RPN contacted product experts and Canadian distributors representing eight of the world's leading mobile impact crusher manufacturers to gain a deeper understanding of the advantages, features and evolution of this overall tool in the C&D, concrete and asphalt recycling industries today.
Mobile impact crushers, also known as crawler impact crushers or recovery impact crushers, can be identified mainly because these crushers are installed on a crawler chassis. The overall capacity of the mobile impact crusher ranges from approximately 100 to 500 tons per hour.
Today's mobile impact crusher is particularly suitable for small-scale recycling operations, on-site recycling of dismantled garbage, and small-space urban and roadside applications. These devices have diesel or electric drive systems, can be transported by trailers, and can be simply driven away at the location of the material to be processed, and start working very quickly.
Due to the ability to produce final products with precise dimensions in the shape of a cubic final product, mobile impact crushers can be well used as closed-circuit stand-alone equipment, or they can significantly increase the productivity of any operation, in conjunction with jaw crushers or screens Working plant.
Crawler-type counterattack crushing stations have been greatly developed in the past few decades, because their designs are constantly updated and the crushing market has also changed. The main trends include the introduction of electric drive and hybrid power systems instead of diesel hydraulic drive systems, as well as reductions in size, weight, fuel consumption, cost per ton, and noise and dust generation.
Today's mobile impact crushers are very suitable for a wide range of applications, including as mobile recycled concrete crushers, or asphalt and mixed C&D waste. They comply with Tier 4 Final emission standards, can be equipped with or without a built-in screen, and many options dedicated to the manufacture of recycled materials. Today's mobile impact crushers are safer, more mobile, easier to maintain and operate, and are equipped with advanced machine automation and monitoring systems.
"The growth of the concrete recycling and asphalt recycling industries has led to an increase in demand for smaller, more mobile crushers," said John O'Neill, vice president of international sales at McCloskey. "In the past 10 years, we have improved our control panel system to provide operators with more knowledge and information about the internal conditions of the machine at any time. These devices are also easier and faster to set up."
Daryl Todd of Frontline Machinery, BC’s Frontline Machinery, the Canadian distributor of Keestrack, a Belgian-based crushing and screening equipment manufacturer, said, “We have seen the conversion of concrete and asphalt macadam materials into higher quality recycled materials (such as construction sand, Washed recycled drainage stones, road coverings, RAP (recycled asphalt pavement) and many other high-quality products with higher value.
"The impact crusher's ability to process reinforced concrete, as well as customized options such as plastic and wood chip removal systems, washing systems, etc., enable recyclers to create higher quality end products, and crush and process previously thought materials will only be wasted. Or too difficult to process."
"The impactor has been developed in the past 20 years and has become one of the most important tools for recycling C&D waste," said Keestrack Global Distribution Manager Michael Brookshaw.
"The reason is the quality of the materials produced and the very cubic shape. The impact crusher is a primary and secondary crusher in one unit, so you can crush a 600mm product into a final product, which is resold as recycled aggregate .
"Our machine is very good at recycling asphalt, because we can reduce the rotor speed to crush the asphalt instead of the aggregate inside the asphalt, so the material can be reused in the asphalt mixing plant, which greatly saves costs."
According to Norbert Dieplinger, International Business Development Manager of Austria-based SBM Mineral Processing, “Specifications are becoming stricter, so crushers must be much more precise than in the past. For example, a few years ago, you could crush aggregates to 0 to 3 inches. Materials and use it for roadbeds. Now, engineers allow more and more recycled asphalt to be used in their mixtures instead of all-natural aggregates and crushed concrete, not just as roadbed materials. With the impact crusher, The shape is exactly what you need, you can shrink it to a smaller size, and they can use steel bars to handle building debris."
Alexander Taubinger, Managing Director and Vice President of Sales of Rubble Master, said: “Cost of ownership and cost per ton are key figures for our customer base.” Rubble Master machines are diesel-electrically driven, burn less fuel, and thanks to the company’s latest Design and product development, low maintenance cost.
"In the past, it was tons per hour. The machine was built too powerful and heavy and used large, inefficient power solutions. This is the second or third priority today, because when it comes to most situations, contracting The business must meet other job requirements. Recycling applications."
He added that as far as the end market is concerned, Rubble Master has always focused on the size and quality of the final product. "Many contractors still only consider reducing the size of materials. Today, everything is related to the size and quality of reusable and resale products."
The value of recycled metals is constantly changing, especially in the past ten years, and is a consideration for all recyclers and contractors who manage recycled materials. For users of mobile impact crushers who handle concrete and C&D crushed stone, effective metal separation is still a key component even if the price of recycled steel has fluctuated over the past few years.
"Unfortunately, with recent developments, the value of scrap iron is not high. But I can tell you that having the proper system to remove it is the most important," Kohlberg Pioneer Breaking and Screening Product Manager Tim Harms said (a KPI-JCI and ASTEC Screens company.)
"If there is any metal contamination in your final product, then you will have trouble trying to resell that product. Therefore, it is very important to remove it. Ten years ago, scrap was more valuable and this is the equation Part. Now you need to take it out to resell the product. Impact crushers are very good at separating scrap iron from concrete."
Stephen Whyte, KPI-JCI and Astec Mobile Screens mobile product development product manager, added that the growth of the contractor/rental market is also the key to driving the growth of all crawler crushing and screening equipment.
"Employees today can load crawler impact crushers, perform a week's work, unload them on weekends, and then they can be ready to move on to the next construction site next week," White said. "It is the contractor/rental market that really promotes the development of the mobile impact crusher market."
He added that for general impact crushing, mobile crawler equipment is the least resistance way to enter the industry. "You have the highest reduction ratio. You may get the lowest capital investment. And you can get the most "value for money". Almost always you will see entry-level crawler impactors as the first choice for contractors to get into construction Hair material recycling business, regardless of the brand."
The outstanding features of mobile crushers or crawler impactors for recycling applications are their mobility and high productivity per hour. The device is completely independent on the crawler landing gear, and can be easily driven from the trailer by an operator and quickly put into work, with excellent ability to move directly to the material. Some models are even capable of tracking (moving in their tracks) while they are smashed.
Screen Machine National Sales Director Jody Beasley (Jody Beasley) said: "The ability to move on the job site and between the workplaces is important to contractors or other end users, thus driving the demand for portable crushers." "One of the biggest costs in material processing is the physical handling of the material. Every time the material is moved, labor and expense are involved. The crawler impact crusher takes the machine to the job site, directly to the pile, and allows very efficient material processing .
"It's all about tons per hour. Our machines are designed to produce the largest tonnage, and an important way for them to achieve this goal more efficiently is through our patented crusher decompression system. Screener crusher decompression system Allows the operator to raise the cover of the crusher to 6 inches when the machine is running. This is very helpful in preventing the internal blockage of the crusher and ultimately deliver thousands of additional tons of product during the life of the machine."
According to Stephen Whyte of KPI-JCI and Astec Mobile Screens, “Mobile impact crushers have a higher capacity than they were at the beginning. When the first crawler crushers came out, they were considered highly portable but less versatile. The crusher is heavier than typical portable [trailer mounted] machines. Now, some of our crawler machines can reach the same capacity and compete with portable settings.
"Another important feature of our impact crushers is that they allow operators to crush and track at the same time," he continued. "That's why you will see a lot of such equipment used on highways. An operator can basically load the machine and operate the crawler crusher at the same time."
"This is very important," added Tim Harms of Kolberg-Pioneer. "You can perform crushing without having to leave the crusher to track the machine. When the machine moves on its track, you can continue crushing, which is a great advantage in saving time. Time is very precious. Great value. If you lose 10% of your time just because you have to wait for the crusher to stop before you can move it, it’s dollars."
Traditionally, mobile impact crushers use diesel hydraulic engines to drive the crawlers and provide power to the crushers. The emergence of electric drive and hybrid power systems is one of the main advancements that have occurred in the past decade. Its development is regarded by many as one of the most important trends in the future, especially considering the importance of fuel efficiency and increasing traffic Transportation and operating costs and the global focus on reducing emissions.
“The lowest production cost per ton is essential to the customer’s business,” said Jouni Hulttinen, Metso Mining’s product manager, adding that the main focus areas of their Lokotrack production line development are ease of transportation, maintenance and service, as well as safety and energy efficiency.
"Energy efficiency has always been a development area of great concern," Hulttinen said. "Using our crawler impactor, we have reduced fuel consumption by 20%." He said a good example is Lokotrack LT1213(S) ("S" stands for built-in screen assembly), which uses "standby function" if the engine Without load, the machine will switch to idling mode. "Only 5 minutes of standby per hour, 10 liters of fuel can be saved every day."
According to Norbert Dieplinger, the drive system in the crusher manufactured by SBM can provide diesel-electric or 100% electric operation. "Electricity can not only reduce the carbon footprint, but it can save contractors up to 30% in fuel costs compared to diesel hydraulic drive systems that were common in the past and are still used by many manufacturers," he said. Say.
For Kleemann, a division of the Wirtgen Group, the new EVO 2 Mobirex mobile impact crusher utilizes a direct drive crusher and an electrically driven vibratory conveyor, belt and pre-screener.
“This allows for high fuel efficiency and optimal loading of the crusher,” explains Joe Schappert, senior technical sales manager at Kleemann. "These machines are equipped with extremely efficient direct drives that make excellent performance possible. The latest generation of diesel engines uses robust fluid couplings and V-belts. This drive concept achieves great versatility because of the rotor speed It can be adjusted in four stages to suit different processing applications."
According to McCloskey’s John O’Neill, the first question to ask when considering a purchase is: What do you want the machine to do? He said that it is necessary to make a solid sense of reality an important part of the purchase decision. "Many times, customers are upset because they expect maximum performance to become the norm, when they need to look at all aspects of the operation and how it supports the crusher and the desired end goal or product."
SBM's Dieplinger said that buyers need to consider many factors and agreed that they need to consider available support equipment.
"What kind of supporting equipment can support the tonnage capacity of the crusher?" He asked. He added that other important questions include: Who are the customers? What application do you plan to use it for? What specifications are you using? How big is the pile to be crushed? "
"If the impact crusher needs parts or maintenance items, do you believe that the manufacturer will deliver these parts to you as soon as possible?" asked Jody Beasley of Screen Machine. "Our machines are manufactured in Ohio, and all parts orders are completed here. We are proud that more than 97% of stock parts orders are shipped the same day."
He added that buyers should also consider long-term durability. "The key components of our machine are made of grade 80 steel made in the United States, which is the strongest and most durable steel in the world."
“Not all impactors are created equal, and they vary greatly,” said Daryl Todd of Frontline Machinery. "We strongly recommend careful observation when comparing the various models. Starting with the technical specifications, including the engine horsepower, the weight of the rotor and the blow bar, as well as the ease of transportation, the weight and dimensions of the machine."
Todd said there are many questions to ask, including: Is the rotor directly driven by the engine, electric or hydraulic? What is the hopper capacity and feed height? What are the behind-the-screen options-single-layer, double-layer, or triple-layer? Does the machine have the ability to track when it is at full capacity? What is the type/quality of key components such as hydraulics and electronics? What is the type and quality of steel used for the frame, crusher shell and rotor? He added that any mobile impact crusher should also have a user-friendly design, easy to replace the blow bars, and easy to maintain and repair.
Keestrack's Michael Brookshaw said that one of the main questions to ask when considering an impact crusher is: Can you use your own means of transport to transport the equipment? "The material you need to shred in your area is important," he said.
"Look at the cost per ton involved in the procurement and operation of the unit. What is the amount of material that needs to be crushed? Are they large deposits of 30,000 tons or small deposits of 500 to 1,000 tons? You should also consider "what you will need Material size and capacity. Will electric drives provide advantages in the business environment? "
He added that the technical aspects of the device are also very important. Electric drive, pre-screening before the crusher, crusher overload system, pan feeder under the crusher, weight, and service and operation friendliness of the unit are all aspects that need to be considered. Joe Schappert from Kleemann said that buyers considering buying should make sure they choose the correct size for the application and consider how the product will flow through the crusher.
"The Kleemann Continuous Feeding System (CFS) manages a more uniform load in the crushing area, where the feeding trough and pre-screening frequency are independently adapted to the crusher level, thereby significantly improving performance.
"Our new impact crusher is unique due to its size and productivity," Schappert continues. "Our model MR 110 Zsi EVO 2 has a crusher inlet opening of 43.3 inches (1,100 mm), while the MR 130 Zi EVO 2 has a crusher inlet opening of 51 inches (1,300 mm). They offer up to 350 or 450 tons/ Hour.
"Consider diesel electric drive," he added. "Our latest EVO 2 Mobirex mobile impact crusher uses direct drive crushers and electric drives for vibrating conveyors, belts and pre-screeners. This allows for high fuel efficiency and optimal loading of the crusher."
Looking to the future, Daryl Todd of Frontline Machinery said that there will be more hybrid technologies, electric/diesel hybrids, which means lower fuel consumption and improved noise reduction. He said that we will also see progress in the pollutant removal system and washing system integrated into the closed-circuit impact crusher.
GPS systems are another area where Todd hopes to continue to make progress. "The GPS system provides remote monitoring and control, and is used in conjunction with a car belt scale," he said. "This gives managers a comprehensive understanding of remote operations."
Keestrack's Michael Brookshaw said that their telematics system allows customers, distributors and manufacturers to monitor their machines, notify them from a distance and make recommendations on capacity, equipment operation and troubleshooting.
"The field of wear parts has also developed a lot and is more durable than ever before," Brookshaw said. "The electric hybrid and full hybrid systems we call Keebrid are outstanding in terms of durability, low emissions, operating costs and all environmental issues."
For McCloskey's John O'Neill, the trend of using one machine to complete multiple parts of an operation will continue to decline. "The crusher should crush, the screener should screen," he said. "Trying to compress it all on one platform is very difficult, and it often leads to compromises. If the customer cannot accept it, this can have disastrous consequences on the job site."
Taubinger of Rubble Master expects to see efficiency improvements in all aspects. "We hope to attach great importance to emissions such as dust and noise, as well as higher fuel efficiency, safety and ease of operation."
"When considering computer diagnostics and digital control, technological progress will become an important trend," said SBM's Dieplinger.
"Advanced diagnostic tools allow operators to monitor the process in real time and adjust settings on the crusher's touch screen, even in the excavator cab. This will further improve safety and efficiency while reducing maintenance, operating costs and downtime.
“Diesel electricity is the future because it offers all the advantages in reducing fuel costs and reducing carbon footprint,” Diplinger added, noting that this will have a significant impact in the coming years, especially considering the new carbon Taxation is being implemented globally.
Metso's Lokotrack LT1213 mobile impact crusher is a fully equipped crawler crushing plant that combines mobility, high productivity and flexibility, and is suitable for various applications.
According to Metso’s Jouni Hulttinen, bicycle lanes, road foundations, and infrastructure in industrial areas are growing end markets for materials made from recycled C&D, concrete, and asphalt. He said that mobile impact crushers and all types of recyclable material crushers will increasingly be used to produce high-quality end products.
"The use of final materials has changed from the most basic application to higher specification building materials," Hulttinen said. "Future trends will shift more towards replacing aggregates, new concrete made from recycled concrete, and adding recycled asphalt to make new asphalt." RPN
This article was originally published in Recycling Products News, Volume 25, Issue 1, January/February 2017.
1 McCloskey Road Keene, ON CA, K9J 0G6
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Website: wirtgen-group.com/america/en-us/products/kleemann
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