership.

Keestrack

By being able to use a significant smaller hydraulic circuit, the reduced oil volume minimizes leakage risks, optimizing the plant’s environmental impact and maintenance costs. Reduced running hours of the onboard diesel extends service intervals and increases the resale value.

All electric components are directly connected to the plant’s PLC controller, which avoids sensor failures (pressure, speed) and allows safe, fully monitored automatic operation, even under the most demanding conditions. The fully integrated systems also provide a better remote access for service technicians via the remote-monitoring telematics tool Keestrack-er, which gives access to real-time machine data and makes reporting possible.

The 44-ton B4e is the midsize-allrounder in Keestrack’s jaw range.

Equipped with a double-deck vibrating 2300 x 1000 mm pre-screen and a proven 1100 x 700 mm jaw crusher unit (max. feed size of 600 mm), the 44-ton B4e provides a capacity up to 400 t/h and suits various recycling applications or primary crushing solutions in quarrying or smaller mining operations. Productive operation and high-end product standards are guaranteed through the patented N.S.S. release system and the automatic hydraulic gap adjustment, which continuously monitors plate wear.

Keestrack

The B4e provides a detachable power module with a 212-kW onboard-diesel combined with a 225-kVA alternator. Positioned remotely from the plant, the running diesel engine and genset are well protected against dust and vibrations. When working “plug-in”, the whole power module can be removed and stored away. A 110-kW electric motor drives the crusher, and a 55-kW e-motor/pump unit supplies the hydraulic drive for pre-screen, tracks, lifting cylinders, and other hydraulic components. To optimize productivity, the B4e can be optionally equipped with a single-deck post-screen with recirculation conveyor.

With their high productivity and end-product diversity, combining the B4e and H4e in production can reduce number of machines and engines from three to two.

With a capacity of 250 t/h in secondary crushing, Keestrack H4e is a perfect match for the B4e. Here also, an optionally detachable power module (328 kW/330 kVA) supplies energy for the electric crusher drive (132 kW) and the separate 45-kW E-motor/pump unit for all hydraulic drives on the plant. The H4e features the KT-H4 cone crusher of a world-leading cone specialist. The fully automated unit provides a maximum feed size of 185 mm and allows with a wide variety of concaves, and high flexibility in secondary or tertiary production of defined end fractions.

To optimize production, the plant can be optionally equipped with a pre-screen with fines chute and an efficient three-deck secondary screen module with recycling conveyor for closed-circuit processing. The large dimensioning of the hanging screen (eff. area: 3 x 5.4 m²) and large stockpiling capacity of the conveyors prevent bottle-neck effects in producing up to four highly defined quality end fractions.

NBM&CW December 2018

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