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us. This streamlinedthe project and madeeverything go verysmoothly,” he says.“Also, Telsmith hasmuch to pull from inthe way of capabilitiesand resources,both internally andthroughout the AstecGroup. There isn’t theconfusion of differententities designingdifferent parts of theplant. Everythingis in one house,which makes it veryconvenient. This reallyaided our initial plansof fast tracking theproject. Because wewere dealing withone source, it made iteasier to handle eventhe smallest detailswithin the design upfront.”MODULAR PLANT CONCEPTThe Telsmith modular plant concept waschosen for the two-stage crushing system.Modularity shortens the time line for newplant development and streamlines theinstallation process. Pre-designed moduleswere pre-assembled at the factory andshipped in segments.“I am familiar with Telsmith modularplants, their size, structure, andsimplicity—and when we were fasttracking the project, the modular conceptmade perfect sense. But no matterwhat the pace, I prefer the modularconstruction as it creates a far betterstructure altogether. I like having thesewelded fabricated structures completedin a shop environment versus out in thefield. You get the best penetration onthe weld,” says LeClair, who adds thatwhen it came time to assemble the plant,the process was simplified. “Along withmy staff and the team from Telsmith,we utilized a contracting company whohad no experience in erecting a plant.Telsmith provided detailed drawings, andeveryone caught on very quickly. For the150-ton haul trucks feed the primary, while 4,000’ of overland conveyor moves material toward the finishing plant andshipping on the Great Lakes.entire structure, we never had one anchorbolt out of place, which is remarkable initself,” he says.Additionally, LeClair explains that anotherincentive for the modular approach isthe ability to economically relocate theprimary circuit within the pit. “In about 15years, we will move the modular primaryto the new quarry face and convey to thesurge pile of the secondary plant,” hesays.DESIGN GOALSThe top goals of the new crushing systemdesign are locating both the primary andsecondary circuits closer to the quarryface; meeting a minimum productionthroughput goal of 1,200 tph; eliminatingany bottlenecks throughout the crushingsystem; minimizing fines production;and maximizing yield of product to thenew Carmeuse specifications. Due tothe previous blasting pattern and theoperation of the older gyratory crusher,the operation was producing in excess of10 percent fines annually, which at thattime they had no market for. Furthermore,they had no opportunity to remove theexcess fines until the material wentthrough both processing operations andwas put into the stockpiles. “So we hadall the cost of processing the fines, andthen had to recover them as well. Now wehave the ability to remove the excess finesright at the quarry face with two tripledeckscreens set up on the discharge sideof the secondary circuit,” he says.The modular primary crushing stationincludes a 60” x 30’ step-deck vibratinggrizzly feeder; a 5566 jaw crusher; anda 175-ton live storage dump hopper. ABTI TM25X boom with a TB830X breakerbreaks up any oversize stone before it hitsthe crusher.“The 5566 jaw crusher was the largestcrusher that we were aware of in theU.S. market. We could have gone with asmaller crusher, but to get the minimumof 1,200 tph, we would have been at thetop end of the capacity of that crusher—and we wanted room for growth. Wenever want the first circuit to ever be abottleneck,” says LeClair, who estimatesthat the unit can process up to 1,600 tphvery comfortably. As such, the conveyorsare sized to handle higher tonnage andthe screens are also sized for excesscapacity with triple-deck versus doubledeckmodels.12 volume 3, number 1 | Today’s aggregate & mining solutions
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, and conveyors actually hanginginside the sections. We just lifted them off the trucks, setthem on the concrete, bolted them together, established allthe connections, and 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 and significantly reduces liner wear, while theautomation program allows them to monitor wear and allowsadjustments on the fly. “We’re getting up to 1,300 tph fromthe secondary and that is exceeding goals,” he says.As to the programming and 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 monitorand track every process at the facility, including transferpoints, conveyors, motors and sensors, as well as materialflow and 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; and 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,and with the new plant, we can operate at our current stafflevel,” he says. Lastly, the new efficient plant produces farless fines, and 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, andimprove the work place for employees. Following are a coupleof examples where technologies are working their way into themodern crushing operation.The expansion and 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 and rundiagnostics to help the crew identify the source of a problem. Evenprogram changes and 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,and overload relief, manufacturers are significantly improvingthe up-time availability of the primary crushing station. Operatorscan now monitor operations, make setting adjustments, and 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 and 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
Page 2: COMPANY LISTINGS:Volume 3, Number 1
Page 7 and 8: emphasis on being physically closer
Page 10: News-DevelopmentsICMM RELEASES NEW
Page 13: A major dolomitic limestone operati
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Page 38 and 39: Bauma 2010Marked a Turnaroundfor th
Page 40: Equipment purchases are a big inves

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