Crushing is a vital step that reduces the size of large rocks and ores in quarrying and mining so that they can be further processed into valuable minerals and other products. Dealing with a supplier that places a high value on not only a comprehensive crushing range, but also critical parameters such as efficiency, reliability and high productivity, is non-negotiable. With Sandvik Rock Processing’s mobile crushing range, all these boxes are easily ticked, says PC Kruger, business line manager Crushing at Sandvik Rock Processing.
Sandvik Rock Processing manufactures a comprehensive range of primary jaw crushers, open and closed-circuit cone crushers, as well as impact crushers – which are all available on crawler tracks or wheels to address the industry’s need for ease of mobility.
The company has plants to suit most process needs, ranging from entry level units weighing in at 35 tonnes (t) to larger units weighing in at a whopping 138 t. In terms of capacity, this ranges from the QJ241 jaw crusher that takes a maximum feed size of 520 mm with a capacity up to 225 tonnes per hour (tph), to the larger UJ640E that takes a maximum feed size of 975 mm, producing up to 1 000 tph.
Withstanding harsh environments
Sandvik Rock Processing’s heavy duty U-range features the company’s trusted stationary derived crushing chambers, jaws, hydrocones and the S-type gyratory, designed for hard rock crushing. These units, says Kruger, are built to last, operating in the toughest of working conditions. The crushers are built from premium quality components, including high-spec materials used in the chassis to withstand both cold arctic operating conditions and the hot climate in some parts of Africa.
“Deployed in a variety of mining and quarrying applications to handle both tough ores and hard rocks, Sandvik crushers are designed to deliver increased levels of productivity, while maximising operator comfort and cost efficiency. Several of the larger tracked units feature on-board diesel generators, allowing customers to choose their preferred energy source – mains grid power or diesel,” adds Kruger.
Maximising reliability
The importance of efficiency, reliability and productivity in crushing cannot be stated enough. With that in mind, most Sandvik Rock Processing mobile units come with innovative features as standard for improved efficiency and high productivity. These include automated systems such as feeder control, jaw level sensors to optimise the feed rate, and dust-proof components to maximise durability and ensure long life.
As part of a wide range of wear solutions, all Sandvik Rock Processing jaw plates have been developed to deliver high reliability and durability. For example, the Sandvik Optitooth jaw plates, available for the Q-range of tracked jaw crushers, have been designed to achieve optimum performance of the crushing chamber.
The Sandvik Optitooth jaw plates ensure that a higher percentage of the jaw is utilised, resulting in longer wear life and less manganese waste. The innovative design enables better breakage and a faster distribution of fines through the crushing chamber. This results in lower engine loading and consequently, a reduction in fuel consumption, thus lowering operating costs. According to Sandvik Rock Processing, the Optitooth jaw plates have been proven to last up to 30% longer and to be up to 20% more productive than conventional offerings.
“In addition, Sandvik long-lasting rubber wear plates with full steel backing or extruded aluminium profiles are available for all-round wear protection. These can be tailor-made to fit most applications, from light to extra heavy duty,” explains Kruger. “Due to a long wear life and impact-absorbing properties, service intervals are longer, less maintenance is required and unscheduled breakdowns are avoided. These rubber wear plates also extend equipment lifetime through reduced vibrations and dampened impact forces, while the reduction of noise levels leads to a better working environment.”
Efficiency and sustainability
Mines and quarries are actively pursuing energy efficiency due to the significant financial benefits of reducing their energy consumption, which is often a major operational cost. In addition, they are fulfilling the need to improve sustainability by lowering their carbon footprint. Essentially, by using less energy, the industry can save money and operate in a more environmentally responsible way.
To help industry meet its energy efficiency and sustainability obligations, Sandvik Rock Processing is one of the crushing original equipment manufacturers (OEMs) at the forefront of fully electric mobile crushers to ensure lower operating costs and reduced environmental impact.
The most recent addition to the tracked electric range of crushers is the UJ443E heavy duty jaw crusher. This machine is built on a new, ‘fully electric’ track platform. It features electric final drives and on-board genset, which can be operated more sustainably, either by an external electricity supply, hydrotreated vegetable oil (HVO) or diesel.
Powering the machine using an external electric source can bring several advantages, including lowering running costs, extending drivetrain service intervals, reducing time spent refuelling, reducing onsite emissions and lowering noise levels. Using fully electric track drives and final drives, the unit is said to decrease the use of hydraulic oil on the plant by up to 91%.
The company also manufactures a wheeled range of crushers that has been made to meet the same high standard as its tracked counterparts, operating at maximum efficiency and designed for high-capacity production. Electrically powered, these units offer lower cost per tonne operation, as well as lower emissions, thus minimising the environmental impact, which speaks directly to the industry’s sustainability drive.
“In addition, our range of hybrid mobile crushers also saves energy and reduces the climate impact of rock processing. These dual-powered crushers offer several benefits, including increased efficiency, reduced operational costs, and lower environmental impact thanks to the potential for using electric power sources,” explains Lodewyk Louwies, field service technician at Sandvik Rock Processing.
Safety to the fore
All Sandvik Rock Processing mobile crusher models place safety at the centre of their design. The units are built with spacious platforms for ease of access to all necessary components, The units are fitted with safety guards over moving componentry as well as emergency stop buttons around the machine.
“User-friendly by design, the operation of our mobile crushers is easy to master and makes processes much simpler to action,” explains Kruger. “The tracked units can be operated by radio remote control for easy and safe operation, while the majority of our best-selling models within our product offering are fitted with My Fleet remote monitoring systems to help optimise operation.”
Optimising performance
The digital solutions developed by Sandvik Rock Processing go a long way in helping customers improve productivity and performance. For example, performance can be easily monitored through the remote monitoring system, which optimises equipment to exact operational requirements.
By using Sandvik Rock Processing quality OEM parts, customers can keep their plants operating at peak performance with minimal downtime. Tested to the extremes, says Kruger, these parts are designed to fit Sandvik equipment perfectly and ensure higher equipment uptime and greater efficiency than non-original parts.
Maintenance and support
For Sandvik Rock Processing, customer support is an essential element of its business. This starts right from decision-making through to the lifetime of the equipment. To support customers with their decision-making, Sandvik Rock Processing mobiles are fully integrated into the company’s Plant Designer programme – a crushing and screening simulation software.
“This proprietary software platform calculates quantitative and qualitative material flow and output levels, assisting customers in the decision-making process of crusher and screen purchasing and ownership. Users can qualify their equipment investment easily through Plant Designer’s state-of-the-art simulations, improving profitability and efficiency,” says Kruger.
When it comes to maintenance, Sandvik Rock Processing has recently introduced its Essential Maintenance Packages for its range of mobile crushers and screens. These packages have been designed as an effective self-service solution for customers to maintain their Sandvik mobile units, providing all the necessary parts for up to 1 000 hours of operation all in one convenient package. This helps customers to stock essential spares in advance and minimise downtime.
“Our large pool of skilled service technicians, decentralised across various regions of the continent, ensure uptime, equipment reliability and productivity for customers,” says Jody Vermaak, aftermarkets sales manager at Sandvik Rock Processing. “This is complemented by local equipment and parts inventory across our regional hubs. Apart from our main hub in South Africa, we have entities in Zambia, the DRC, Tanzania and Ghana. We have also placed a premium on training, not only for our employees, but also for other partners that work with our equipment, such as distributors and customers themselves.”
