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Application presentation.

Application presentation. What is it.? This is a THIRD stage crusher. It can be used a stand alone crusher but the feed must be controlled for size. What can it do?

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Application presentation.

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  1. Application presentation. • What is it.? • This is a THIRD stage crusher. It can be used a stand alone crusher but the feed must be controlled for size. • What can it do? • Reduce feed material from 75mm down to >20mm and all product down to 0 i.e. 20mm, 14mm, 10mm, 6mm, 3mm sand. As all crusher you must use a screen for this. • Also used in producing ´all in` products i.e. 20 to 0 mm or 40 to 0mm or 16 to 0mm. • Can be used as a pre crusher for ball mills and heap leaching operations.

  2. Power consumption. • OM 50 Maximum power is 200kW / 275 hp • Example  OM50 throughput 100tons • Power used is 150kW/200hp for 100 tons • There for 2 hp per ton. • Aggregate production is 2.5 hp per ton. • Sand production is 4.4 hp per ton. • OM 80 maximum power is 320kw/440 hp. • Example OM 80 throughput 200 tons. • Power used is 220kW/340hp for 200 tons. • There for 1.7 hp per ton. • Aggregate production 2.1hp per ton. • Sand production 4.8hp per ton. • OM 100. Maximum power is 500kW/660hp. • Example. OM100 throughput 400 tons. • Power used is 400kW/660hp, • There for 1.65hp per ton. • Aggregate production 2.0 hp per ton • Sand production 3.7hp per ton

  3. Summary. • Throughput power requirements are between 1.65 / 2hp per ton • Aggregate power requirements are between 2.0 / 2.5hp per ton • Sand power requirements are between 3.7 / 4.8hp per ton.

  4. Barmac Duopactor • Barmac only make 3 port rotors in varying sizes from  12” to 40”. All rotors below 27” are for special mineral machines very small and not good for quarries. • To get access to the rotor you need a crane to remove the lid (4 bolts) and the cascade assembly.  This will take about 1 hour and two men. With the rotor out you then have to remove 27 bolts (18 are special bolts from Barmac) to change the wear parts. Wear parts are cheaper than Ore Sizer but have a life of 50 to 60 % of the Ore Sizer parts. • Some wear parts are cassette type but not the tip plates trail plates and deflector plates. On most rotors these have two bolts each and on the new one there are three. • Barmac have Cascade system to bypass the feed to the rotor. This will work but only up to 12 % in Cascade. Very few machines benefit from this with some success with very week material. Most machine do not use the cascade as this REDUCES the crushing action. • Machines are manufactured in New Zealand. • Two men. 3 hours. For the rotor change only. • 41 bolts. • 6 tools ( two are special from Barmac) plus welding and rebalancing tools. Estimate 4 hours for welding and balancing. • Rotor requires repair with welding and rebalancing. • Customer not so happy!

  5. Sandvik Merlin. • Sandvik only make 2 size of 3 port rotor 33” and 39”. These rotors are very light construction and have many problems with high wear. Each tip has three bolts. There are the same number of bolts used in the assembly of there rotors as well as some need for welding repairs and balancing. Wear parts are cheaper than Barmac but only last 70 to 80 % of the life due to the fact they are smaller and lighter. • Access time is the same as Barmac and cost is the same or slightly higher due to more man hours. • Machines are manufactured in Turkey we think! The first 10 machines we bought from Barmac!! • Sandvik have a Bi Flow system. Similar to the Barmac Cascade with the same results – REDUCED crushing. • Two men. 3 hours. For the rotor change only. • 41 bolts. • 6 tools plus welding and rebalancing tools. Estimate 4 hours for welding and balancing. • Rotor requires repair with welding and rebalancing. • Plus one magic wand in a little white box to make the Merlin work! • Customer not happy !

  6. REMco. • Remco machine was developed at the same time as Ore Sizer. This is basically a good machine but more bolts in the rotor than Ore Sizer (12 more). Remco make 3,4,5,6 port rotors in 5 different sizes. Each machine is individual there are not many machines the same – customers are confused with large range of options and different rotors. When we asked the owners of Remco about this they said the idea was to confuse the customers so they were afraid to go to another supplier. They claim to be the Experts.  Customer support is from California USA from one man – the owner. Wear part life is close to Ore Sizer but no new technology is coming through. Ore Sizer is now converting the last two Remco machines in Europe to Run with Ore Sizer rotors. • Access is by hydraulic lid and is quick (15 minutes) Rotor removal is same as Ore Sizer. Remco rotors require re-welding and Balancing. • Machines are now manufactured in China. • Two men. 1hr 30mins. For the rotor change only. • Between 29 to 41 bolts. • 6 tools • Plus welding and rebalancing tools. Estimate 4 hours for welding and balancing. • Rotor requires repair with welding and rebalancing. • Customers are fairly happy.

  7. Ore Sizer OM Series. • Ore Sizer rotors are 3,5,6,7,and 8 port in sizes of 29”(3and 5 port) 35” (3,5and 6 Port) and 40” (3,5,6,7 and 8 Port) • All wear part except two are cassette type NO BOLTS. A total of three bolts are removed to access the rotor. Two on the hydraulic ram top and one on the side door. To remove the rotor another 13 bolts are removed and the rotor is ready for lifting out. Wear parts life is greatly increased due to new technology and continuing investment in development. Mina mum increase in life compared to Barmac is 50% Maximum achieved to date is 320%. • Ore Sizer has advanced chamber development to increase crushing action. • Access time maximum 15 minutes. Rotor removal will be 30 minutes. Rotor wear part change 30 minutes. Replace the rotor 30minutes. • Machines are manufactured in Brazil by Furlan. • ONE MAN 1h 15 mins. • 20 bolts. • Three tools. • Rotor needs No welding and No rebalancing. • Happy customer!

  8. Summary. • Barmac. • Medium production. • Medium Machine availability. • Medium own time • High repair time • High operation cost

  9. Summary. • Sandvik. • Medium production. • Medium Machine availability. • High down time • High repair time • High operation cost

  10. Summary. • Remco. • High Production. • High Machine availability. • Low down time • Medium repair time • Medium operation cost

  11. Summary. • Ore Sizer. • High production. • High machine availability. • Lowest down time. • Lowest repair time. • Lowest operation cost.

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