News
POWERSCREEN MOBILE UNITS BOOST HANSON PRODUCTION IN WESTERN AUSTRALIA
- with the Chieftain 2100 3 Deck.
The current and forecasted high rate of infrastructure growth in Western Australia has resulted in a large increase in demand for aggregates from the quarrying industry for rail, road and construction use.
Hanson Construction Materials are currently showing an increase in production levels as a result of major mobile plant investment. At the heart of this operation is a crushing and screening plant combination of Terex-Pegson/Powerscreen mobile units supplied by the Australian dealer, Lincom Pacific Equipment, whose head office is in Queensland. www.lincom.com.au
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Hanson’s WA Metropolitan Operations Manager, John Symonds opted for the total Terex package because
“the Pegson crushers and Powerscreen units have a well proven performance for making high quantities of good shaped quality aggregates and the machines come with the backing of a global brand name. Also, the credibility of their world-wide network of close dealer support, in terms of machine backup and spare parts availability was very significant in our decision ”
The mobile plant will be used at Hanson’s northernmost Quarry in WA at Mount Regal, Karratha, where it will produce single sized and concrete blend aggregates during a campaign crushing program in the dry season.
Working a large outcrop of hard and abrasive dolerite, the quarry is situated some 2000km North of Perth in Western Australia. Recent demand for the quarry’s quality stone means that Hanson’s Mt Regal quarry will be supplying aggregates and road-base materials to this rapidly growing and yet remote industrial centre.
Mobility for Hanson both on site and between sites is therefore critical and the whole plant can be set up within a day or so once relocated by standard low bed trailers between the remote sites in Western Australia. Once on site it is anticipated the whole plant will be moved every couple of days to enable the excavator to work directly off the ROM pad.
Prior to moving to Karratha the plant was installed for 4 months at Hanson’s Byford Quarry, just south of Perth, to train personnel and commission the plant. Both single sizes and concrete blends were produced alongside the fixed plant.
Cliff Kelly, Byford Quarry Manager for Hanson was very impressed with the performance of the plant. He said
“in terms of capacity, product grading and shape requirements the Terex Pegson/Powerscreen mobile plant matched the performance of our much larger fixed plant operation.
The Pegson/Powerscreen units are all fully mobile tracked machines. The primary is a Pegson Premiertrak fitted with an 1100x800mm super heavy-duty single toggle jaw crusher. The machine is built around a heavy-duty fabricated chassis and track frame and powered by a high-efficiency Caterpillar C12, 224 kW, 6 cylinder diesel power pack. The crusher features grease lubricated eccentric shaft bearings. Both fixed and swing jaws are reversible to extend operating life, and the inside of the crusher body is fitted with hardwearing, replaceable lining plates.
The crushers large 9.1 m3 capacity feed hopper can be folded down by hydraulic rams to reduce headroom when being transported by road, and can be fed from the end or either side. The 62 tonne unit features remote operator control to enable it to be moved on its tracks within the quarrying area for positioning with other units. Dust suppression sprays are fitted above and below the crusher and at the conveyor head. An overband magnetic separator takes out any metals on the belt to the side of the plant. To prevent spillage a level sensor on the jaw stops the grizzly feeder when the feed bin on the cone is full and re-starts it when the level drops.
Material is fed to the jaw crusher direct from the face via a 45 tonne excavator. Crushed rock from the jaw crusher is then fed to a Pegson 1300 Maxtrak secondary unit, which features Pegson’s well-proven 1300 Automax cone crusher. At a closed side setting of approx. 28mm and with a recirculating load of approx. 80 tph the cone gives a total throughput of approx. 290tph resulting in almost 210t/hour of 0-22.5mm finished product.
The direct feed from the jaw to the cone crusher improves the product shape when compared with other competitors machines used on the same application.
The Pegson 1300 Maxtrak is an ideal secondary crushing unit working in combination with the primary jaw. It provides high reduction and output of specific sized aggregates with excellent product shape. A metal detection system in the feed prevents any tramp metal from entering the crushing chamber, so ensuring the safety of the machinery. When activated the feed conveyor is stopped and an audible warning given.
Dust suppression sprays are fitted over the crusher mouth and at both the product conveyor feed and discharge points.
A PLC management system with plant start-up and shutdown sequences ensures safe operating of machine. Crusher controls enable crusher setting to be made and to calibrate and monitor manganese wear.
Product from the 1300 Maxtrak is transferred to a Powerscreen Chieftain 2100, (6mx1.5m - 20’x5’) three-deck screener which separates the material into 20mm, 14 mm and -10mm sizes, whilst the oversize material at +22.5 mm is re-circulated via a portable conveyor back into the cone crusher in a close circuit, for further crushing.
The -10mm material is transferred to a second Chieftain 2100 three deck screener, fitted with different meshes, which separates and grades the material into 10mm, 7mm, 5mm, and 0-2mm dust. Materials tested to date have all met with the required specifications to satisfy customer demands. Two additional mobile conveyors can also be moved around the plant to increase stockpiling capacity as required.
According to Cliff Kelly the mobility and versatility of the tracked machines has provided major operational benefits: “they are easy to transport, have very short set-up times, they are easy to operate and changes to product demands are easily met. This saves on cost and adds to the quarry’s productivity”.
The Byford Quarry produces a wide range of aggregates to standard sizes and is a major supplier of aggregates to asphalt and premix concrete plants within the Perth Metropolitan area.
Due to the proximity of urban development, Hanson implements all the necessary dust and noise suppression systems to keep within the most stringent of environmental regulations. Sensitive to the local environment, any dust on the roadways is kept down by regular spraying by water trucks, and water canons treat all open stockpiles. An on-going dust monitoring policy is carried out to safeguard both the quarry workers and the local environment. This, together with noise and vibration monitoring for each blast, keeps the quarry well within defined operational limits. To conserve water supplies, all the water used for dust suppression from the pit and access road run-off is collected and allowed to settle before being recirculated to the dust suppression systems on site.