Environmental Products

Modular plant with capacity of a large crushing station

Terex MPS installed its first MJ47 module at the Hanson Flagstaff Gully Quarry in Lindisfarne, about 10km east of Hobart, Tasmania, in 2015. The quarry has an average output of up to 430,000 tonnes per year and its finished products include concrete/sealing aggregates and roadbase.

Flagstaff Gully Quarry, which has been operating since the 1960s, is notable for being developed on the eastern side of the Meehan Range at an elevation of 330 metres. Therefore, the modular plant was elevated about 200m above the main processing plant at Lindisfarne, overlooking the gully below. An 840m long conveyor and reclaim tunnels deliver processed aggregate from the MJ47 modular plant to the main processing plant below.

Access to the installation site was via a 1.2km dirt road. Incomplete earthworks did not allow direct access to the construction pad with heavy haulage transport, or a suitable set-down area for heavy equipment and shipping containers. All components had to be hauled up the access road in stages during assembly. These constraints would have presented a significant challenge to building a typical fixed plant in this location.

The entire MJ47 module was easily transported in 12m shipping containers direct to site, and a three-man team from Terex Mineral Processing Systems assembled the modular station on-site over a three-week period using standard tools provided from a single service vehicle. The modular plant’s pre-assembled sections allowed the team to load individual sections onto a smaller truck for transport to the assembly area. A 30-tonne mobile crane was hired to lift components directly from the shipping containers.

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In addition to limited space, no mains electricity was available during assembly. A portable 10kVA generator, running on less than 10 litres of fuel per day, was sufficient to run all required tools and an air compressor for the duration of the installation period.

The MJ47 kit comprises a 85-tonne, live capacity large truck dump hopper, a 150kW Terex Jaques ST47 jaw crusher with a 125mm closed side setting and 200mm jaw output, a Terex Simplicity stepped deck vibrating grizzly feeder with 100mm aperture, plant chute work, a 1200mm wide skirted discharge conveyor (with 15kW motor), a rock breaker and a galvanised steel structure with walkways.

Frank Carpenter, the quarry manager at Flagstaff Gully, told Quarry he has been happy with the throughput of the modular plant since its installation, as it processes an average 350 to 400 tonnes per hour. He has also been very pleased with the aftermarket support that Terex MPS has provided since the plant began operation.

In September last year, 15 members of the IQA’s Tasmanian branch visited the quarry and were able to see the modular plant up close. Carpenter was able to explain to them the logistics of establishing the plant and of hauling and erecting the infrastructure on an extremely steep incline. “The tour group was very impressed with the MJ47 and downhill conveyors,” Carpenter said. “Although the plant wasn’t operating at the time, the IQA members expressed interest in returning at a later date to view the plant running.”

Source: Terex Mineral Processing Systems

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