World trend in Mining: Replacing fixed plants with mobile ones

Mineração Tamoio S/A – Indústria e Comércio de Agregados is breaking paradigms in the sector by implementing over 8 mobile crushing plants by Kleemann, which have a high production capacity and a reduced operational cost.

The Project

The project, which consists on the largest mobile crushing plant for the aggregates industry in Latin America, is located in Jacarepaguá, in Rio de Janeiro. It was structured by Kleemann for Mineração Tamoio S/A.

The choice of Tamoio Project happened with the visit and knowledge about the procedures used at other large miners of the world in North America, Asia, and Europe, in addition to the quality of Kleemann equipment and Kleemann’s know-how.

This change, which is already a trend throughout the country, allows for the reduction of operational costs of the jobs, considering that the high costs to transport the rock to the crushing plant no longer apply. Kleemann joins this initiative with mobile crushing and screening equipment.

Machinery

There are eight mobile crushing and screening machines by Kleemann added to the operations at Tamoio. Thanks to the use of those machines, the results achieved by this project, brand new in Brazil, reach the milestone of 900t/h, a record in production.

The use of such equipment offers, beside exceptional speed, mobility to do any necessary alterations. “The mobile plants, added to the commitment of the professionals, have contributed a great deal for the excellent results”, analyzes Orlando Lopes Ribeiro Neto, vice-president of Mineração Tamoio S/A - Indústria e Comércio de Agregados.

In order to ensure the correct use and maintenance of the equipment, there are meetings to talk about the project. In addition, there is also 24 hours assistance with professionals who dispose of a mobile repair shop for eventual problems and a huge storage of parts.

The equipment present in the project is as it follows:

  • Two conic crushers MCO 13
    With a production britador de mandíbulascapacity of approximately 400t/h, its total weight is 57.000 kg and its dimensions are 19.000 mm length x 3.550 mm width. The drive system is electric and it has a dust removal system. The power of the engines varies according to the application. It is mounted on tracks, which allows for mobility. The power of the conic crusher engine is of 400 HP.
  • Two conic crushers with three-deck secondary screens MCO 13S
    With a production capacity of approximately 400t/h, its total weight is 105.000 kg and its dimensions are 23.000 mm length x 3.550 mm width. With an electric drive system, it also has a dust removal system and it is assembled on tracks. The power of the conic crusher engine is 400 HP. The vibrating screen with three decks has 6.000 mm length x 2.350 mm height and a banana type slope.
  • Two three-decks mobile screens on tracks MS 23D
    It is made with high resistance steel and it has integrated traction on the tracks. Feeding is done through a conveyor belt. It has electric drive and a production capacity of up to 800 t/h. It is ideal for feeding materials with size of up to 200 mm. All functions can be locked electrically, inclusive the units of screening of upwards or downwards flow or the conveyor belts.

For primary crushing, the plant has the following models:

  • MC 120 Z – jaw crusher on tracks with pre-screening integrated system
    This equipment can also be used for concrete recycling. The discharge vibrating chute located below the crusher reduces the wear of the main discharge conveyor belt and considerably increases the operational safety of the equipment. The exclusive system of electric drive of the engines (except the traction drive and the adjustment of the gap width) allows for an operation with great economic efficiency. This system makes it possible to optionally connect it to an external power source, increasing its autonomy even more.
  • MC 140 Z – jaw crusher on tracks with pre-screening integrated system and hydraulic breaker attached to the feeding silo
    Specially projected to achieve high production levels, it has an input opening that allows feeding rocks of large dimensions. Double deck pre-screening has about three meters of length and engine with a power of 400 kW are differentials of this model. Weighting 54 tons, the jaw crusher is able to process feeding materials of up to 1300 mm x 1000 mm and to reach production ranges of up to 700 t/h, depending on the feeding material to be processed.

The operational cost is low when compared to competitors, with Dual Power drive concept, Kleemann’s mobile plants operate through an external energy source where they work both with electric network and diesel, in a way that the machine is adapted to the needs of the customer, and not the opposite. This method was created based on Kleemann’s policy of demanding the maximum evolution of all machinery produced.

For the case of the equipment used on Tamoio Project, the advantage is on the highest added value, thanks to its mobility, because when a job with mobile machines is completed, they can be reused in other projects.

In addition to be projected to optimize the continuous flow of material and generate final products of high quality, the robustness of Kleemann crushers ensures the stability and reduction of impact on the internal components. Those factors increase the lifetime of the system, which reflects on a lower operational cost of the plant.

To Orlando Ribeiro, vice-president of Tamoio Mining, all these qualities allow for the mobile crushers and screenings by Kleemann to bring high productivity and convenience, "We have an exceptional production speed, in addition to mobility to make any alterations that are necessary to us”.

Production

The productive capacity is the high point of the mobile crushing model, because it is able to reach the same levels of processing as the fixed one. In the case of Tamoio, that means 900 tons per hour.

Kleeman mobile units are projected to avoid early wear of the spare parts. This is possible, among other factors, due to scalp pre-screening, which results in the decrease of substitution of parts and consequently, on operational cost reduction.

Different from the fixed models, which take, on average, between assemblage and installation, 120 days for the beginning, the mobile systems are ready for production.

Importance of the Project

Kleemann equipment meets a demand of great relevance for the urbanization and infrastructure in Rio de Janeiro, being Tamoio the only supplier of crushed stone to the city. The crushed stone production, starting at the quarry, is the main input of civil construction and, for the specific case of Rio de Janeiro, the demands have been speeding up.

This way, all advantages presented by the mobile crushing and screening machinery reinforce the well-known slogan by Wirtgen, a company that always seeks to meet the demands and to be as close as possible to its customers.

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