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New lighting range targets explosive environments »

Managers of hazardous industrial plants know only too well the huge time losses and cost implications that result from shutting down operations in order to replace faulty lighting. A new range of high-powered LED lights launched today offer a much needed solution.

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Offering more than seven years of 24h continuous usage, NeoBulb’s new Escort ATEX range are said to have up to 10 times the lifespan of existing commercial ATEX lighting solutions. Crucially for hazardous industries, the new range will help considerably reduce manufacturing downtime and resultant operational losses.

Designed specifically for industries that have to deal with explosives, extreme temperatures and ignitable particles, the NeoBulb Escort ATEX range offers a 70% energy saving compared to existing solutions. This provides energy-intensive industries a simple and cost-effective mechanism for achieving challenging energy reduction targets.

NeoBulb Escort ATEX lighting fixtures bring all of the benefits of high-quality LED lighting – long, maintenance-free life, excellent efficiency and incredible durability – to heavy industry applications.

The high-power LEDs are ATEX compliant, meaning they are suitable for environments with flammable vapours, ignitable dusts, corrosive, wet, dusty, and extremely hot or cold conditions.

Simon Leggett, managing director of OCG Lighting, who have exclusive distributor rights for the range in the UK, commented: ‘The NeoBulb Escort ATEX is an important addition to our product portfolio, extending the range of industries that can benefit from our innovative LED technology.’

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Kelston Sparkes choose RDS Technology again »

Kelston Sparkes, the plant hire and sales group founded in 1952, have taken delivery of two Loadmaster 8000iX systems fitted to Volvo L110G loaders. Kelston Sparkes are long-term customers of RDS South West who supplied their very first Loadmaster 5000 system to Kelston back in 1994.

Loadmaster has benefitted from more than 17 years of continual development at RDS Technology’s headquarters in Stroud, Gloucestershire, and the latest 8000iX model benefits from additional standard features including temperature compensation to enhance system performance particularly on loaders with a wide variation in operating temperature and angle compensation providing an additional level of precision which is said to be beneficial on most sites.

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The Volvo L110Gs will join a fleet of 20 loaders and be put to work within Kelston Sparkes’ crushing and screening division deployed on a wide variety of sites including one of the company’s specialist areas, serving the South West quarrying industry particularly in the Mendip Hills.

The Loadmaster system brings a range of operational benefits. Commenting on the systems effectiveness and service from RDS South West, Alan Sparkes, managing Director said: ‘Loadmaster is an integral part of the ‘load out’ process. Trucks are accurately loaded at the face eliminating return trips from the weighbridge and therefore maximizing productivity. I have a positive working relationship with Roger Hawker at RDS South West, he knows what we want and is always available on the end of the phone.’

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How to Choose Crusher for Quarry »

How to Choose Crusher for Quarry

Factors should be considered to choose crusher

Mining technology has been highly development in the modern time, there are so many types of crushing machines in the world market. If you want to set up a new quarry or crushing plants. It is very important to know how to choose a right crusher for your quarry or projects. There are many factors need to be considered when you choose a crusher.

Ore characteristics for choosing crusher

Ore characteristics are a critical element in both crusher selection and plant design. Dry ores require greater provisions for dust suppression and collection, including dust enclosures around screens, sealing on conveyor skirts, and vacuum and wash-down systems. Wet, sticky ores can plug chutes, reduce surge capacity, and decrease the live storage capacity of bins and silos. To address this problem, chutes must be easily accessible for clean-up, and large feeder openings must be provided for bins, silos and tunnels. If it is practical to obtain representative ore samples, it is prudent to have testwork conducted to establish ore flow properties, which will influence design parameters. At virtually all mines, ore characteristics change over time, and it can be costly to “design in” the optimal flexibility required to handle such changes. Some owners stipulate that initial capital investment be kept to a minimum, with design modifications paid for out of the operating budget. This is not always easy to achieve.

Popular crushing plants

There are many different types of crushing plants available in the market. Jaw crusher is the most favorite crushing plant in primary crushing. PEW jaw crusher is a newly designed crushing plant on the basis of traditional jaw crusher, PEW jaw crushers are based on a revolutionary modular, non-welded frameconstruction. This design offers owners the highest possible fatigue strength, excellent reliability and numerous mounting possibilities. This design combining with high-quality caststeel components and premium spherical roller bearings, means exceptionally high crusher availability, cost-efficient crushing and low cost per ton.

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Four Unique features of Single Roll Crusher »

Four Unique features of Single Roll Crusher

single roll crusher There are many different types of crushers for mining industry nowadays, such as jaw crusher, cone crusher, impact crusher etc. Single roll crusher is a great choice for many quarries and mining industry, because it has many benefits. Single roll crusher plays important roll in primary crushing stage. With it is unique design and high performance, it is welcomed by most quarry operators. Here are some unique features of single roll crusher.

Safety Guard

Where used, the automatic toggle relief mechanism is completely guarded by hinged access doors. Operation of these doors is controlled by a hazardous-location limit switch, which when wired (by others) in series with the motor holding coil will discontinue electric power to the crusher when the doors are open. Countershafts are also covered with personnel access guards. Steel sectionalized protective V-belt drive guards and sealed oil bath gear guards can be provided. The Cobra Single Roll Crusher can be provided with an open atmosphere gear guard when standard gear lubrication compounds are utilized for this crusher.

Protective Device

Roll and countershaft bearings can be equipped with temperature warning devices, which can be connected to an alarm system, or automatic shut off devices. Zero speed switches to monitor the operation of roll or countershafts are also available.

Lubrication

Dust proof fittings on roll and countershaft bearings ensure effective lubrication. The hinge shaft at the top of the crushing plate and steel toggle mechanisms, when used, are equipped with industrial grease type fittings. Distribution blocks are provided as grease lines are banked to a common location on each side of the crusher frame in order to facilitate maintenance. As an option, an automatic lubrication system to all bearings and lubrication points can be supplied.

Automatic Toggles—Advanced Protection Against Uncrushable Materials

When the compressive strength of an uncrushable material is higher than the combined forces holding the curved crushing plate in position relative to the crushing roll, the automatic toggle mechanisms provide relief by allowing the curved crushing plate to move back and allow tramp iron and similar uncrushable material to pass through the crusher. The toggle and spring mechanisms instantly return the crushing plate to its original position assuring a minimum passage of oversize material. There are no shear pins, blocks or bolts to break or be replaced. Continuous operation is assured. Utilizing spring-loaded toggles assures that the crushing plate is either fully closed or open momentarily to pass tramp material within reasonable size. The toggle relief mechanism can be set at any desired resistance simply by adjusting the compression of the coil springs. Reasonable effort should be made to remove excessively large tramp material ahead of the crusher. SBM machinery is a global manufacturer and supplier of technology and services for mining and beneficiation equipment. We provide high advanced different types of crushers, our single roll crusher is designed in unique structure and high quality materials, it shows excellent performance in crushing process, and create much wealth for our customer.

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Hammer Crushers for cement industry »

hammer crusherCement industry has made tremendous strides in technological upgradation and assimilation of latest technology. the cement production requires widely different properties of raw materials. The limestone deposits used today as base material with very different characteristics regarding hardness, abrasiveness and stickiness. To optimize the crushing process as well as minimize the investment and operating costs, there are many different types of crushers for choice. Several important points should be considered in advance to make a proper selection.

The main crushing process of a Double Shaft Hammer Crusher is performed by rotating hammers between the rotor and on the anvil.

It is important to understand, that the material is not ‘ground’ on the grate baskets. The grate baskets calibrate the material grain size by different openings, in order to produce raw material either for ball mills (0/25 mm) or vertical mills (0/80 mm). Double Shaft Hammer Crushers are used in the cement industry to solve crushing problems in difficult materials like wet limestone combined with clay. This capability to operate under such severe conditions without clogging problems is achieved by the self-cleaning effect of this machine, which results from the fact that the material is mainly in contact with rotating elements. Only the grate basket to calibrate the final grain size is fixed but also cleaned by the rotating hammers. Of course the entire crushing chamber geometry, the design of the anvil and the grate baskets have to be optimized and adapted to avoid clogging problems. Impact Crushers and Single Shaft Hammer Crushers crush the material by impact of the blow bars or hammers and by throwing the material against fixed side walls, which are not cleaned. The Double Shaft Hammer Crusher works like a Double Roll Crusher, where the material is only in contact with moving, self-cleaning crushing tools. The ability to crush sticky materials allows the simultaneous feeding of several materials by means of two or three apron feeders, causing a pre-homogenization within the crusher.

Other crushers

Double Roll Crusher and RollSizer

Despite of their low crushing ratio both Double Roll Crusher and RollSizer are used in the Cement and lime Industry. Unlike the impact and hammer crushers with their high rotor speed, the roll crushers operate at low speed, producing a minimum of fines content. This fact makes these machines especially suitable for the lime production, where a maximum of stones for the kiln is required. But also under difficult conditions like extremely sticky (clay) or abrasive (clinker) material this type of system is the perfect solution, thanks to low operating speeds and non-clogging effect. Because limestone is mainly not very abrasive or extremely sticky it can be crushed in one step and the Double Roll Crusher and the RollSizer are rarely installed as primary limestone crusher. But especially regarding additive processing they are important, in order to achieve an economic crushing solution.

Jaw Crusher and Gyratory/Cone Crusher

Jaw Crushers and Gyratory/Cone Crushers are the perfect choice for hard rock applications. They can be used for very abrasive but dry and non-sticky materials with a compressive strength of up to 400 Mpa. Their crushing ratio is relatively low, compared to Impact and Hammer crushers, thus for primary limestone applications a two step crushing system is necessary. Because of that, they are rarely used for the production of main material for raw mills. Just like Roll Crushers these systems can minimize the fines and maximize the stone content in the crushed product to be used in the lime production. Additives like e.g. iron ore can also be processed perfectly with Jaw and Gyratory Crushers.

Conclusions

Although the materials used for the cement production are quite different regarding hardness, abrasiveness and stickiness, there is a wide range of crushers and crushing systems available, meeting all requirements. They allow the optimization of each crushing process and thus a minimization of investment and operating costs.

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Gypsum processing equipment »

gypsum

Gypsum ore

The mineral Gypsum precipitated some 100 to 200 million years ago through the evaporation of seawater. Gypsum is calcium sulfate dihydrate (CaSO42H2O), a white or gray naturally occurring mineral.Gypsum is a useful mineral material. It is extensively applied as construction material, most of which is produced as plaster for painting walls or making decorative material in buildings. Raw gypsum ore is processed into a variety of products such as a portland cement additive, soil conditioner, industrial and building plasters, and gypsum wallboard. To produce plasters or wallboard, gypsum must be partially dehydrated or calcined to produce calcium sulfate hemihydrate(CaSO4½H2O), commonly called stucco.

Gypsum manufacturing process

Gypsum ore, from quarries and underground mines, is crushed and stockpiled near a plant. As needed, the stockpiled ore is further crushed and screened to about 50 millimeters (2 inches) in diameter. If the moisture content of the mined ore is greater than about 0.5 weight percent, the ore must be dried in a rotary dryer or a heated roller mill. Ore dried in a rotary dryer is conveyed to a roller mill, where it is ground to the extent that 90 percent of it is less 149 micrometers (µm)(100 mesh). The ground gypsum exits the mill in a gas stream and is collected in a product cyclone. Ore is sometimes dried in the roller mill by heating the gas stream, so that drying and grinding are accomplished simultaneously and no rotary dryer is needed. The finely ground gypsum ore is known as landplaster, which may be used as a soil conditioner

Gypsum plaster

Plaster of Paris is mixed with sand and water to produce a mix suitable for plastering walls and ceilings, for external rendering in dry climates, for mortar, and for making building blocks. It can also be used as a soil stabilizer in stabilized soil blocks. If mixed into limebased plasters and mortars, it will give a fast initial set compared with the much slower-setting lime.
Gypsum-based mortars and plasters are typically made up of one volume of gypsum to two or three of sand, with enough water added to make the mix sufficiently workable. As the mix may start to stiffen only five minutes after adding the water, it is important to make up only small quantities of plaster and to apply these quickly, unless retarders are used. A typical mix for wall blocks would be one volume of gypsum plaster to one volume of sand, two volumes of gravel, and one volume of water. Such blocks would be hard enough to de-mould after 10 to 15 minutes, before being left to dry for several days. The blocks should satisfy the standard requirements forbuilding blocks for general internal structural purposes, and not be used in wet or damp conditions.
SBM is a professional global manufacturer of mining equipment, we could provide complete set of gypsum manufacturing plants. these plants mainly including jaw crusher, impact crusher, cone crusher, vibrating screen, belt conveyor, ball mill, high pressure mill, dryer etc. Our equipment has the benefits of high performance, low operation cost, cost-effective. They have create huge wealth for our customer. If you have interests, please know more about SBM machinery.

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Gypsum processing »

Gypsum processing plants vary widely in scale and level of technology. They range from plants producing one or two tonnes per day using low-cost manual technologies, to plants of a thousand tonnes per day that are highly mechanized and capable of producing different types and grades of gypsum plaster or plaster boards. There are five basic stages in gypsum processing:

Excavation

Excavation is sometimes carried out by digging out an area of ground where the gypsum is located using open-cast techniques. To reach deeper deposits drift or shaft mines may be needed.

Crushing

Crushing the gypsum rock is advisable before processing further, especially if subsequent heating is to be done in a pan rather than a shaft kiln. Crushing will ensure a product which is more uniform and requires less energy to heat. Crushing can be done manually with a hammer or handheld roller, but mechanical crushing is faster and less laborious. Most clay-crushing equipment, such as that used for brick-making and pottery, would be suitable. Crushing should reduce the gypsum to grains of less than a few millimetres across. Gypsum sand does not need crushing.

Screening

Screening with a sieve (manual or motor-driven) will remove large grains which have not been crushed properly and which may contain impurities.

Grinding

Grinding, for example in a ball, rod, or hammer mill, is necessary if the gypsum is to be used for high quality plaster work or for moulding, medical, or industrial applications. Unlike with other cements, such as lime and Ordinary Portland Cement, special mills for mineral grinding may not be required and the relatively soft gypsum could be pulverised in agricultural mills, which are generally widely available.

Heating

Heating may be done in a number of ways involving a range of technology levels and costs. The simplest method is to mix the gypsum stone and fuel in a mound or in a shallow pit in the ground and burn it. Mediumscale batch production might be carried out in an excavated hillside kiln, a shaft kiln with alternate fuel and stone layers, or a permanent walled kiln. An alternative method is to heat the gypsum in large pans or on a flat metal plate positioned above a kiln. Industrial production may be carried out in a purpose-built enclosed batch kiln, a continuously fed vertical shaft kiln, a specially designed large kettle, or in rotary kilns. Kiln-based systems are more efficient than burning the gypsum in mounds or pits, and even a small kiln may use less than half of the fuel of a pit or mound.

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