1. What is a modular plant?
A modular plant is a crushing plant consisting of standard, transportable, self-contained feeding, crushing and screening stations mounted on static steelwork with on-board electrics set up to be linked together by
belt conveyors.
2. Modular plants are not new but seem to be back ?in fashion?. Are quarry suppliers revisiting the concept due to feedback from the operators?
The growth of the track mounted mobile crushing market in the past 10 years has highlighted advantages and increased the acceptance of standard, transportable, self-contained crushing stations which operate on a small footprint, unlike large custom-built crushing plants. While operators enjoy the advantages of mobile plants they lament their shortcomings, eg high operating cost, lack of robustness, poor maintenance access. For several years, operators have been asking for a solution that combines the advantages of mobile and fixed plant. They are telling us the modular concept suits their needs.
3. What is different about modular plant now, compared to the past? What improvements have been made to the plant concept?
In the past, there was no commitment to the design of modular plant. Designs are now set up to allow for quick site assembly and ease of transportation. The on-board electrics support a previously unavailable level of control and communication between modular stations.
4. What are the advantages of modular plant compared to mobile or fixed plant?
Terex modular plants have better access for maintenance and are more robust than traditional mobile plant, making them attractive from an operational perspective. When compared with traditional fixed plant, they are more affordable and available in a shorter delivery time. The ability to quickly generate income from a modular arrangement is a
big positive.
5. What extractive operation components are offered in a modular format?
? Modular primary stations with hopper, vibrating grizzly feeder and jaw crusher.
? Modular surge bins with discharge vibrating feeder.
? Modular cone crushers suitable for secondary and tertiary crushing.
? Modular horizontal shaft impactors.
? Modular vertical shaft impactors.
? Modular screening stations.
? Conveyors to link plant sections together.
6. Are your modules purely pre-designed or can they be customised?
Our designs allow for the use of standard modules with pre-determined options in most applications. However, we have the ability to include a level of customisation in our offering.
7. Do your modular plants run on electricity or diesel? What are the benefits of the power supply options?
Our plants operate on electricity, either via mains power or genset. This is an efficient, lower cost and environmentally friendly alternative to the individual diesel engines that provide power to most mobile plants.
8. How relocatable are your modular plants? Can they be disassembled and reused frequently?
Modules are designed for quick assembly with simple ?plug in? electrical connections that make relocation attractive. Most applications are set up for six months between moves.
9. What is the greatest output/throughput on your modular plant?
We expect 300 tph to be processed through our current designs but larger capacity plants are currently on the drawing board.
10. What capacity are the feeders/hopper bins?
The primary hopper has a 15m3 capacity with a 1070mm x 4300mm vibrating grizzly feeder for discharge. We offer two surge hoppers – the MSF24 and MSF34 – which each have an electromagnetic vibrating feeder for discharge and live capacities of 24m3 and 34m3.
11. What sort of feedback have you had from customers following the installation of the modular plant?
To date, our customers have been very impressed with the ease the modules are assembled and removed from the sea containers ?ready to work?.
12. Can you give us one or two examples of projects/where your modular plant has been successfully installed?
In May, a primary MJ42 jaw module was commissioned in South Africa. The plant is processing a dolerite material fed by an excavator as part of a system designed to produce a 10mm, 20mm, 28mm and 36mm material for road construction. Day one consisted of unloading the containers and placing the base, discharge conveyor and jaw crusher into position. The installation was completed on day two, including crushing a full hopper of material to test all settings.
We have just received into Brisbane the first of a set of modules that will be set up in a basalt quarry operation in central Queensland.
13. Any further information you would like to contribute about modular plant?
Our modular products enable us to bring to the marketplace crushing and screening solutions that are quick and easy to assemble and simple to operate and maintain. The modules can be easily integrated with a high degree of interchangeability. Designed with logistics in mind, each module, including all its components, can be transported in sea containers or on road trailers.
{{image2-a:l-w:100}}John Flynn, Sales Director (Australia and New Zealand), Terex Mineral Processing Systems, explains why modular plant is increasingly becoming more attractive for customers than rigid or tracked mobile plant.
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