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Modular crushing plants defy conventional plant approach

The benefits of the modular approach are as follows:

  • Pre-designed modules reduce the engineering requirement for new plant construction.
  • Modules are pre-assembled at the factory and ship in segments that stack up at the job site with minimal crane time.
  • Motors, handrails and other accessories arrive pre-installed.
  • The number of bolts required for assembly has been reduced from thousands to hundreds.
  • Modules have been field tested and incorporate real maintenance access.

Both US supplier Telsmith and South African supplier Osborn Engineered Products have a range of modular plant designs. Astec Australia is the dealer for both suppliers in the Australian market.

Telsmith has developed a modular plant concept that shortens the timeline for new crushing plant development. Its modular plants can work independently as stand-alone crushing or screening stations or be packaged into ?single source? processing plant solutions. The options include:

  • Primary modular stations. Production outputs range from 500 tonnes per hour (tph) to 1500 tph.
  • Modular cone stations. Feeder bins in 50 and 100 tonne storage capacities are optional.
  • Horizontal and inclined screen modules, which are suited to screen sizes from 6? x 20? up to 8? x 24?. Both dry and wet screening options are available.

The modular jaw crusher is for excavator feed and requires no retaining wall, although a conversion is available that incorporates a feed hopper for truck dumping and a Telsmith heavy duty vibrating grizzly feeder. The conversion does not include a retaining wall.

The current modular cone crushing plant design is based on the Osborn/Telsmith 44SBS Gyrasphere cone crusher, which can be used as a stand-alone crusher fed by a conveyor or a feed bin and variable speed vibrating pan feeder. Other crusher options that use the same structure are the 38SBS and 36 Style ?D?. The cone crusher applications vary from secondary to tertiary and capacities depend on crusher choice and settings.

This sturdy heavy-duty modular structure has easy access for maintenance. An optional add-on module incorporates a vibrating pan feeder fitted with a roll-back frame to allow for unhindered liner replacement of the cone crusher.

The Osborn modular cone crusher plant has been well engineered. Many typical problems in designing a plant of this nature have been ironed out. For example, Osborn has designed the chute work to have a minimum number of liner plates by introducing drop boxes.

The load-out conveyor is a slide-in unit designed for ease of installation and maintenance and is optional. A through conveyor running through the length of the structure can be fitted or alternatively supplied by the client.

Source: Astec Australia

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