Kleemann

To obtain final products for the production of asphalt, a PRO plant train from Kleemann is being used on the twin island state of Trinidad & Tobago: the mobile jaw crusher MOBICAT MC 120 Z PRO and the mobile cone crusher MOBICONE MCO 11 PRO. The mobile screening plant MOBISCREEN MS 953 EVO rounds off the process in the limestone quarry.

The good quality of the final product and simple line coupling of the individual machines to form a plant train were decisive criteria for the selection of the plant technology. With the PRO plant train from Kleemann, the uncomplicated coupling of the machines and the automatic processes tuned to one another facilitate operation.

Availability and output doubles thanks to line coupling

The plant train consists of three machines whose technical processes are coupled to one another (Figure 2). Thanks to the automated tuning, the burden on operators is reduced, the process is harmonised and therefore stabilised. Each machine basically operates independently but forwards signals to the upstream and downstream machines in the event of malfunctions or overfilling of feed material. The feed control Continuous Feed System (CFS) also guarantees optimum utilisation of the crushers, which are therefore loaded evenly with material. Furthermore, the connection of all machines guarantees safety: if an emergency stop is pressed within the plant train, all plants are stopped immediately. This concept prevents damage or overload situations.

During operation in Trinidad & Tobago, with the help of the line coupling the company performing the work was able to double the availability and output compared to the plants previously used in the quarry.

Personnel deployment was also more efficient. Normally one operator per plant is used, plus the excavator driver. Line coupling now allows the complete process to be controlled by two operators instead of four. The other two employees can therefore perform other tasks parallel to production, such as material provision or also logistics in the quarry.

Intuitive operation – under special conditions

After delivery of the new plants in September 2020, the project had to face the special challenge posed by the Covid-19 pandemic: the plant train had to be put into operation online without local supervision. How well plant start-up functioned in spite of these adverse conditions was shown after a year: there were no significant problems and the machines and crushing tools revealed hardly any wear. On the one hand, the long lifetime of the components resulted because the material was not so abrasive. On the other hand, due to a very finely tuned process and therefore the optimum material flow.

The SPECTIVE operating system makes its contribution to a trouble-free start-up because it can be operated easily and intuitively. The visual presentation and logical user guidance make errors almost impossible. Thanks to its simple operation, several employees received instruction in the use of SPECTIVE at the same time. High flexibility in work with the plant was therefore guaranteed right from the start.

Simple maintenance and care

The advantage for maintenance is that the components of the crushing and screening plants are very easy to reach. All positions can be accessed without any problems and without significant disassembly work. Regular maintenance of the plant train is therefore made easier. The simple screen media change with the screening plant MOBISCREEN MS 953 contributes to smooth operation. “Above all, we appreciate the readiness to find practical solutions. We already experienced good co-operation with the other brands we have from Wirtgen Group”, says Kyle Parsons, the Project Manager in charge at Jusamco Ltd. We know for sure that the contact partners on site can always provide professional support and guarantee a parts supply.

Further information:
Wirtgen SE
www.wirtgen-group.com

At this year’s bauma, Kleemann presents innovations from its comprehensive product portfolio with a total of nine mobile crushing and screening plants and its operating concept SPECTIVE. A world premiere is celebrated by the new impact crusher MOBIREX MR 130(i) PRO.

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World premiere for new PRO line plant

With the impact crusher MOBIREX MR 130(i) PRO, Kleemann presents a new family member from the PRO line. The plant is used as a primary and secondary crusher and combines output, precision and sustainability.

Thanks to its all-electric drive concept with the option of an external power supply and therefore CO₂-free operation, the plant guarantees low energy consumption per ton of final product. The optional large double-deck secondary screening unit permits the production of two classified final grain sizes. The MR 130(i) PRO covers a very wide application range in natural stone and recycling. With its heavy rotor and powerful electric 250 kW drive, the crushing unit guarantees a very high and stable throughput. A continuous crusher load is guaranteed by the Continuous Feed System (CFS).

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Operating concept SPECTIVE with new functions

The innovative operating concept SPECTIVE includes various components that are ideally tuned to one another and accompany the machine operator during the entire working day. Apart from the intuitive touch panel and different radio remote controls, the digital application SPECTIVE CONNECT, above all, supports the work site digitalisation. All relevant process information and reporting are now displayed on your smartphone without having to leave the feeding device. SPECTIVE CONNECT has new features, which will be presented at Bauma and which make work for the operator even easier. A new configuration tool, for example, supports the operator in the selection of the correct machine settings.

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Kleemann screening program extended

The new MOBISCREEN MSS 802(i) EVO has been designed as a powerful mobile screen for coarse elements for changing challenges in different applications. With its clever plant design and flexible conversion options, it guarantees an optimum material flow in natural stone and recycling applications. The large range of screen surfaces and simple setting of screen parameters make it possible to adapt the MSS 802(i) EVO easily to new application conditions. If a fine final product is to be screened from particularly coarse feed material, the plant can be quickly converted from three to two final grain sizes. Further advantages of the plant include its simple operability thanks to its intuitive control system, easy access to all relevant machine components and its drive concept with the option of an external power supply for emission-free and therefore environmentally sound work.

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EVO2 line for flexible application possibilities

The plants in the EVO2 generation demonstrate that output, efficiency and flexibility belong together. The latest members of the product line – the jaw crusher MOBICAT MC 110(i) EVO2 and the cone crusher MOBICONE MCO 90(i) EVO2 – will be presented together to the public at Bauma with line coupling. Both plants have an efficient drive concept and intelligent overload systems. Operation is simple thanks to SPECTIVE and SPECTIVE CONNECT.

The EVO2 line also includes the mobile impact crushers MOBIREX MR EVO2.  The plants impress with flexible application options in natural stone and recycling. The SPECTIVE operating concept ensures simple, intuitive control. The new feature here is that SPECTIVE CONNECT is now also available.

Further information:
WIRTGEN GROUP
www.wirtgen-group.com

Avoid downtimes with effective overload systems

In rock and stone processing, during the crushing process various short-term or prolonged overload situations can arise. The overload systems of the MC 110 EVO2 and MCO 90 EVO2 pursue an important goal: increase in the operational readiness of the plant in a sustainable manner by guaranteeing a crushing process that is as continuous as possible. Both crushing machines are equipped with mechanically and software-supported overload systems.

 Overload system on the jaw crusher MOBICAT MC 110(i) EVO2

With its multi-stage overload system, the jaw crusher MOBICAT MC 110(i) EVO2 provides more safety with uncrushable material. If, for example, metal enters the crushing process, the crushing gap (CSS) opens automatically in up to two seconds over the complete gap range. The crusher itself does not have to be stopped during the temporary overload situation, which means that the crushing chamber is empty and manual clearing of the crusher is not necessary which saves work and time. When the overload situation is corrected, the system then moves back to the original crushing gap and the crushing process is continued. The pressure plate installed as a predetermined breaking point is preserved. The consequences are reduced downtimes and increased crushing capacity.

Overload systems on the cone crusher MOBICONE MCO 90(i) EVO2

The cone crusher MOBICONE MCO 90(i) EVO2 has two different systems installed. The overload system “Tramp Release” protects the crusher against uncrushable material such as wood or metal. The bowl including the bowl liner lifts automatically to allow uncrushable material to fall through. The “Ringbounce Detection”, on the other hand, reacts to an excessively high share of fines in the feed material and prevents “briquetting” – which means the clogging of the crusher or sticking together of the material. Here, the hydraulic pressure of the crusher is monitored continuously. The system reacts as required and therefore prevents latent overloads. Depending on the machine application, the “Ringbounce Detection” can be oriented via the control system to output (“Mixture Mode”) or product quality (“Precise Mode”).

By preventing machine damage and thus production downtimes, the overload systems from Kleemann therefore guarantee increased operational reliability for the users.

Further information:
WIRTGEN GROUP
www.wirtgen-group.com

Environmentally sound combined with an economic solution – The jaw crusher MOBICAT MC 110(i) EVO2 and the cone crusher MOBICONE MCO 90(i) EVO2, with their efficient crusher direct drive, have a holistic drive concept that forms the basis for high cost-effectiveness.

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Crusher direct drive with electric auxiliary drives – fuel-efficient and quiet

Both machines of the new EVO2 generation are equipped with a patented power train. The crusher is driven directly, enabling high fuel-efficiency, via a reliable fluid coupling. Conveying components, such as the vibrating feeder, the double-deck prescreen or the discharge conveyors, are all-electric. A robust and easily accessible gearbox guarantees efficient power transmission. It not only operates with a high level of efficiency but also has ideal protection against dust. Downtimes can be avoided to a large extent. The power and load-dependent fan drive also ensures low-noise and economical operation. Operation in ECO mode can additionally reduce fuel consumption as well as wear in idle phases. The plants can be optionally equipped with a heat package (-15 to + 50 °C) or cold package (-25 to +40 °C). The cold package has an autonomous auxiliary heater with a convenient timer function.

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Environmentally sound operation – less noise and dust

In the new drive concept, the speed of the cooler fan and therefore also the cooling capacity is controlled automatically, which considerably reduces the noise level. Apart from less dust penetration thanks to a lower volume of moved cooler air, work near to the machine is a lot more agreeable for the operator.

For the jaw crusher MOBICAT MC 110(i) EVO2, which is frequently used in urban environments, an optional noise protection package is also available. The considerably reduced noise level would even permit work without special ear protection – depending on the material to be processed, further environmental conditions and local regulations.

To reduce dust, the machines are equipped in the standard series, among other things, at the crusher inlet and crusher discharge conveyor with water nozzles and the corresponding technical infrastructure. As a result, an optionally available water pump or an external water source, if available, can be used. Optional belt covers also contribute to an improvement of the air quality during crushing.

These measures benefit the machine operator, the further peripheral devices on the job site, local residents and the environment.

Further information:
WIRTGEN GROUP
www.wirtgen-group.com

The new MOBISCREEN MSS 802(i) EVO offers users a mobile, efficient screening plant that was designed to meet changing challenges in different application areas. With its well-thought-out plant design and flexible conversion options, Kleemann demonstrates how a high material flow can be guaranteed in natural stone and recycling applications.

Screening made easy

With the development of the MOBISCREEN MSS 802(i) EVO, a new generation of screening plants and successor of the MS 15 Z, Kleemann consciously places the focus on the user perspective. The technology behind the screening process must be easy and safe to use for all users. The new plant impresses not only with technological highlights in the process sequence, but also through its ergonomic design, optimised operation and the user-friendly maintenance concept.

Improved mobility and flexibility in application

With its proportionally controlled running gear, the plant can be quickly relocated either by a low-loader to the job site or within the building site. Apart from other improvements of the new MSS 802(i) EVO, folding of the side discharge conveyors without the need for disassembly clearly reduces set-up times. Increased application variability is provided by a hopper rear wall that can be folded to three heights, which permits feeding of crushing plants with a lower discharge height. The large offer of screen surfaces and simple adjustment of the screen parameters, which make rapid adaptation of the MSS 802(i) EVO to a very wide range of feed materials possible, reduce set-up times and thus personnel requirements and costs. The screen casing angle with a wide adjustment range from 15.4 – 20° makes optimisation of the screening capacity possible. Special highlight: the simple and fast conversion from 3- to 2-way grit. The MSS 802(i) EVO can therefore be used to produce and discharge two or three final grain sizes and the conversion is fast and simple.

Operability and ergonomics for more comfort and safety

An intuitive plant control with automatic start reduces the risk of operating errors and saves learning times. All relevant functions can be operated from a safe distance, which offers high work safety. Further user-friendly aspects include very good access options and intelligent cleaning solutions, which minimise downtimes caused by maintenance. With all of these solutions, Kleemann placed the focus on the typical workday of users. This also applies to the standard series LED lighting, the optionally available extended premium lighting of work areas or the generously proportioned work platforms.

Efficient and precise process sequences for optimum material flow

An optimised material flow is a central aspect of all screening plants. Only if all components are tuned to one another can high productivity with minimised operating costs be achieved. With its new mobile screen for coarse elements, Kleemann demonstrates what screening plants of the latest generation can achieve. This includes a wide crusher discharge conveyor on which, like all of the other conveyors, the speed can be steplessly adjusted, as well as a large material transfer system to the screen deck for optimum utilisation of the screening surfaces. High discharge heights and thus higher stockpiles thanks to the optionally available extended crusher discharge conveyor and telescopic side discharge conveyors guarantee ideal processes on the building site.

It goes without saying that the new MOBISCREEN MSS 802(i) EVO can be operated through line coupling with all EVO and PRO crushing plants integrated in the process and safety system. Special application flexibility is provided by the stockpile probe required for the process coupling, which can be placed on any discharge conveyor of the plant.

Further information:
WIRTGEN GmbH
www.wirtgen.com