Interlinked mobile crushers and screen produce high-quality aggregates for asphalt production
A PRO plant train from Kleemann is being used by Jusamco Ltd in a limestone quarry on the twin island state of Trinidad & Tobago to obtain aggregate products for the manufacture of asphalt.
Good quality 0–7mm, 7–16mm and 16–19mm final products, simple line coupling of the individual machines to form a plant train, and automatic processes tuned to one another to facilitate operation were decisive criteria for the selection of the technology.
The plant train consists of three machines – a Mobicat MC 120 Z PRO mobile jaw crusher, a Mobicone MCO 11 PRO mobile cone crusher, and a Mobiscreen MS 953 EVO mobile screening plant – whose technical processes are coupled to one another.
Thanks to the automated tuning, the burden on operators is reduced and the process is harmonized and stable. Each machine operates independently but forwards signals to the upstream and downstream machines in the event of malfunctions or overfilling of feed material.
The Continuous Feed System (CFS) ensures optimum utilization of the two crushers, which are loaded evenly with 0–400mm blasted material, whilst the connection of all three machines ensures safety: if an emergency stop is pressed within the plant train, all plants are stopped immediately, preventing damage or overload situations.
With the help of the line coupling, the company performing the work on Trinidad & Tobago has been able to double the availability and output compared with the plants previously used in the quarry.
Personnel deployment is also more efficient. Previously, one operator per plant was used, plus the excavator driver. Line coupling now allows the complete process to be controlled by two operators instead of four, allowing the other two employees to perform tasks parallel to production, such as material provision or logistics in the quarry.
After delivery of the new plants in September 2020, the project had to face the challenge posed by the COVID-19 pandemic: the plant train had to be put into operation online without local supervision.
How well plant start-up functioned despite these adverse conditions was shown after a year: there were no significant problems and the machines and crushing tools revealed hardly any wear. The longevity of the components was partly because the limestone material is not particularly abrasive, but also due to the very finely tuned process with optimum material flow.
Kleemann’s SPECTIVE operating system makes its contribution to rouble-free start-up because it can be operated easily and intuitively. The visual presentation and logical user guidance make errors almost impossible. Thanks to its simple operation, several employees received instruction in the use of SPECTIVE at the same time.
The advantage for maintenance is that the components of the crushing and screening plants are very easy to reach. All positions can be accessed without any problems and without significant disassembly work. Regular maintenance of the plant train has, therefore, been made easier, whilst simple screen media changes on the Mobiscreen MS 953 further contribute to smooth operation.
‘Above all, we appreciate Kleemann’s readiness to find practical solutions. We already experienced good co-operation with the other brands we have from Wirtgen Group,’ said Kyle Parsons, project manager in charge at Jusamco Ltd. ‘We know for sure that the contact partners on site can always provide professional support and guarantee a parts supply.’