New mobile crushing, screening and shredding equipmentPublished 22/4 at 15:32
New slow speed shredders, jaw and cone crushers, are some of the latest additions in the world of mobile material processing units for recycling .PDi takes a look at the latest machines on the market as well as highlighting some case stories of their use.
Doppstadt has launched two new slow speed shredders, the ‘Inventhor Type 6’ and ‘Methor’. The Inventhor has been optimised for economic efficiency, ease of use, accessibility and minimal downtime. Its ‘VarioDirect Drive’ forms the core technology that combines high throughput, low fuel consumption and optimum start up performance even with difficult shredding jobs. The shredder is able to handle a range of pre shredding applications thanks to its configurable shredding system. It can be used combined with other machines enabling the inline generation of a finished product.
The Methor has been redesigned and offers flexibility when handling smaller volume flows being based on a new approach for Doppstadt, as it leverages for the first time the advantages of Doppstadt technology for smaller volume flows, mono batches or special materials and is geared to maximum flexibility. The shredding system can be switched over within 60min, thus, it is designed for jobs with smaller volumes of materials or frequently changing tasks. It can be combined as part of more complex systems with other ‘Smart Solutions’ from Doppstadt. The drive system also reacts to blockages so that the machine protects itself. The internal components are cooled thanks to large ventilation openings. The machine is powered using diesel engine technology, but the line will be expanded to include an electric drive option. Based on the range of applications, the Methor is available as a stationary version as well as a mobile version for use with hook lift or on a track mounted chassis. The Methor can be configured and monitored via Wi-Fi to a smartphone, laptop or tablet that is internet enabled and has a browser installed, regardless of operating system.
Hybrid technology from Rubble Master
RM has introduced a new fully electric hybrid screen, RM MSC8500e, which was developed on the basis of the tried and tested RM MSC8500M screen unit. All the hydraulic drives have been replaced with electric ones, with only the crawler gear remaining hydraulic. One customer that has used the hybrid technology is Manfred Schrefler, founder and director of the company Manfred Schrefler GmbH. Since the spring of 2019, he has owned a RM 100GO! with hybrid drive. The crusher can be used for processing material both with diesel operation and electrically. Depending on the application, he combines the mobile impact crusher with the RM HS5000M pre-screen or uses the crusher on its own. With system, Schrefler can process concrete, asphalt and C&D waste as well as natural stone, gravel and excavated material. “When we crush using electric power, we manage even lower noise levels, which gives us a great advantage on inner city construction sites,” says Schrefler. “With regard to emission regulations, with the RM 100GO! Hybrid and its Tier 4f/ Stage IV engine we are among the best. Also, even though the new RM crusher is really great with its low fuel consumption, when I think about how diesel prices are developing compared to electricity, I can recycle more cheaply with an electric powered hybrid crusher.”
Low speed single shaft shredder ‘Terminator’ from Komptech
With the Terminator, Komptech offers a machine for defined pre shredding of waste for recycling or thermal reclamation. With this new addition to the Terminator family, the Type V, Komptech have aspired to create a tough, stoppage free and well-designed shredder. The ‘V’ stands for ‘versatile’ in terms of material and range of applications. The focus during development was on users who need to process many different materials, such as household or commercial waste, biomass, or used wood. The Terminator Type V is a line extension, i.e. a new version of the existing U, F, and XXF shredders. The modular idea played a major role in the development and the ability to replace all major components was designed in from the beginning. Komptech integrated all future variants in the basic layout, which is meant to ensure flexibility since by putting together the right components they can set up a machine for the customer’s requirements. For the first time an optional re-shredding unit under the drum is available, expanding the range of grain sizes.
The Terminator is suitable for waste wood, mixed construction waste, household or bulky waste, commercial waste, tyres or special applications like white goods or electronics waste, to name but a few. It generates the grain size range suited for subsequent processing. With three different shredding units (U, F and XXF) it can do everything from coarse pre shredding to reducing materials to a defined particle size. The grain size is set by adjusting the cutting gap between the counter comb and the drum. This cutting gap remains constant during shredding for consistent output. The large drum diameter prevents wraparounds from tapes, belts and wires. The drum also has an automatic reversing function that acts as an overload protection, as well as performing self-cleaning. With the wide, high output channel and its conveyor system, shredded material is discharged without blockages.
Jaw crusher from EvoQuip, cone module from Terex
EvoQuip has introduced a new hybrid hook lift jaw crusher, the EvoQuip ‘Bison 160’. Suited to hard rock as well as construction and demolition recycling applications, the Bison 160 Hybrid is the fourth model in the Bison series and the first to utilise hybrid diesel electric drive technology to reduce running costs in addition to cutting noise and fuel emissions, making it ideal for urban areas. The dual powered Bison 160 is equipped with a 700mm x 500mm single toggle hydraulically adjustable jaw crusher. The electric drive allows customers to reverse the crusher to clear a blockage or run in reverse for asphalt recycling. An optional deflector plate is fitted on the moving jaw providing belt protection by allowing uncrushable objects to pass through the crushing chamber and onto the discharge belt.
The jaw crusher is suited for working in space restricted sites. EvoQuip has aimed at creating a compact crusher that is easy to transport and operate, and quick to set up. It is ideal for recycling with under crusher clearance, minimal snag points and a short distance between the crusher discharge conveyor and magnet. The over band magnet removes rebar which can be discharged to the right or left of the machine depending on site configuration. Additionally, it includes a heavy duty vibrating grizzly feeder. The intelligent control system is based on power draw and feed level to ensure material flow in the jaw and throughput. The aim of the design is to make a machine small enough to fit inside a standard high cube container, but tough enough to withstand challenging applications.
Following the recent launch of the new Terex MPS TG/TGS Series bushing cone crushers, Terex has introduced the MC320 cone module. The MC320 features the TG320 or optional TGS320 cone on the same universal base structure as the MC and MV series modular lines. The all electric, pre-engineered solution can be transported in standard containers and can be bolted together onsite quickly with basic tools and minimal wiring enabling installation with or without full concrete foundations. The TG320 is a 225kW bushing cone with large feed opening, adjustable eccentric throw and multiple liners, with the 1800/1500rpm motor and crusher being mounted on a rubber isolated frame. The galvanised/painted steel structure includes oversize walkways, repositionable stairs and guard rails. Four plant emergency stops are placed around the platform. The MC320 comes with standard AIC crusher controls. Additional options include an overflow chute and off plant conveyor starter kit.
Haas waste wood plant in operation since 2004
The recycling company Van Vliet, part of Renewi, has been active in waste processing in the Central Netherlands region for more than 100 years, with the company also processing waste into semi-finished products and green waste into compost. In 2003, Renewi (then named the Van Vliet Groep) hired Haas to design a new waste wood plant, the largest project for Haas at the time. Over a period of several weeks, numerous planning discussions were held. The challenge was to design a plant that would be able to process 70t to 80t of waste wood (unsorted waste and demolition wood) per hour, as well as separate ferrous and non-ferrous metals and carry out exact screening of individual chip sizes according to customer specifications. The end product would be wood chips for biomass plants and high quality chips for the chipboard industry.
The solution delivered was a Haas waste wood processing plant with primary and secondary shredders with a capacity of up to 80t of waste wood per hour. The plant contains five round silos for intermediate storage of the recycling chips until loading by truck or ship loading system. The total size of the plant is approximately 2,000m². In 2003, the originally installed horizontal hammermill, type HSZ 2000, was replaced after thousands of operating hours by a new vertical fed hammermill, type ‘Arthos 2000’ and is still running. In 2018, more than 170,000t per year had been processed. “We are very satisfied that we have chosen Haas,” says Johan Peter Post, operations manager at Renewi. “We are convinced of the good consultancy and the entire management and service team of Haas, supporting us at any time, solving any problems and assisting us in any possible way. Maintenance intervals and regular service visits are planned well in advance and the spare and wear parts are manufactured in time, and stored at Haas or at our warehouse. There are no downtimes for longer periods of time and the entire plant still has a very high availability until this day. We have maintained a good partnership with Haas right from the start, which means that communication has never been a problem and mutual trust has built up. I would again implement a new plant project with Volker Haas and his team today.”
New RC150 RubbleCrusher from CMB International
UK-based manufacturer CMB International releases their updated RC150 RubbleCrusher. It can efficiently work from a trailer or placed on a stationary skid. The typical capacity is 180-300t per day, based on an eight-hour day, and 20-40t/h depending on feed grading and output setting. In their own words, it is easily towable by 4x4 as it weighs under 3,500kg and can be set up in less than 5 minutes. It is loaded with a 5-8t excavator or backhoe loader. The jaw crusher is 650mm x 350mm with a maximum recommended feed size of up to 520mm x 280mm. The adjustable output size is 0-25 to 0-200mm. It can crush concrete, brick and stone up to 210kN. The updated version will feature hydraulic drive with a reverse function and a Tier 5 Yanmar engine for applicable markets. The overall dimensions of the skid are 1200mm width x 4570mm length, while the trailer’s dimensions are 1550mm width x 4900mm length x 270mm height, with conveyor folded for transport.
Kleemann’s Mobirex in use in Germany and the UK
CK Abbruch & Erdbau has been using a MR 130 Z EVO2 impact crushing plant to crush rubble from a demolished department store. Additionally, a Mobirex MR 110 Z EVO2 is being used by Leeds, UK, based Mone Brothers.
Established in 2003, CK Abbruch & Erdbau engages primarily in demolition and earthworks. The company processes some 250,000t of recycled feed material annually. Recently, it was hired to take down a shopping centre in central Göppingen, Germany, and process the material on site. In applications of this kind, the company uses the mobile Mobirex MR 130 Z EVO2 impact crushing plant. The company fleet also includes a Mobiscreen MS 13 Z screening plant, mostly used to screen rubble and soil. Markus Christadler, managing director of CK Abbruch & Erdbau, explains his thoughts on choosing Mobirex.
“Quality is the deciding factor in processing the material. It is very important to deliver a perfect product to customers, because we compete with natural products like crushed stone and gravel. In other words, our final product has to be processed to be as cubic and as accurately classified by grain size as possible. We also attach great importance to efficiency. Every drop of fuel and every kilowatt of electricity counts in our work, because these savings add up over every hour of operation. My team and I also see safety as a top priority. Systems such as the ‘Lock & Turn’, with its key transfer system, are a real improvement in safety.”
Markus further explains how he uses Kleemann plants for different jobs. “We always adapt the rotor ledges on our MR 130 Z EVO2 impact crusher. We have a rotor ledge set for hard material like concrete rubble and natural stone, and another for soft material like asphalt. But since we usually feed the plant with hard stone, we actually don’t have to change sets very often. Together with our contact at the Wirtgen Group sales and service company in Augsburg, we have set up a schedule for the provision of wearing parts, so we are automatically supplied every three months with new rotor ledges for our Mobirex impact crushing plant. If we occasionally see more extensive wear, they get the corresponding spare part to us right away. In addition, our employee who operates the plant always keeps a set of rotor ledges and the most important wearing parts on hand at every construction site.”
The crusher is well thought of by Markus’ staff. “What my guys are truly thrilled about is the ‘Spective’ control system. It is very intuitive and simple to operate. It’s also incredibly practical that operating statuses like fuel level are so easy to check. From the standpoint of cost efficiency, I like the high productivity combined with low fuel consumption and the short set up times associated with Spective. There is one more technical detail that workers always praise: the air classifier. We used to do the final sorting of crushed material by hand. Now the air classifier handles most of that job by separating oversized grain from lightweight foreign material with a blower. That increases quality and saves time.”
Mone Brothers based in Leeds, UK, is another company that relies on the Mobirex. At the company’s fireclay recycling centre to the west of Leeds, a MR 110 Z EVO2 recycles mixed rubble. The impact crusher changes between brick and concrete rubble. Dumper trucks drive into the centre bringing mixed rubble from demolition work and construction sites and takes back crushed and cleaned material. While broken bricks are recycled into hardcore according to British Standard 6F2 and used primarily as a capping layer in road construction, the concrete is used as a Type 1 layer for sub base purposes. Mone Brothers works with the local utility industry and supports the expansion of the electricity, water and gas network with its material. The companies deliver their mixed rubble and drive away again with recycled Type 1.
Thanks to a higher permissible oversize grain content, it is possible to dispense with a closed circuit for 6F2 and increase feed capacity. The MR 110 Z EVO2 then has a capacity of 280t/h. For the recycled Type 1 material, the system changes its location and the secondary screening unit is mounted in approximately 15min. With the integrated oversize grain return conveyor, the capacity is still 250t/h while meeting the necessary standards for road construction. These products are typically produced in the United Kingdom with jaw crushers, of which Mone Brothers also having one from Kleemann based in a quarry.
According to Michael Coleman, managing director of Mone Brothers, the impact crusher achieves a grain shape in one crushing stage that a jaw crusher could not come close to without a second crushing stage. The slightly higher fine content helps to bind the material during later use and equates to the required quantity. The higher performance of the Mobirex is also a highlight. While jaw crushers offer a recommended crushing ratio of 7:1 in recycling, impact crushers can achieve a ratio of 15:1 and a greater feed size. Mone Brothers therefore replaced two of its jaw crushers with one impact crusher. Thanks to the diesel direct electric drive concept of the Kleemann Evo crusher, this reduces operating costs by another 15%. “We did try other machines but actually they could not produce enough of the product at the right speed and they were much more expensive to operate,” says Coleman. “The output is truly mesmerising and it has been a real benefit to the business.”
Rockster’s hydrostatic drive a key factor for recycling specialist
Forster Recycling has developed into an industry specialist with 27 employees. The German recycling company has been focused on processing contaminated soil, gravel, stone, litter, construction rubble and waste from sewer cleaning. The company has three landfills and a thermal processing plant, which transforms contaminated rock or debris into recyclable material. Forster’s customers include road construction companies, municipalities, district and water management offices and the German National Railways.
Richard Forster and his company have been using mobile crushers for quite some time; however they have always been rented. This led him to look for a mobile crusher of his own in the 35t range and tested a few, including the Rockster impact crusher R1100DS with screening system and Cat C9 Stage V engine. “The large openings and good access to the engine compartment make service and maintenance easier,” says Forster. “We also have much better experiences with hydraulic drives, as is the case with Rockster's fully hydraulic drive, in comparison with diesel electric drives, where you have to expect cable breaks and which are usually more sensitive to dust or vibrations.” Since the crusher is used on multiple locations, i.e. the recycling site and at the company's own gravel quarry or landfills, transport was an important issue. “I like the fact that we don't have to disassemble anything on the R1100DS to transport it, just fold in the screening system and drive it onto the flat-bed trailer,” explains Forster.
Forster often produces 0-60mm material for underground stabilisation from broken concrete or mixed rubble. The granite gravel from railroads is processed to a 0-16mm or 0-32mm end product, suited for road construction as an underfill or for land consolidation. “Performance and material quality are really excellent, the composition of fine and coarse fraction is exactly right for our customer requirements,” says Forster. “The attached air blower also works perfectly. It has the optimal suction to blow away non aggregate materials such as polystyrene, textiles, wood parts or plastic. This light material is collected directly in a container, which is surrounded by a net, and can then be disposed of. So, everything is done in one step.”