Crushing, Environmental News, Features, Screens & Feeders

Green-tick crushing equipment and renewable energy


Supplying in-demand equipment to the crushing and screening market, Wirtgen is a proud supplier of Kleemann technology that has proved invaluable in the Snowy 2.0 project.

Supporting the renewable Snowy 2.0 Hydro project, the Wirtgen Group is making its impact in a development that is set to supply sustainable energy to New South Wales.

The project involves linking two existing dams, Tantangara and Talbingo, through 27km of tunnels and building a new underground power station.

Water will be pumped to the upper dam when there is surplus renewable production and the demand for energy is low, and then released back to the lower dam to generate energy when electricity demand is high.

To facilitate the development of the project, the Kleemann track-mounted jaw crusher Mobicat MC 110 Evo 2 has been utilised in pre-crushing and stone recycling aspects of the project.

With compact dimensions, efficient pre-screening and simple operation via the Spective Connect app and strong production outputs, the Mobicat is a key player with a variety of options that make it suitable for a large range of materials and operations.

Reinforcing the environmentally efficient nature of the operation, Wirtgen also ensures the factories that produce Kleemann machines have strong environmental initiatives in place, as Kleemann sales manager David Dixon told Quarry.

“Our production facilities are state-of-the-art and employ measures that ensure we are minimising our environmental impact wherever possible,” he said.

“Waste heat from the production plants is reused in our factories to heat offices and factory halls, a closed water cycle reduces consumption of fresh water and the low pollutant cracking systems we employ remove impurities from the wastewater and returns the purified water to the factory halls to further reduce water usage.

“The wastewater that cannot be treated is disposed of without harming the environment and we then have retention basins to safeguard adjacent bodies of water.

“In addition, there are decisions we make to reduce emissions through aiming to minimise distances between our material suppliers by having our factories be close in vicinity to them wherever possible.

“Our machines and spare parts are also preferably shipped by rail, inland waterway or ocean freight to further reduce our CO2 emissions where possible.”

Kleemann technicians are trained to utilise fuel-saving operations and techniques when manufacturing the products.

Kleemann is a part of the Wirtgen Group and is owned by John Deere, giving the crushing equipment company the backing of a tried-and-tested business.

Among the market leaders in diesel-electric hybrid technology and initiatives, Kleemann equipment offers a 30 per cent reduction in fuel usage in comparison to diesel-hydraulic machinery, which is furthered reduced through implementation of the Spective operating system, which serves to decrease fuel usage and increase productivity.

“Our equipment can be manufactured as dual power, offering more environmental benefits in their operation,” Dixon said.

“The Kleemann MC110 Evo 2 and Pro series equipment [MCO11 Pro] have surplus electric power that can be used by auxiliary equipment such as screens and stackers, further reducing energy usage of that auxiliary equipment.

“All Kleemann equipment includes Witos telemetry software. The software is a versatile program that allows the user their own log-in to monitor live equipment and export data such as machine hours, fuel burn, start–stop times, hours used and material production quantities.”

A continuous feed system allows for automatic control of the level of material in the crusher, through a frequency-controlled vibrating feeder.

The Kleemann MC 110 Evo 2 also includes an intelligent overload system with short-term overloading at selected points that works with an intelligent load-reduction system to protect the crusher during long operation under extraordinarily high forces.

With knowledge of how the machinery operates on-site, GCE Contractors operations manager Martin Grealish is especially well placed to discuss the usability of the Kleemann machinery being employed as part of Snowy 2.0.

“The computerised system the Mobicat uses for materials has increased the speed with which we can have materials crushed,” Grealish said.

“This means that we can get the work that we need to get done faster, so the savings in time are passed directly onto the operation.

“We haven’t had an experience quite like this with other crushers, so it is really a standout.”

The change in crushing efficiency based on material is a part of the Aggflow software used by Wirtgen.

The AggFlows production outcome tool is based on information supplied by the client regarding material type and feed to the manufacturing factory, to give an indication of what the customer can expect in terms of processed material. This helps increase productivity and generate positive environmental outcomes.

“We have a focus on continuous improvement, with on-demand AggFlow updates for operational scenarios,” Dixon said.

“Wirtgen also offers quality servicing, with specific coverage for its operational crushing and screening assets and predictability in servicing costs and overall reduction in unplanned downtime.

“Our service technicians are original equipment manufacturer factory trained and the best team to have on side when maintaining Kleemann equipment. One of the benefits of working with Wirtgen is that you are working directly with a subsidiary of the manufacturer.

“That level of detailed experience exceeds that of just simply working for a dealer selling multiple equipment types. At Wirtgen our service technicians are focused on Kleemann.”

The Snowy 2.0 project is currently in the middle of its development and is expected to be completed in 2026, with first power expected to be drawn in 2025.

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