Rock Solid!
POWER & RENEWABLE ENERGY

Rock Solid!

Which are the hot-selling crushing and screening plants? What allied services do vendors offer? Do clients have a range of after-sales services to choose from? Charu Bahri has some answers.

Make no mistake, the Indian crushing and screening market is among the leading emerging markets in the global arena. It has seen major growth in the past few years, mostly because of frenetic activity in the mining sector and the launch of numerous infrastructure projects. According to RS Raghavan, Managing Director, Proman Infrastructure Services Pvt Ltd, “At present, the opportunities stem from major accounts in the mineral and contractor segment, manufactured sand plants, industrial minerals processing, road and dam contractors in India and neighbouring countries, and mines and mineral processing industries.”

Quantifying the opportunities, GN Raju, Managing Director, Nawa Engineers & Consultants Pvt Ltd, points out that the 320 million tonne of mineral ores produced in 2006-07 is estimated to increase by 80 per cent in the 11th Five-Year Plan, which would mean that 240 million tonne of additional minerals would be processed during the period from 2007 to 2012. This would generate a market for the crushing and screening equipment valued at about Rs 56,000 crore from the mineral sector while the aggregates industry would need an additional Rs 45,000 crore worth of equipment to meet the needs of infrastructure development.

Changing client preferences

Satya Raju, Deputy General Manager – Crushing & Screening, Sandvik Mining and Construction, observes, “The boom in the infrastructure sector has led major contractors to set up higher capacity crushing and screening plants for their infrastructure projects and given rise to crushing plants set up for commercial quarrying purposes.” As for preference of plant capacity, he says, “We see maximum demand for crushing plants with a capacity between 200 to 250 mtph. This range of crushing plants best suits road contractors; it isn’t easy to feed plants beyond these capacities. Commercial quarrying set-ups producing 5 mm, 10 mm, and 20 mm products and supplying railway ballast to the railways also prefer this size.”

According to Satya Raju, “Easy to install and shift mobile and semi-mobile portable plants have also become popular because of the limited timeframe of about three to four years of road projects after which contractors need to shift the plant to another site. Even so, wheeled plants only save the time taken for transportation and installation. Time-consuming activities like site preparation, retaining wall construction, other nominal civil works, conveyors erection, DG set and cabling must still be performed. Hence, the trend is now slowly shifting towards track-mounted mobile plants that can move as the quarry progresses. These need no installation, nor a retaining wall or civil works, and the power required is also available on board.”

Demand for newer technologies

The demand for newer technologies is also being driven by stricter quality norms governing construction companies engaged in infrastructure projects, particularly highways. “The Ministry of Surface Transport’s specifications to keep the elongation and flakiness ratio in control ensure that most road contractors go in for a three-stage crushing and screening plant with vertical shaft impactor (VSI) at the tertiary stage,” adds Satya Raju. “In contrast, commercial quarrying contractors prefer a two-stage plant with a jaw crusher as the primary and a cone crusher as the secondary crusher.”

The emerging needs of the industry are encouraging leading global brands with a presence in the country to bring bigger and better plants to India. Powerscreen, for instance, is adding the 1500 Maxtrak to its range of jaw, impact and cone crushers in 2011. “This machine will be one of the largest track mobile cone crushers on offer,” reveals Rajen Khoda, Director - Sales, Powerscreen, South Asia and Middle East. “Specifically developed for larger end users, the plant can accept an all-in feed from a primary crusher to produce up to 950 tph of aggregate. And as it utilises Terex® Automax cone crusher technology, operators benefit from hydraulic overload protection, excellent product shape and a high reduction ratio.”

Green is in

‘Green’ has emerged as a buzzword of the construction and mining industries, as a result of which contractors operating their own quarries and commercial quarrying and mining companies are also increasingly looking at procuring equipment that incorporates green features to reduce their environmental footprint.

“Clients nowadays take into account the size of the plants, as they wish to cause minimum disruption to the natural environment says V Venkataramana, Vice-President, Puzzolana Machinery Fabricators. “This necessitates compact plants, which we provide.” “Environmental norms now stipulate the use of eco-friendly dust control systems, which are a key feature of our aggregate plants,” adds GN Raju. “What’s more, these are water-based suppression systems free from any chemical and effluents.” In addition to offering conventional dust suppression systems, Proman plants are designed to considerably reduce the dust emission from the discharge - “the air transfer assembly in its VSI [vertical shaft impact crushers] assures this,” says Raghavan.

Power shortages are also increasingly leading companies to review potential buys for their power consumption. “It means a lot to us that all Powerscreen machines meet CE specifications and offer dual power options for screening equipment providing environmental benefits,” says Khoda.

Allied services

Measures to increase productivity are always welcome, as users grapple with the challenge to lower the cost per tonne of finished products. But this requires more than the best equipment, service, support, training, and consumables. As Satya Raju says, “It also calls for a thorough knowledge of the whole quarrying process, including extensive knowledge of rock characteristics in various parts of India.” To further its knowledge base, Sandvik practices a system of collecting samples from quarries of every potential and operational sites of existing clients, which are sent to the Sandvik Test Centre in Sweden for work and abrasion indices testing. As a result, hundreds of tests have been conducted over the past 15 years. The results of these tests, which indicate that rocks of different kinds are marginally to significantly harder in India than Europe, and flow-sheets prepared using Sandvik’s PlantDesigner® patented software help estimate how proposed plants would perform in real time.

Leading manufacturers with a pan-Indian presence cater to all kinds of rocks found in different parts of the country. “Puzzolana crushers, for instance, boast of robust designs and are suitable for all types of rocks such as hard basalt and can be used for both abrasive and non-abrasive stones,” says Venkataramana. Additionally, as know-how is essential to ensure the peak performance of these plants, the scope for end-to-end solutions is increasing, leading vendors to extend customer support to the operation of the plant. Affirms GN Raju, “As an extension of customer support, we offer to operate and maintain the entire crushing and screening systems that we build for our customers.”

After-sales services

As after-sales services figure high in the list of factors driving a client towards a certain brand, vendors are coming up with an array of service options to benefit their existing clientele and attract potential customers. Recognising these needs of clients, Puzzolana has introduced parts contracts wherein the prices of spares are fixed for the year in advance. “This gives customers control on the pricing of parts,” points out Venkataramana. Regular annual maintenance contracts covering parts, the maintenance of plants and periodic visits to the plant site to check the health of the plant and offer the customer advice on maintaining the same; operation contracts wherein the plant is run by the vendor and kept up-to-date both in terms of quality production and maintenance; and plant refurbishments offering the client life cycle support are also on offer.

“It is not enough for suppliers to promptly attend to service calls within 48 hours,” says Raju. “They must also stock all essential wear and spare parts for their entire range of products to meet any emergencies.” Powerscreen looks to reduce downtimes to a minimum with the support of an extensive dealer network offering both service and spares. “We don’t take after-sales services lightly; we have adopted performance measures to ensure consistently high ratings within the industry,” adds Khoda. To this end, Powerscreen counts customer satisfaction as one of its key performance indicators and measures it using a net promoter score system.

It’s evident, then, that as long as vendors continue to lay emphasis on customer services, users can look forward to getting maximum returns from their investments in crushing and screening equipment.

CASE 1:

Equipment: Three-stage plant consisting of Proman-Lippmann Jaw Crusher, the Procone cone crusher, the Proman-Remco Vertical Shaft Impact Crusher (VSI) and PROMAN-Finedoor Screens and Feeders.
Vendor: Proman Infrastructure Services Pvt Ltd.
User: Enviiro Buildmate Pvt Ltd, based in Pune.
Project: Commercial production of aggregates at its plant on the outskirts of Pune.
Purpose: The plant is used to crush basalt, a tough rock when it comes to producing cubical and good shaped aggregate. The plant produces very high quality 20 mm, 10 mm, manufactured sand (concrete and plaster sand). The output is 120 to 140 tph, of which 60 to 70 tonne comprises sand, 65 to 70 tonne is 20 mm, and 30 to 35 tonne is 10 mm aggregate produced as required.
Key features: The Proman-Remco VSI feature using multiport technology, variable speed options and variable chamber options, helps fine tune and optimise the performance of the plant to maximise the quality (shape) and quantity of its output.
Accessories: Soft-starters, variable frequency drives, belt weighers, metal detectors, tramp magnets, and dust suppression systems.
Client's comments: "We needed a crushing plant with more than 50 per cent product being sand. Technically we felt Proman was best suited as it also manufactured indigenously under the collaboration of the best designs from the world. This has helped us buy international standard machines at an economical price. Further, the availability of the machines has been very quick and the rates very competitive. The after-sales service rendered by Proman and the proactive support given by its team has helped us become a reliable and leading supplier of quality aggregate and sand in Pune," shares Nitin Chavan, Projects Manager, Enviiro Buildmate.

CASE 2:

Equipment: 300 tph aggregate crushing and screening plant consisting of 1-off NAWACONE secondary cone crusher RBC3000; 1-off NAWACONE secondary cone crusher GLH3000; 1-off NAWAPACTOR tertiary VSI NP4503RR; and 2-off NAWASCREEN HiFlow Vibrating Screen HF2160 3-Deck.
Vendor: Nawa Engineers.
User: Jaiprakash Associates Ltd.
Project:Yamuna Expressway Project.
Purpose: The plant is processing quartzite to make road-base materials and aggregates of sizes 40-20 mm, 20-10 mm, 10-5 mm and 0-5 mm.
Key Features: As the plant was intended to be used for quartzite, which is very abrasive, the vendor carried out several field tests to improve the life of the wear parts. Subsequently, the vendor specially developed the high wear parts in the plant machinery like VSI crushers using exotic metallurgies.
Clients' Comment: "Our first purchase from Nawa Engineers was a vertical shaft impactor (VSI). At the time, we opted for Nawa because they were able to quickly deliver the equipment to meet our need. We observed the performance of the equipment and the engineering capabilities
and after-sales services of the company and found them satisfactory. We have also usedPuzzolana and Metso plants," says BV Raisinghani, Sr Joint President (Purchase), Jaiprakash Associates Ltd.

CASE 3:

Equipment: 175 tph 2-stage crushing plant consisting of Sandvik grizzly feeder SW1252H (1,200 mm wide × 4,600 mm long), Sandvik jaw crusher CJ411 (with an opening of 1,045 mm × 840 mm), with a CSS range of 75 - 225 mm, and a crushing capacity of up to 430 tph, secondary Sandvik cone crusher, CH430, and final screen, Sandvik CS86 III Deck (1,800 mm wide × 4,800 mm long).
Vendor: Sandvik Mining and Construction
User: Rock N Rock Sand Pvt Ltd, a commercial aggregates supplier based in Hyderabad for more than two decades.
Project: At its commercial aggregates quarry in the outskirts of Hyderabad.
Purpose: To crush fairly hard granite feed material (Work Index 20) and boulders VI 750 mm coming from their quarry, adjacent to the crushing plant, into final size fractions of 0 - 5 mm, 5 - 10 mm, 10 - 20 mm and 20 - 40 mm.
Key features: Even though the capacity of the plant is smaller, Sandvik chose a bigger jaw crusher CJ411 for this application as it can accept boulders as large as 750 mm, which considerably helps reduce mining costs. The plant also incorporates the concept of a primary stockpile that provides the client much-needed independence between the primary and secondary circuits.
Client's comments: "We had been using conventional crushing equipment of much smaller capacities, in the region of 30 tph, with the traditional jaw-jaw combination. We realised that we would need to adopt modern crushing technology to cater to the current quantity and quality aggregate specifications. We expected quality, price and after-market sales and service from Sandvik, and it has far exceeded our expectations," says Satyanarayana Reddy, Partner, Rock N Rock Sand Pvt Ltd.

CASE 4:

Equipment: Puzzolana 200 tph III stage crushing and screening plants
Vendor: Puzzolana
User: Ramky Infrastructure Ltd
Project: Outer Ring Road, Hyderabad
Purpose: The plant is used to crush stones excavated from the road, which means very few fines and same size boulders produced by rock breakers. About 1,300,000 tonne was crushed in a period of 12 months, with a record production of more than 75,000 tonne in one month. Thus, the project was completed ahead of schedule. The guaranteed output of the plant is 200 tph of (-) 40mm aggregates and 150 tph of (-) 24mm aggregates.
Key features: The primary crusher of the plant is designed to take such feeds that are not run of mines (ROM) and still achieve the capacity of plant.
Client's comments: "As we and Puzzolana are both based in Hyderabad, we benefit by not having to keep high inventories of spare parts. We're happy with their services. We've been able to use their machines well and achieve optimum output levels. Now we've ordered eight [more] numbers for various road projects across India," says KS Ravi Kumar, Deputy General Manager - Resources, Ramky Infrastructure Ltd.

CASE 5:

Equipment: Powerscreen® H6203, one of four machines in the Powerscreen® H Range
Vendor: Powerscreen®, a Terex brand.
User: Fomento Group, a leading iron ore exporter with a presence in Goa and Karnataka.
Project: At its major mines in and around Goa at Pissurlem, Kudegal, Navelim with extraction capacity at 20 mn tonne a year.
Purpose: The machine features horizontal screens ideal for handling high volumes of materials for the exact fine sizing of high specification concrete or asphalt aggregates demanded in many construction contracts. It is also well-suited to coal and iron ore. The H6203 has an output potential of up to 800 tph.
Key features: The adjustable elliptical throw combines linear and circular amplitude producing an aggressive screening action. Powerscreen® H products are especially effective for scalping after a primary impact or jaw crusher and are capable of screening out specific small sizes. The products also come with a high-capacity variable speed belt feeder, oil bath screenbox bearing lubrication, screen walkway and access ladder, hydraulic folding stockpiling conveyors, engine protection shutdown system, heavy duty triple shaft screenboxes with adjustable stroke, elliptical throw adjustable up to 19 mm (3/4"), diesel hydraulic power unit, and heavy duty, low ground pressure tracks.
Accessories: Options for the H6203 include radio-controlled tracking, dual power, roll-in bogie prepared and equipped, and variable speed incline apron feeder.

“At present, growth opportunities stem from major accounts in the mineral and contractor segment, industrial minerals processing and road and dam contractors in India.” - RS Raghavan, Managing Director, Proman Infrastructure Services Pvt Ltd

“We see maximum demand for crushing plants with a capacity between 200 to 250 mtph.” - Satya Raju, Deputy General Manager - Crushing & Screening, Sandvik Mining And Construction

“The 1500 Maxtrak plant can accept an all-in feed from a primary crusher to produce up to 950 tph of aggregate.” - Rajen Khoda, Director - Sales, Powerscreen, South Asia And Middle East Ltd

“Environmental norms stipulate the use of eco-friendly dust control systems, a key feature of our aggregate plants.” - GN Raju, Managing Director, Nawa Engineers & Consultants Pvt Ltd

“Clients nowadays take into account the size of the plants, as they wish to cause minimum disruption to the environment.” - V Venkataramana, Vice- President, Puzzolana Machinery Fabricators

Quick bytes:

• The mineral sector is expected to generate a Rs 56,000 crore market for crushing and screening equipment.
• The trend is now slowly shifting towards track-mounted mobile plants that can move as the quarry progresses.
• Companies are looking at procuring equipment with green features to reduce their environmental footprint.
• Most aggregate plants today are water-based suppression systems free.

Which are the hot-selling crushing and screening plants? What allied services do vendors offer? Do clients have a range of after-sales services to choose from? Charu Bahri has some answers. Make no mistake, the Indian crushing and screening market is among the leading emerging markets in the global arena. It has seen major growth in the past few years, mostly because of frenetic activity in the mining sector and the launch of numerous infrastructure projects. According to RS Raghavan, Managing Director, Proman Infrastructure Services Pvt Ltd, “At present, the opportunities stem from major accounts in the mineral and contractor segment, manufactured sand plants, industrial minerals processing, road and dam contractors in India and neighbouring countries, and mines and mineral processing industries.” Quantifying the opportunities, GN Raju, Managing Director, Nawa Engineers & Consultants Pvt Ltd, points out that the 320 million tonne of mineral ores produced in 2006-07 is estimated to increase by 80 per cent in the 11th Five-Year Plan, which would mean that 240 million tonne of additional minerals would be processed during the period from 2007 to 2012. This would generate a market for the crushing and screening equipment valued at about Rs 56,000 crore from the mineral sector while the aggregates industry would need an additional Rs 45,000 crore worth of equipment to meet the needs of infrastructure development. Changing client preferences Satya Raju, Deputy General Manager – Crushing & Screening, Sandvik Mining and Construction, observes, “The boom in the infrastructure sector has led major contractors to set up higher capacity crushing and screening plants for their infrastructure projects and given rise to crushing plants set up for commercial quarrying purposes.” As for preference of plant capacity, he says, “We see maximum demand for crushing plants with a capacity between 200 to 250 mtph. This range of crushing plants best suits road contractors; it isn’t easy to feed plants beyond these capacities. Commercial quarrying set-ups producing 5 mm, 10 mm, and 20 mm products and supplying railway ballast to the railways also prefer this size.” According to Satya Raju, “Easy to install and shift mobile and semi-mobile portable plants have also become popular because of the limited timeframe of about three to four years of road projects after which contractors need to shift the plant to another site. Even so, wheeled plants only save the time taken for transportation and installation. Time-consuming activities like site preparation, retaining wall construction, other nominal civil works, conveyors erection, DG set and cabling must still be performed. Hence, the trend is now slowly shifting towards track-mounted mobile plants that can move as the quarry progresses. These need no installation, nor a retaining wall or civil works, and the power required is also available on board.” Demand for newer technologies The demand for newer technologies is also being driven by stricter quality norms governing construction companies engaged in infrastructure projects, particularly highways. “The Ministry of Surface Transport’s specifications to keep the elongation and flakiness ratio in control ensure that most road contractors go in for a three-stage crushing and screening plant with vertical shaft impactor (VSI) at the tertiary stage,” adds Satya Raju. “In contrast, commercial quarrying contractors prefer a two-stage plant with a jaw crusher as the primary and a cone crusher as the secondary crusher.” The emerging needs of the industry are encouraging leading global brands with a presence in the country to bring bigger and better plants to India. Powerscreen, for instance, is adding the 1500 Maxtrak to its range of jaw, impact and cone crushers in 2011. “This machine will be one of the largest track mobile cone crushers on offer,” reveals Rajen Khoda, Director - Sales, Powerscreen, South Asia and Middle East. “Specifically developed for larger end users, the plant can accept an all-in feed from a primary crusher to produce up to 950 tph of aggregate. And as it utilises Terex® Automax cone crusher technology, operators benefit from hydraulic overload protection, excellent product shape and a high reduction ratio.” Green is in ‘Green’ has emerged as a buzzword of the construction and mining industries, as a result of which contractors operating their own quarries and commercial quarrying and mining companies are also increasingly looking at procuring equipment that incorporates green features to reduce their environmental footprint. “Clients nowadays take into account the size of the plants, as they wish to cause minimum disruption to the natural environment says V Venkataramana, Vice-President, Puzzolana Machinery Fabricators. “This necessitates compact plants, which we provide.” “Environmental norms now stipulate the use of eco-friendly dust control systems, which are a key feature of our aggregate plants,” adds GN Raju. “What’s more, these are water-based suppression systems free from any chemical and effluents.” In addition to offering conventional dust suppression systems, Proman plants are designed to considerably reduce the dust emission from the discharge - “the air transfer assembly in its VSI [vertical shaft impact crushers] assures this,” says Raghavan. Power shortages are also increasingly leading companies to review potential buys for their power consumption. “It means a lot to us that all Powerscreen machines meet CE specifications and offer dual power options for screening equipment providing environmental benefits,” says Khoda. Allied services Measures to increase productivity are always welcome, as users grapple with the challenge to lower the cost per tonne of finished products. But this requires more than the best equipment, service, support, training, and consumables. As Satya Raju says, “It also calls for a thorough knowledge of the whole quarrying process, including extensive knowledge of rock characteristics in various parts of India.” To further its knowledge base, Sandvik practices a system of collecting samples from quarries of every potential and operational sites of existing clients, which are sent to the Sandvik Test Centre in Sweden for work and abrasion indices testing. As a result, hundreds of tests have been conducted over the past 15 years. The results of these tests, which indicate that rocks of different kinds are marginally to significantly harder in India than Europe, and flow-sheets prepared using Sandvik’s PlantDesigner® patented software help estimate how proposed plants would perform in real time. Leading manufacturers with a pan-Indian presence cater to all kinds of rocks found in different parts of the country. “Puzzolana crushers, for instance, boast of robust designs and are suitable for all types of rocks such as hard basalt and can be used for both abrasive and non-abrasive stones,” says Venkataramana. Additionally, as know-how is essential to ensure the peak performance of these plants, the scope for end-to-end solutions is increasing, leading vendors to extend customer support to the operation of the plant. Affirms GN Raju, “As an extension of customer support, we offer to operate and maintain the entire crushing and screening systems that we build for our customers.” After-sales services As after-sales services figure high in the list of factors driving a client towards a certain brand, vendors are coming up with an array of service options to benefit their existing clientele and attract potential customers. Recognising these needs of clients, Puzzolana has introduced parts contracts wherein the prices of spares are fixed for the year in advance. “This gives customers control on the pricing of parts,” points out Venkataramana. Regular annual maintenance contracts covering parts, the maintenance of plants and periodic visits to the plant site to check the health of the plant and offer the customer advice on maintaining the same; operation contracts wherein the plant is run by the vendor and kept up-to-date both in terms of quality production and maintenance; and plant refurbishments offering the client life cycle support are also on offer. “It is not enough for suppliers to promptly attend to service calls within 48 hours,” says Raju. “They must also stock all essential wear and spare parts for their entire range of products to meet any emergencies.” Powerscreen looks to reduce downtimes to a minimum with the support of an extensive dealer network offering both service and spares. “We don’t take after-sales services lightly; we have adopted performance measures to ensure consistently high ratings within the industry,” adds Khoda. To this end, Powerscreen counts customer satisfaction as one of its key performance indicators and measures it using a net promoter score system. It’s evident, then, that as long as vendors continue to lay emphasis on customer services, users can look forward to getting maximum returns from their investments in crushing and screening equipment. CASE 1: Equipment: Three-stage plant consisting of Proman-Lippmann Jaw Crusher, the Procone cone crusher, the Proman-Remco Vertical Shaft Impact Crusher (VSI) and PROMAN-Finedoor Screens and Feeders.Vendor: Proman Infrastructure Services Pvt Ltd.User: Enviiro Buildmate Pvt Ltd, based in Pune.Project: Commercial production of aggregates at its plant on the outskirts of Pune.Purpose: The plant is used to crush basalt, a tough rock when it comes to producing cubical and good shaped aggregate. The plant produces very high quality 20 mm, 10 mm, manufactured sand (concrete and plaster sand). The output is 120 to 140 tph, of which 60 to 70 tonne comprises sand, 65 to 70 tonne is 20 mm, and 30 to 35 tonne is 10 mm aggregate produced as required.Key features: The Proman-Remco VSI feature using multiport technology, variable speed options and variable chamber options, helps fine tune and optimise the performance of the plant to maximise the quality (shape) and quantity of its output.Accessories: Soft-starters, variable frequency drives, belt weighers, metal detectors, tramp magnets, and dust suppression systems.Client's comments: We needed a crushing plant with more than 50 per cent product being sand. Technically we felt Proman was best suited as it also manufactured indigenously under the collaboration of the best designs from the world. This has helped us buy international standard machines at an economical price. Further, the availability of the machines has been very quick and the rates very competitive. The after-sales service rendered by Proman and the proactive support given by its team has helped us become a reliable and leading supplier of quality aggregate and sand in Pune, shares Nitin Chavan, Projects Manager, Enviiro Buildmate. CASE 2: Equipment: 300 tph aggregate crushing and screening plant consisting of 1-off NAWACONE secondary cone crusher RBC3000; 1-off NAWACONE secondary cone crusher GLH3000; 1-off NAWAPACTOR tertiary VSI NP4503RR; and 2-off NAWASCREEN HiFlow Vibrating Screen HF2160 3-Deck.Vendor: Nawa Engineers.User: Jaiprakash Associates Ltd.Project:Yamuna Expressway Project.Purpose: The plant is processing quartzite to make road-base materials and aggregates of sizes 40-20 mm, 20-10 mm, 10-5 mm and 0-5 mm.Key Features: As the plant was intended to be used for quartzite, which is very abrasive, the vendor carried out several field tests to improve the life of the wear parts. Subsequently, the vendor specially developed the high wear parts in the plant machinery like VSI crushers using exotic metallurgies.Clients' Comment: Our first purchase from Nawa Engineers was a vertical shaft impactor (VSI). At the time, we opted for Nawa because they were able to quickly deliver the equipment to meet our need. We observed the performance of the equipment and the engineering capabilities and after-sales services of the company and found them satisfactory. We have also usedPuzzolana and Metso plants, says BV Raisinghani, Sr Joint President (Purchase), Jaiprakash Associates Ltd. CASE 3: Equipment: 175 tph 2-stage crushing plant consisting of Sandvik grizzly feeder SW1252H (1,200 mm wide × 4,600 mm long), Sandvik jaw crusher CJ411 (with an opening of 1,045 mm × 840 mm), with a CSS range of 75 - 225 mm, and a crushing capacity of up to 430 tph, secondary Sandvik cone crusher, CH430, and final screen, Sandvik CS86 III Deck (1,800 mm wide × 4,800 mm long).Vendor: Sandvik Mining and ConstructionUser: Rock N Rock Sand Pvt Ltd, a commercial aggregates supplier based in Hyderabad for more than two decades.Project: At its commercial aggregates quarry in the outskirts of Hyderabad.Purpose: To crush fairly hard granite feed material (Work Index 20) and boulders VI 750 mm coming from their quarry, adjacent to the crushing plant, into final size fractions of 0 - 5 mm, 5 - 10 mm, 10 - 20 mm and 20 - 40 mm.Key features: Even though the capacity of the plant is smaller, Sandvik chose a bigger jaw crusher CJ411 for this application as it can accept boulders as large as 750 mm, which considerably helps reduce mining costs. The plant also incorporates the concept of a primary stockpile that provides the client much-needed independence between the primary and secondary circuits.Client's comments: We had been using conventional crushing equipment of much smaller capacities, in the region of 30 tph, with the traditional jaw-jaw combination. We realised that we would need to adopt modern crushing technology to cater to the current quantity and quality aggregate specifications. We expected quality, price and after-market sales and service from Sandvik, and it has far exceeded our expectations, says Satyanarayana Reddy, Partner, Rock N Rock Sand Pvt Ltd. CASE 4: Equipment: Puzzolana 200 tph III stage crushing and screening plantsVendor: PuzzolanaUser: Ramky Infrastructure LtdProject: Outer Ring Road, HyderabadPurpose: The plant is used to crush stones excavated from the road, which means very few fines and same size boulders produced by rock breakers. About 1,300,000 tonne was crushed in a period of 12 months, with a record production of more than 75,000 tonne in one month. Thus, the project was completed ahead of schedule. The guaranteed output of the plant is 200 tph of (-) 40mm aggregates and 150 tph of (-) 24mm aggregates.Key features: The primary crusher of the plant is designed to take such feeds that are not run of mines (ROM) and still achieve the capacity of plant.Client's comments: As we and Puzzolana are both based in Hyderabad, we benefit by not having to keep high inventories of spare parts. We're happy with their services. We've been able to use their machines well and achieve optimum output levels. Now we've ordered eight [more] numbers for various road projects across India, says KS Ravi Kumar, Deputy General Manager - Resources, Ramky Infrastructure Ltd. CASE 5: Equipment: Powerscreen® H6203, one of four machines in the Powerscreen® H Range Vendor: Powerscreen®, a Terex brand.User: Fomento Group, a leading iron ore exporter with a presence in Goa and Karnataka.Project: At its major mines in and around Goa at Pissurlem, Kudegal, Navelim with extraction capacity at 20 mn tonne a year. Purpose: The machine features horizontal screens ideal for handling high volumes of materials for the exact fine sizing of high specification concrete or asphalt aggregates demanded in many construction contracts. It is also well-suited to coal and iron ore. The H6203 has an output potential of up to 800 tph.Key features: The adjustable elliptical throw combines linear and circular amplitude producing an aggressive screening action. Powerscreen® H products are especially effective for scalping after a primary impact or jaw crusher and are capable of screening out specific small sizes. The products also come with a high-capacity variable speed belt feeder, oil bath screenbox bearing lubrication, screen walkway and access ladder, hydraulic folding stockpiling conveyors, engine protection shutdown system, heavy duty triple shaft screenboxes with adjustable stroke, elliptical throw adjustable up to 19 mm (3/4), diesel hydraulic power unit, and heavy duty, low ground pressure tracks.Accessories: Options for the H6203 include radio-controlled tracking, dual power, roll-in bogie prepared and equipped, and variable speed incline apron feeder. “At present, growth opportunities stem from major accounts in the mineral and contractor segment, industrial minerals processing and road and dam contractors in India.” - RS Raghavan, Managing Director, Proman Infrastructure Services Pvt Ltd “We see maximum demand for crushing plants with a capacity between 200 to 250 mtph.” - Satya Raju, Deputy General Manager - Crushing & Screening, Sandvik Mining And Construction “The 1500 Maxtrak plant can accept an all-in feed from a primary crusher to produce up to 950 tph of aggregate.” - Rajen Khoda, Director - Sales, Powerscreen, South Asia And Middle East Ltd “Environmental norms stipulate the use of eco-friendly dust control systems, a key feature of our aggregate plants.” - GN Raju, Managing Director, Nawa Engineers & Consultants Pvt Ltd “Clients nowadays take into account the size of the plants, as they wish to cause minimum disruption to the environment.” - V Venkataramana, Vice- President, Puzzolana Machinery Fabricators Quick bytes: • The mineral sector is expected to generate a Rs 56,000 crore market for crushing and screening equipment.• The trend is now slowly shifting towards track-mounted mobile plants that can move as the quarry progresses.• Companies are looking at procuring equipment with green features to reduce their environmental footprint.• Most aggregate plants today are water-based suppression systems free.

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