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The product of 100 years of cone crusher evolution, Metso’s new MX redefines the way we think about cone crusher performance with claims previously unimagined; efficiency, wear part utilisation, safety and automation.
Metso unveiled the new machine at last year’s CONEXPO-CON/AGG global trade show in Las Vegas. MIMICO, the New Zealand distributor of Metso's fixed and mobile crushing and screening equipment, parts and service, will display a Metso MX4 cone crusher at QuarryNZ, which is set for Hamilton’s Claudelands Arena between July 18 and 20.
According to Metso, MX is the first ‘Multi-Action’ cone crusher on the market. It combines the very high reduction ratios of the most demanding mining applications with superb end-product shape and consistency critical in aggregate applications. The machine’s engineering team says that the MX cone crusher was designed with one objective in mind - making the machine owner’s business more profitable than ever before. The company states that the MX reduces total-cost-of-ownership whilst supercharging productivity.
Patented ‘Multi-Action’ Technology
Garth Taylor, Head of Crushing & Screening at MIMICO, says that the company’s patented ‘Multi-Action’ technology is a revolutionary way to automatically optimise crusher operation. "The MX is able to simultaneously adjust its setting with a rotating bowl above its cavity and a hydraulic piston inside the machine’s fixed shaft. Dynamic setting adjustments can be made when the crusher is operating under full load conditions without the need to stop production," said Taylor.
"Both rotating bowl and piston adjustments are fully automated, so no human intervention is required. The MX also provides a maximised tramp release distance, delivering high levels of protection against uncrushable objects and overloading. Protection is optimised under all conditions, even with completely new wear parts."
More uptime and lower operating costs
According to Taylor, the MX with its Multi-Action technology is the most cost-efficient crusher on the market. It enables operational cost savings of 10% or more compared with traditional cone crushers. Savings in wear components coupled with an effective and continuous crushing action, provide an unbeatable starting point to bring down the cost per ton in any quarry or mining application.
The new machine’s uptime is significantly better than traditional cone crushers. The MX’s Multi-Action design allows dynamic setting adjustment and wear composition with its hydraulic piston, minimising interruptions to production. It also provides rapid, fully automated protection via its rotating bowl. The combination of rotating bowl and piston adjustment enables optimised wear part utilisation.
The MX features a very robust design that is based on Metso’s experience over the years with its Nordberg MP, HP and GP Series cone crushers. The new crusher is designed for the most challenging operating conditions with very hard and abrasive feed material. From the start, the MX was engineered to minimise downtime and allow 24/7 crushing in the harshest applications.
One of the big advantages of the MX are its quick and easy wear component change-outs. All the wear parts are accessible from the top of the machine, allowing a complete change-out in just two to three hours.
Up to 70% wear part utilisation
Metso says that the MX delivers record breaking wear parts utilisation rates. The crusher can use up to 70% of the mass of new wear parts. Optimal cavity design, stroke direction and an effectively distributed crushing action are combined to provide a highly optimised rock-on-rock crushing motion. Together with the machine’s Multi-Action technology, this results in extended intervals between maintenance and higher production rates. Quality characteristics of all sized end product fractions stay consistent throughout the lifetime of wear parts.
Selective production
Taylor says that the smart optimisation of Metso's Multi-Action technology is the key to reaching desired end-product shape and particle size distribution while eliminating waste. End products can be measured as often as ten times per second and shown directly on the crusher’s automation display. Operators can easily control and automate parameters such as material cavity level, crusher speed, power setting and piston pressure.
Crushing quality can be monitored via Metso’s ‘VisioRock’ which measures real-time production through a photo particle size analyser that is connected to the crusher’s automation system. VisioRock is compact in design and easy to install. Its Modbus interface enables quick access to particle size distribution from cameras that are mounted above the crusher’s output conveyor.
Designed with operator safety and the environment in mind
Less human machine interactions for adjustment and maintenance naturally means a safer working environment for machine operators and maintenance staff. Combined with purpose made lifting components and wear part tightening tools, the MX is said to be a big win for operator safety. The machines have also been designed with the environment in mind. There is no lead used in the MX’s counterweight design and no backing is required to set the liners. The machine’s lubrication system has been optimised to use up to three times less oil than previous models. Machines can be equipped with Metso's offline filtration system which keeps oil clean for extended periods.
Technology proven in the ‘real world’
As part of its MX development programme, Metso included a pre-launch field testing period. Machines were secretly tested in four different countries. By the time of the global launch in Las Vegas, the test machines had completed a combined operational time of more than 10,000 hours. “Our prospective customers can be confident that our new machines already have a proven track record in some really challenging applications,” explains Taylor.
Metso is a world leading industrial company serving the mining, aggregates, recycling, oil, gas, pulp, paper and process industries. They help their customers improve their operational efficiency, reduce risks and increase profitability by using our unique knowledge, experienced people and innovative solutions to build new, sustainable ways of growing together.