Sepor, Inc. began business in 1953 with the introduction of the Sepor Microsplitter , a Jones-type Riffle splitter, developed by geologist Oreste Ernie Alessio for his own use in the lab. Sepor grew over the next several decades to offer a complete line of mineral analysis tools, as well as pilot plant equipment for scaled operations.
Nordberg HP Series cone crushers are characterized by the optimized combination of crusher speed, eccentricity, and cavity profile. This mix has proved revolutionary, providing higher capacity, better product quality and suitability to a wider range of applications.
From limestone to compact hematite, from ballast to manufactured sand production, and from small aggregate plants to large mining operations, Nordberg HP crushers are unbeatable in secondary, tertiary, and quaternary applications.
Nordberg HP crushers feature a unique combination of crusher speed, throw, crushing forces and cavity design. This combination is renowned for providing higher capacity and superior end-product quality in all secondary, tertiary and quaternary applications.
In a size-class comparison, Nordberg HP crushers have a higher output capacity, higher density in the crushing chamber, better reduction ratio, and they produce higher on-spec yield end products with the same energy consumption.
Nordberg HP crushers produce finer products by limiting crushing stages, which lowers your investment cost and saves energy. This is achieved through a combination of optimized speed, large throw, crushing chamber design and increased crushing force. The efficient crushing action of the best power utilization per cone diameter.
Designed for your needs, Nordberg HP crushers are safe and easy to maintain. Fast and easy access to all the main components from the top, and dual-acting hydraulic cylinders significantly reduce downtime and are more environmentally friendly.
Nordberg HP crushers are engineered to ensure maximum operator safety and easy maintenance. The crushers have an access from the top of the crusher to the principal components, an easy access for liner maintenance, and mechanical rotation of the bowl for removal with a simple press of a button. Maintenance tools are also available.
With Metso IC70C you can control maintenance, setting modifications, production follow-up and data extraction. All parameters can be adapted to your plant characteristics, and you can easily do all this close to the crusher or remotely from the control room.
You set the goals and Metso IC70C helps you reach them. It allows you to monitor the feeding, change the settings automatically depending on the load or liners wear, and select the product size distribution according to your preference of coarse or fine aggregate production.
Get the maximum potential out of your size reduction process to achieve improved crushing performance and lower cost per ton. By using our unique simulation software, our Chamber Optimization experts can design an optimized crushing chamber that matches the exact conditions under which you operate.
Each company or site should have clear safety guidelines outlining best practices for the entire site, as well as when working with crushers. Before even stepping on site to work with your sites crusher, employees and operators must be trained on all safety procedures of your site and crusher.
For instance, is the operator clear on warning signs to look for, emergency stop locations and appropriate walkaways? Make sure the operator or maintenance personnel perform a hazard analysis before each new operation. Conditions such as time of day, weather and area around a piece of equipment can all affect the operation about to be performed.
It is also a good idea to have a fresh set of eyes look at conditions. Even when someone is experienced and well trained, it is very easy to see the same thing day after day and accept the way things are or even miss something.
The aggregate industry is heavily regulated, but regulations alone will not make managers, workers, contractors and others safer or better safety stewards. If a company wants to achieve high safety and environmental standards, that company and the communities in which it does business cannot achieve these goals through fear of retribution for non-compliance.
To be successful, the industry must rise above the mentality that it is simply complying with regulations, inspections and penalties, and instead focus on these areas because it is the right thing to do. A good place to start is to provide effective signage, keep the site clean, walk the site daily and maintain quarry faces and haul roads.
Dont allow yourself to turn a blind eye to a hazard or a hazardous situation. Dont allow yourself to say, Its not my job or Im not the one who left it there or someone else will fix it. Every incident, accident or event should be investigated. Through these investigations, recommendations should be made to improve safety and to prevent the event from occurring again.
While new technologies and equipment are emerging every day to make the workplace safer, your best resource is your workforce. Its not only important to make sure employees are trained on the safety procedures of the workplace, but also on the proper use of their machine.
Untrained, unknowledgeable work staff can lead to an unsafe work environment. Just because a person is on your site working with other equipment doesnt necessarily mean they are trained on the proper use of a crusher or a breaker. Do they know proper feed size and capacity? Not knowing these can lead to oversized material entering the crusher and cause malfunction.
Safety on a crusher starts with the person feeding the plant. The person feeding the plant needs to be trained on best practices specific to the crusher they are working with. An operator may have years of experience operating and loading a cone crusher, but that doesnt translate into experience loading and operating a jaw crusher.
Operators need to be trained on what to look for to prevent unnecessary maintenance. Spending the time and resources to train your operator not only leads to a safer workplace, but it ultimately increases production. The safer you are, the more productive you are.
When operators proactively keep their crusher running safely and effectively, they increase production. A couple of minutes spent on cleaning or maintenance can lead to hours of productivity later and an overall safer working machine. Operators should also keep detailed records of maintenance and other issues.
Make sure your operator is in protective clothing. Also, when you reach the crusher, make sure all guards and safety devices are in place, secured and functional before operating. Be sure to review and follow all lockout, tagout and tryout procedures for the crusher when performing equipment maintenance, repairs or adjustments.
Additionally, keep your crusher working safely and efficiently by performing regular maintenance inspections. This allows you to pinpoint problems that may make the machine unsafe to use. Some tips to keep a safe crusher: Operate at the appropriate capacity. Keep platforms and areas around the machine clean. Ensure lubrication, flow, temperature, wear and pressure are monitored.
Safety is something that can be practiced and planned daily, monthly and yearly. Try to make yourself or your workspace safer every day. Clean up hazardous debris. Walk to your workstation a different way to see if you notice anything unsafe.
In our industry, hazards are everywhere due to the nature of our business and the equipment and tools we use. When less-than-desirable housekeeping practices are present, they add unnecessary hazards to the workplace. Housekeeping takes a lot of time if it is practiced once in a while, but it takes virtually no time at all if it is practiced continuously.
Its important to make sure your crusher operator follows all operational guidelines and that all safety best practices are in place. But also take the time to make sure your entire site is properly trained on site safety procedures and best practices. Hold regular safety meetings to review new procedures or address any safety concerns. Set yearly safety goals and commend operators on years of safety excellence.
After securing the chain around the rock in the crushing chamber, a man still in the chamber tells the loader operator to lift the rock. The operator lifts it about three feet into the air when, suddenly, the chain snaps. The rock plunges back into the crusher, missing the mans leg by a matter of inches.
Stories like these involving crusher blockages unfortunately still happen in the industry. Fortunately, this particular event unfolded without an injury. Still, an inch or two one way or another can often make the difference between a safe trip home from work and no trip home at all.
Ive heard and read stories about guys getting killed, says Paul Smith, international marketing manager for Astecs Aggregate and Mining Group. These machines can be deadly. After 20 years of climbing into quarries, I still keep my head on a swivel.
Aggregate producers cant control all of the factors that lead to accidents related to crusher blockages. They can, however, create a work environment and culture that best positions people to return home from work every day.
To Smith, one of the key factors that should be addressed related to crusher safety is a companys workforce. A number of people operating and working around crushing equipment dont have the adequate experience, he says. Producers and recyclers sometimes turn to a transient workforce, and that can present problems.
Our industry is so much about tribal knowledge, Smith says. Were still relying on grandpa to educate a grandson to operate a plant. Or, were adding crews to do short-time jobs and leaning on temporary labor.
Effective operators and contractors tend to put one of their best teams on crusher duty because they realize production starts and stops with these workers. But teams often consist of just two people a loader operator and a plant operator. A third person can make a difference in a number of areas, Smith says.
Its a luxury to have a third guy, but I would argue that having a guy at $15 an hour on the ground pays for itself, Smith says. Maybe this is the new guy whos being trained, or its the boss son. I do know that if that guy prevents a cone crusher from going down and losing a thrust bearing once or twice a year, hes going to pay for himself.
Operating a crusher at 90 percent efficiency versus 80 percent or less will boost a companys bottom line, as well. A third person focused on the crushing operation should improve efficiency, Smith adds.
Use a 30-[in.] x 54-[in.] jaw for example, he says. Take 80 percent of the first number thats 24 in. Thats the lump size you want to put into that crusher. Size the crusher to the size of the material. If you want to have max production, youll pay attention to those rules.
The workforce isnt the only area producers can focus on to avoid crusher blockages and enhance safety related to crushers. The most economical form of crushing is blasting, Smith says, so tighten shot patterns to reduce the amount of oversized material.
Its very practical to have a rock breaker right next to the primary crusher, says Ilkka Somero, Metsos product manager for jaw crushers. Often, you dont even need to break the rocks. Its enough to pull or push the rocks a little bit. Then the materials flow again.
Breakers and hydraulic hammers attached to excavators are also useful to reduce oversized material that can be loaded into a crusher, Somero adds. Smith suggests prepping material with a grizzly feeder if possible, as well.
Still, theres an additional cost associated with a grizzly, he says, as there is with a breaker. A sensor is yet another option for operators to alert themselves when oversized material is present in the feeder. Sensors obviously wont pull a large rock from the crusher for you, though.
They still cause the operator to react, Smith says. The oversized piece of material still has to be extracted. You have to shut down the plant. Its not a perfect solution, but it does help you from plugging the crusher.
Crusher design is another area some manufacturers have focused on to help producers and recyclers avoid blockages and create safer work environments. Sandvik, for example, addresses the blockage issue with its Prisec horizontal shaft impact (HSI) crusher.
According to Rowan Dallimore, an impact crusher manager at Sandvik, the Prisec model can be cleared while the crusher is running. To clear blockages, Dallimore says users stop the feeder and activate the hydraulic system. This lifts either the first or second curtain, allowing a blockage to pass through the crusher.
Once the blockage has been cleared the curtain can be lowered, and they will reset automatically into the previously set position with the hydraulic system switched off and the feed re-started by the crusher, says Dallimore, who estimates that the Prisec clears about 90 percent of blockages without having to stop the crusher. All of this is done with the crusher still running and no operator intervention inside the crusher.
Such a system saves users considerable time, too. Clearing a blocked crusher can take an hour or more, Dallimore says. He estimates that a typical blockage occurs in a stationary plant between five and six times a year, with mobile crushers experiencing even more blockages.
With the recycling business we never know what were going to crush within reason, Dallimore says. When its on a tracked mobile unit, they can be on one site one week and on a completely different site crushing completely different material the next week.
These dont necessarily behave well in a crusher, Smith says. You have the potential to rip belts; for stuff to get hung up at the bottom of the crusher. Or, it might block the discharge part of the crusher and you get buildup in that area.
Every producer is encouraged when they start up a new plant to baby the plant for a period of time, he says. See how the equipment handles that material. If they move it to a second location, things like moisture index change.
Ive read a story about a guy inside an impact crusher on a recycle job, Smith says. The door of the impactor was open, and he was inside it cleaning off some of the asphalt buildup. While in there, he motioned the guy to turn the impactor a little bit. When the guy did that the impactor came up to full speed, and the guy got chewed up in a matter of seconds.
Some of these machines behave like Swiss watches: They require a certain amount of oil, Smith says. We do a lot of things to safeguard and keep bad things from happening, but you still need to find, hire and train the right people. We really need to do that.Get in Touch with Mechanic