Modular crushing, screening plant built for extreme conditions

Perth-based OPS Screening and Crushing Equipment is now the dealer for Osborn, a South African manufacturer of crushing and screening plant, in Western Australia, South Australia and the Northern Territory. OPS previously supplied mobile equipment only, and the addition of Osborn, which is also a member of the Astec Group, to OPS’s portfolio means it can now offer modular and static equipment to its quarrying customers as well.

“As the product is manufactured in South Africa, its suits the Australian market very well because it’s very robust and has to work in similar conditions,” OPS group sales manager Kieran Hawkes said.

Osborn’s export sales manager Douglas Mouton said that OPS would be “a strong and proactive partner in Australia” and added that the plant and equipment available to Australian customers was highly versatile. “We have equipment in parts of Africa, such as Namibia, which resemble Australia in terms of the climate,” he said. “We also have installed equipment in northern China, which again has harsh conditions at the other end of the temperature scale.”

Plant options

Osborn has manufactured crushing and screening equipment from its Johannesburg headquarters since 1911.

Osborn modular equipment is available across a range of jaw crusher, cone crusher, impactor and screening plants.

Primary crushing plants are available with jaw crusher sizes of 2540, 3042, 3055, 3648 and 4248 (in metric terms, feed sizes ranging from 635mm x 1016mm to 1066mm x 1219mm). These are mounted on modular-style chassis. Feed hoppers for the units range from 15m3 up to 35m3 as standard. Osborn can also make special hoppers for dump truck applications.

Modular cone crusher plants are available in sizes from the Osborn SBS range of 38, 44, 52 and 57 sizes. Again all units are mounted on a modular frame. There is a range of surge bins which are also in modular format and designed to directly suit the range of crushers. The hoppers are in sizes ranging from 9m3 to 40m3. They are fitted with vibrating pan feeders that have rollout frames for crusher maintenance access.

A modular impact crusher is available, with sizes ranging from 1010 up to 5260. These units are mounted on a modular skid frame.

The modular crushers are also complemented by modular screening plants, including the SuperKing inclined screens, whose sizes measure from 5m x 2m (16’ x 6’) up to 6m x 2m (20’ x 8’). The units are on skid frames with rollout discharge chutes for clear maintenance access.

Performing in peak conditions

Mouton cited two examples in which Osborn’s modular plant had performed in extreme climates: for an aggregates supplier in Tsumeb, Namibia and an iron ore plant which operates 3500m above sea level in China’s Xinjiang Province.

Henning Crushers supplies aggregate throughout northern Namibia. The Osborn modular crushing and screening plant the company ordered featured a 914mm x 1219mm (3648) jaw crusher, a BTI hydraulic rock breaker boom system, two 1066mm x 1219mm (4250) KPI-JCI horizontal shaft impactors, two 6m x 2.5m (20’ x 8’) Osborn SuperKing screens, all interlinking conveyors and two 36150 KPI-JCI “super stackers”.

“Our client has essentially acquired a full quarry processing plant, but with the advantages of a modular plant,” Mouton said. “All of the plant’s components are ideally suited to Henning Crushers’ applications, [such as] the horizontal shaft impactors, which have the advantage of fracturing stone through impact to create a more cubical product versus the cleavage fracture from a compression crusher.

“The advantage of a modular plant is that substantial cost savings can be achieved in terms of the civil and installation costs needed for a traditional plant, as well as savings on transport,” Mouton explained. “Our modular plants are easy to build and are mounted on skids, so they are easier to set up. They are also easy to transport and re-erect on a new site. These plants are designed to fit into containers when they are dismantled, which makes transportation easier and cheaper.”

Henning Crushers’ new plant was transported by road from Osborn’s Elandsfontein manufacturing facility in South Africa to Tsumeb, Namibia, in 22 trucks. Osborn’s contract included designing and supplying the plant, its delivery to site, and the supervision of the installation and commissioning of the plant.

Mouton said modular crushing and screening plants “offered an ideal solution for plant expansion. All that a customer needs to do is put down a concrete slab, unpack their new modular plant and their expansion is done. They immediately have the desired duty and capacity”.

The plant sold into Xinjiang Province was Osborn’s second export order to China, and showed the modular plant’s ability to withstand the most testing operating conditions. “The Dundee iron ore processing plant is situated 3500m above sea level and the temperature goes down to minus 40 degrees,” Mouton said. “It only operates between May and October due to severe weather conditions. Our machines’ power packs have been installed with heat packs and up-rated electric motors to cope in high altitude.”

The modular plant – which replaced “locally-made equipment” at the Chinese facility – comprised a primary Osborn jaw crusher, secondary cone crusher, screen and tertiary cone crusher. With a capacity of 300 tonnes per hour, the modular plant was producing a nominal 12mm minus product.

Mouton said Osborn won this export order to China amid stiff competition from leading global players. The company partnered with a China-based operation that manufactured the plant’s conveyors.

“This was a groundbreaking order,” Mouton said. “It is an exciting and significant development to see an Osborn machine shipped to China, and it reflects the exceptional quality of Osborn’s equipment.”

OPS are confirmed as dealers in the western regions of Australia, while AQMS handles inquiries about Osborn plant and equipment in the eastern states.

Source: OPS Screening & Crushing Equipment


Osborn plants in extreme places


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