Download Today's Aggregate and Mining Solutions - Vol 3 ... - KPI-JCI
Download Today's Aggregate and Mining Solutions - Vol 3 ... - KPI-JCI
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Material is conveyed from the jaw to the surge tunnel whichfeatures pan feeders to control the feed to the secondarycircuit. “The tunnel was delivered to us in pre-assembledsections with lights, feeders, <strong>and</strong> conveyors actually hanginginside the sections. We just lifted them off the trucks, setthem on the concrete, bolted them together, established allthe connections, <strong>and</strong> never had to touch the tunnel again,”says LeClair. The tunnel conveyor feeds a modular scalpingscreen station with an 8’ x 20’ triple-deck Vibro-King screen.The modular secondary crushing station includes a 68SBSCone with TRAC10 automation. LeClair likes the antispinsystem on the SBS Cone as it stops the head fromspinning <strong>and</strong> significantly reduces liner wear, while theautomation program allows them to monitor wear <strong>and</strong> allowsadjustments on the fly. “We’re getting up to 1,300 tph fromthe secondary <strong>and</strong> that is exceeding goals,” he says.As to the programming <strong>and</strong> PLC-controlled operation ofthe plant, LeClair says that again, Telsmith streamlinedthe process by assigning one of their in-house electricalengineers to interface with the Carmeuse electrical engineer.Either in the control house or remotely, LeClair can monitor<strong>and</strong> track every process at the facility, including transferpoints, conveyors, motors <strong>and</strong> sensors, as well as materialflow <strong>and</strong> tons per hour. “We can also run diagnostics onsite,remotely, or at Telsmith,” he says.Finally, meeting design goals resulted in significantoperating cost reductions. In energy costs alone, LeClairestimates a savings of more than $50,000 monthly, in partdue to the use of properly sized, high-efficiency motorsthroughout the plant. The operation also eliminated one 150-ton haul truck that carries a purchase price in excess of $1million; burns more than 250 gallons of fuel in one two-shiftday; <strong>and</strong> has an annual maintenance operating cost thataverages out to $25 per operating hour. LeClair is happy tosay that Carmeuse is fortunate to have retained its seasonedemployees throughout the recession, with nearly 70 beingon staff today. “Through attrition we lost some personnel,<strong>and</strong> with the new plant, we can operate at our current stafflevel,” he says. Lastly, the new efficient plant produces farless fines, <strong>and</strong> fortunately all current fines output is beingsold. There is no waste.During its first year of seasonal operation (April to mid-November), the Cedarville plant produced nearly 2.4million tons. “This year, we’re on pace to hit 3 million tonswith the future growth capability of up to 5 million tons peryear running at full capacity. That’s a great anniversarypresent for Carmeuse which is celebrating its 150th year inbusiness,” says LeClair. ■Technology Puts the Operator in ControlModern crushing plants are employing an ever increasing amountof technology to maximize output, reduce operating costs, <strong>and</strong>improve the work place for employees. Following are a coupleof examples where technologies are working their way into themodern crushing operation.The expansion <strong>and</strong> accessibility of various “wireless” technologieshas made it practical for even portable crushing operations tolink directly to the manufacturer when equipment problemsarise. Systems can now allow factory service people to “dial-in”to the plant control circuits to assist with troubleshooting. Almostinstantaneously the factory can view all trending records <strong>and</strong> rundiagnostics to help the crew identify the source of a problem. Evenprogram changes <strong>and</strong> updates can be downloaded on the spot.Jaw crushers are now starting to incorporate the same featuresthat cone crushers have included for years. By designing new jawcrushers with hydraulic adjustment, hydraulic chamber clearing,<strong>and</strong> overload relief, manufacturers are significantly improvingthe up-time availability of the primary crushing station. Operatorscan now monitor operations, make setting adjustments, <strong>and</strong> clearthe crusher, with relatively no downtime, all without leaving thecontrol room.History shows us that technologies which prove themselvesultimately become the new paradigm. Keep your eyes openbecause it is an exciting time with lots of new ideas working theirway into the modern crushing plant.New jaw crushers allow operators to change settings <strong>and</strong> clear thechamber from the control room, improving up-time availability.Wantmore?For more information on Telsmith, contact Jim Schreiner at 800.765.6601, e-mail jschreiner@telsmith.com, or visit www.telsmith.com.Today’s aggregate & mining solutions | volume 3, number 1 13