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Lehigh Cement invest in Hazemag crushing plant

Hazemag installation

In September 2015, Lehigh Cement Company (part of the HeidelbergCement Group) ordered a large semi-mobile limestone crushing plant for their cement plant in Union Bridge, Maryland, from HAZEMAG.

The plant is designed to process up to 2,500 tons/h limestone at a feed size of up to 2,000mm edge length. The Union Bridge cement plant requires 3.5-3.8 million tons of limestone per year, which will be processed in the HAZEMAG crushing plant in Lehigh´s New Windsor Quarry. The crushed material will be transported via a 7km (4.5 mile) long overland conveyor from the new quarry to the cement plant; a journey where the crushed limestone will be conveyed under streams and across country side. The plant produces around 2.1-2.5 million tons of cement from the limestone each year. The newly developed New Windsor quarry has a limestone reserve in excess of 200 million tons, which will last for more than 65 years. Due to the close living area, noise levels have to be kept within certain limits. The new primary crushing system will ensure that the Lehigh Cement Company continue to deliver a high-quality product, economically and without interruption.

The raw material is delivered to the primary station by large, 100-ton capacity quarry trucks and discharged via a HAZEMAG HAF 25160 apron feeder with integrated scraper conveyor from a 400-ton feed hopper.

A critical component in the design of the plant is the HAZEMAG HRS 2638 roller screen, which effectively removes any minus 100mm fines from the raw feed material. These fines can be problematic as they are made up of sticky clay, with a high-moisture content and some times a high percentage of the overall feed stream.

The primary impact crusher is a type HPI 2230 fitted with the very latest design and operational technology - a extra-heavy-duty GSK-Rotor System; HAZtronic automated control system; and a retractable grinding path.

The gap settings can be aligned to the specific characteristics of the raw material conditions, to ensure production of a consistent, high-quality product. The HAZEMAG HPI 2230 primary impact crusher processes the material down to D99 less than 125mm.

The required mobility is achieved by use of special heavy transport systems (SPMT), which can relocate the crushing plant (pontoon design) in two units within the quarry.

In total, HAZEMAG supplied more than 1,000 tons of steel and equipment. Erection of the plant took place between August 2016 and April 2017 with performance tests in March 2018.

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