New jaw crushes bottleneck for Stevenson AggregatesSponsored
Stevenson Aggregates' Drury quarry recently upgraded the capability of its operation, installing a new Metso Outotec Nordberg C120 jaw crusher to replace an older model Universal 42” x 32” jaw crusher.
MIMICO was engaged to review the existing primary crusher and recommend a replacement for the aging jaw crusher. The existing jaw crusher had become a bottleneck to production and needed to be replaced.
After extensive review a Metso Outotec Nordberg C120 jaw crusher was recommended.
“We reviewed the primary and secondary process using Metso Outotec’s Bruno simulation software and found the Nordberg C120 was a great match with Stevenson Aggregates' existing Metso Outotec GP300S. The ability to take a larger feed size, easy setting adjustment and automation made the Nordberg C120 an obvious choice,” explains Garth Taylor, MIMICO’s crushing & screening business manager.
Metso Outotec's Nordberg C Series range of jaw crushers, distributed in New Zealand by MIMICO, is engineered for the toughest feed material in the primary crushing stage. The C Series product family consists of nine models of different sizes that are engineered to deliver the maximum productivity at the lowest operating costs.
Stevenson Aggregates also has a positive, long-standing relationship with MIMICO and the Metso Outotec brand. “When looking at our options, the MIMICO/Metso Outotec offering was the standout,” says Kurt Hine, Stevenson Aggregates’ general manager. “We’ve operated Metso Outotec C Series jaw crushers in our mobile fleet for decades and we can trust the expertise and support provided by MIMICO.”
Stevenson Aggregates' new Metso Outotec Nordberg C120 jaw crusher replaced an older model Universal 42” x 32” jaw crusher
High production and reduction
“The C120 has a maximum feed size of 700mm from a large feed opening [of 1200mm x 870mm] that gives a hefty material intake and ensures the rocks enter the jaw crusher’s cavity without restrictions,” explains MIMICO’s Taylor. “Cavity, kinematics, and operating parameters have been defined and optimised to ensure the outstanding performance which Nordberg C Series jaw crushers are known and valued for.
“Crusher height gives the steepest possible cavity cross section, and the nip angle high up in the cavity, together with an aggressive, well-aligned stroke at the bottom, ensure high throughput capacity and reduction, resulting in high production levels for Stevenson Aggregates.”
The setting of the Nordberg C Series jaw crusher can be adjusted with two wedges without shim plates. While the adjustment system can be mechanically adjusted as standard, Stevenson Aggregates’ C120 has opted for the optional full hydraulic setting adjustment.
This allows for quick and easy closed side setting adjustment, making the wedge movement even faster and safer. Other safety-enhancing features on the C120 are the lightweight yet impact resistant composite guards for the flywheels and V-belts.
Hine says Stevenson Aggregates have seen some positive benefits since the C120 began operation. "Key for us has been less downtime due to rock jamming in the jaw. The hydraulic adjustment has saved us maintenance time in changing the jaw close side setting and we can change close side setting on the fly to match the source rock."
The hydraulic adjustment on the C120 has saved Stevenson Aggregate maintenance time in changing the jaw close side setting
Crushing consistency was ensured thanks to the installation of Metso Outotec's IC10C crusher automation system, which also led to downstream crusher performance improvement. IC10C automation provided Stevenson Aggregates with control over the crusher's cavity level, push button close side setting adjustment, and a visual display of all crushing vitals.
The IC10C package, which controls and monitors the C120 and ancillary equipment, helps achieve the best performance, protection, and safety, and maximises the crusher's uptime. "Our IC10C provides constant throughput by giving us full control of the crushing process, as well as condition and data monitoring. It was easy to install," said Ross Ashby, Stevenson Aggregates’ engineering manager.
When replacing any piece of plant with new equipment there is always some form of engineering involved. This is where the MIMICO Engineering team came into play with 3D design software and extensive industry knowledge and experience.
“To accommodate the new jaw crusher MIMICO Engineering designed and installed a new jaw crusher sub-frame, as well as made modifications to the jaw in-feed chute and existing scalping screen,” said Scott Welsh, MIMICO’s engineering manager. “We were working with a tight space so had to get innovative to make everything work together as it should.”
The installation of a Metso Outotec Nordberg C120 jaw crusher has upgraded the capability of Stevenson Aggregates' Drury quarry
Nordberg C Series jaw crusher range
Nordberg C Series jaw crushers have proved to be reliable and productive in thousands of mining, quarrying, recycling, and industrial applications with up to 11,000 jaw crusher installations since 1975.
Developed to crush the hardest ores and rocks, C Series jaw crushers also perform outstandingly with less demanding materials. In addition to the stationary jaw crushers, many models are also available as mobile or portable versions.
The core of the C Series jaw crusher is a pinned and bolted, non-welded frame construction that provides excellent fatigue strength and uncompromised reliability. All the frame components are casted using an alloy developed in-house by Metso Outotec especially for jaw crushers.
In addition to solid casting, the crushers’ frame has a cellular, honeycomb structure that, like in nature, has proved to be stronger and more durable, while also utilising premium-quality components.
Nordberg C Series jaw crushers can be upgraded with crusher automation that enables monitoring and adjusting the settings of a feeder, crusher, and conveyor remotely. This way the crusher can be controlled from a distance, making it easier and yet safer to operate. The critical areas of these jaw crushers are protected against wear, while the components and parts that require renewal from time to time are engineered to be easily accessible and replaceable when needed.
Nordberg C Series jaw crushers are customisable with options for any application. Safe flywheel and drive guards protect operators from moving objects. An optional integrated motor base allows installing the crusher drive motor directly to the back of the crusher. An optional feed chute, on the other hand, is engineered for uninterrupted material flow from the feeder into the crusher.
Contact your local MIMICO sales professional if you’d like to find out more about Metso Outotec’s range of crushing and screening equipment. Phone 0800 646 426 or visit www.mimico.co.nz