30.04.2009

Stationary plants now become mobile thanks to interlinked plants

Kleemann demonstrates what is possible today with process know-how and high-performance plants

500 t/h feed capacity, up to seven final fractions of which five comply with the strict standards for asphalt and concrete production - and all this is possible using mobile plants? Using the plant combination at Kelly’s of Fantane in Ireland, Kleemann demonstrated what can be achieved today using mobile plants.

Kelly’s of Fantane, Ireland: Three crushing and screening stages, up to seven final fractions, total capacity of over 500 t/h

Kelly’s of Fantane, Ireland: Three crushing and screening stages, up to seven final fractions, total capacity of over 500 t/h

Mobile crusher and screen plants are advancing more and more into output ranges that up to a few years ago were only possible using stationary plants. Examples such as the one quoted above are guiding the way for the future.

What exactly are "interlinked plants"? "Interlinked mobile plants are crusher and screen plants, which are coordinated to work together in terms of output and operation". Two, three or several plants can be combined for use in both natural stone quarrying and recycling. The potential output of such plant combinations currently ranges from 100 t/h up to 500 t/h, whereby the upper limit has not yet been reached.

Why are interlinked mobile plants becoming more popular?

Experience shows that the licensing procedure for mobile plants is, for the most part, considerably shorter and less complicated than that for stationary plants. In addition, the flexible use of the plants in spacious areas and in technical applications reduces the investment risk. The plants can also be resold, thus further lowering the risk. An equally important contributory factor is the fact that manufacturers such as Kleemann have been able to offer plants for such large tonnage in various crushing and screening stages.

Reconstruction company Lauchhammer, Germany: Concrete and rubble processed in final fractions of 0 - 32 mm and 32 - 45 mm

Reconstruction company Lauchhammer, Germany: Concrete and rubble processed in final fractions of 0 - 32 mm and 32 - 45 mm

What are the potential areas of application?

Due to the development of these plants in recent years, the mobile plant is increasingly becoming a real alternative to the stationary version in a great number of projects. For this reason, it is now examined more often whether an original stationary concept with mobile units is more economical. This is of particular benefit to existing operators of stationary plants who are about to make new investments in machinery. This is also a feasible concept for larger infrastructure projects as such projects are mostly limited in terms of time or in scope and are often located in sparsely populated areas. A suitable combination of mobile plants could also be used for newly opened quarries, as well as recycling projects which demand top-quality end products.

LSR Zement, Russia: Two-stage crushing process for achieving four final fractions.

LSR Zement, Russia: Two-stage crushing process for achieving four final fractions.

Requirements and expectations

Of course, the requirements are high: On the one hand, there must be a guarantee that top-quality end products, with regard to cubicity and output, can be manufactured. On the other hand, the process must be reliable and economically worthwhile, which, of course, also applies largely to the machines used.

There must be cost advantages, which are not necessarily noticed in the procurement stage, but mainly during the operation of the plant. For example, in quarries which cover a large geographical area, it is often possible to load the crusher directly at the wall. Thus the use of heavy duty vehicles is partially or completely avoided. This leads to considerable savings not only in vehicles and machines, but also personnel costs. In the example at Kelly’s of Fantane, Martin Flynn, Operation Manager, explains that all machines are linked through a computer-supported system. "The bottom line is we produce 500 tonnes per hour with only one man", he added. He went on to say that since they have been using Kleemann plants, their costs have dropped significantly. "We now produce more during a single shift compared to the previous two-shift operation", he explained.

What does Kleemann specifically offer?

Kleemann not only offers the required plants but also the relevant process know-how. Decade-long experience in the construction of stationary plants combined with over 25 years' experience in the construction of track-mounted crushing and screening plants means Kleemann can offer its customers a comprehensive service. Therefore, not only does Kleemann assess and design the required technical process safely and reliably, but it also ensures its successful implementation by providing support for the customer during the difficult transition stage from stationary to mobile plants.

Maxwell, England: Two crushing and three screening stages allowing up to seven final fractions.

Maxwell, England: Two crushing and three screening stages allowing up to seven final fractions.

The decisive factor is, however, the plants themselves. Kleemann plants offer, on the one hand, the relevant operations in the plant design, and, on the other, robust, sophisticated, high-performance machine technology. Jaw, impact or cone crushers have split feeding for optimal loading (no blockades), large primary screens for optimal final fraction quality, stable control voltage and separate monitoring of the individual machines. They also have ideal access, easy maintenance and, last but not least, diesel-electric drives with the option of external power supply (quarry machines) which also make feed capacities of up to 700 t/h possible. All these characteristics are ideal for interlinked plant concepts. In addition, optimally coordinated mobile screening units, available in double or triple deck design, provide reliable end classification.

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KLEEMANN GmbH
Mark Hezinger
Manfred-Wörner-Str. 160
73037 Göppingen
Phone +49 7161 206-0
http://www.kleemann.info

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