Hazemag Presentation

Cone

Crushers

CYBAS-i Cone Crusher

◼︎ Special Spherical Bearing Design
◼︎ Patented MSI Liners
◼︎ Unique Crushing Chamber Design
◼︎ Customized Design to Suit Application
◼︎ Continuous Improvement & Optimization

CYBAS-i Cone Crusher

Assembly

CYBAS-i Cone Crusher

Mechanical
Structure

CYBAS-i Cone Crusher

What are the key benefits?

◼︎ Special Spherical
     Bearing Design =
     Lower friction / heat;
     no bearing failure

◼︎ Patented MSI Liners
     Energy savings
     Increased throughputs
     High Reduction Ratios

◼︎ Unique Crushing
     Chamber Design
     High Set-under
     Optimal Wear Profile
     Consistent Feed Opening
     Improved Nipping Angle

◼︎ Customized Design to
Suit Application

◼︎ Continuous Improvement
& Optimization

CYBAS-i Cone Crusher

What are the key features of the HAZEMAG CYBAS-i Cone Crushers ancillaries?

◼︎ Vortex Blower
     ◼︎ Positive displacement to
          keep dust out
     ◼︎ Donaldson Filtration, 100%
          North American sourced

◼︎ Hydraulic and Lubrication Unit
     ◼︎ Weg Motors
     ◼︎ Viking Pumps
     ◼︎ NPT Fittings and Hoses -
          STANDARD Couplings
     ◼︎ 100% North American Sourced

◼︎ Lube Unit Cooler
◼︎ 100% North American Sourced
◼︎ NPT Fittings, Weg Motor

◼︎ Controls
     ◼︎ Allen Bradley Control
          system standard
     ◼︎ 100% North American Sourced
     ◼︎ Standard Electrical
          Components
     ◼︎ Shared PLC/HMI with
          HAZtronic for Impacts

CYBAS-i Cone Crusher

What are the key features of the HAZEMAG CYBAS-i Cone Crushers?

◼︎ Automation and control:
     ◼︎ The hydraulic type design and setting system
          is ideally suitable for complete PLC operation
          and control.
     ◼︎ Can be controlled by plant PLC or a local PLC.
     ◼︎ CSS can be adjusted during operation.

◼︎ Hydraulic and lubrication unit.
     ◼︎ Compact modular design.
     ◼︎ Accumulators for effective tramp relief.
     ◼︎ Lubrication oil heating and cooling systems.
     ◼︎ Available Cold Weather Package

◼︎ Condition monitoring
     ◼︎ Continuous condition monitoring of all
          relevant parameters
     ◼︎ Remote monitoring available
     ◼︎ Remote access to review faults available

CYBAS-i Cone Crusher

What are the key features of the HAZEMAG HAZtronic Cone Crusher Control?

◼︎ Automation and Control

◼︎ Rockwell Automation (Allan - Bradley)
Controls are standard

◼︎ Simple and clear screen Selections,
with alarms, testing capability, and
safety interlocks

◼︎ Alarms page to ensure machine protection

◼︎ Warning levels and machine
shutdown high alarm levels are tracked

CYBAS-i Cone Crusher

Spherical Bearing Design vs. Spider Bush

CYBAS-i Cone Crusher

MSI Liner Design

MSI (Material Specific Insert) design result in the formation of controlled depth grooves

Grooves induce bending and shearing in addition to compression

Result in:

◼︎ Energy savings of up to 25%

◼︎ Improved nipping ability

◼︎ Considerably improved set under

◼︎ Improved PSD with fewer fines generated

◼︎ Improved crushing pressure
(Screw feeder effect)

CYBAS-i Cone Crusher

MSI Liner Design The Leading Edge of Liner Technology

CYBAS-i Cone Crusher

Mantle / Concave Wear

◼︎ Special inserts cast into
mantle & concave to
solve problem

◼︎ Design of inserts is such
     that they wear away
     quicker than surface of
     the mantle/concave

◼︎ The result is a constant
depth of groove through
the component life

CYBAS-i Cone Crusher

Crushing Chamber Design MSI Liner Results

CYBAS-i Cone Crusher

Unique Crushing Chamber Design

Material Distribution Comparison

◼︎ Lower point of first crush

◼︎ Bulk of crushing occurs towards outlet

◼︎ Results in concentration of material in
lower end of chamber

◼︎ Higher point of first crush

◼︎ Crushing better distributed
throughout chamber

◼︎ Results in high crushing pressures,
leads to high set-under

◼︎ Results in improved liner utilization

◼︎ Distribution of position
where material is crushed
for the first time

◼︎ Total crushing frequency
distribution
(◼︎ integrated)

CYBAS-i Cone Crusher

Unique Crushing Chamber Design

Implications of Liner Wear

Material concentration in lower end results in:

◼︎ Poor liner utilization

◼︎ Varying liner profile -
big performance implications

Good distribution results in:

◼︎ Vastly improved liner utilization

◼︎ Limited changes in profile - stable
performance from new to worn

CYBAS-i Cone Crusher

Unique Crushing
Chamber Design

FINE GENERATION HAZEMAG 1200KM VS. Typical High Speed,
Fix Shaft Cone Crusher

CYBAS-i Cone Crusher

Unique Crushing
Chamber Design

FINE GENERATION - Testing:
Application: Ready Mix Stone
Material: Gravel
Work Index: 16
CSS: 13mm (½”)

◼︎ HAZEMAG KM1200
◼︎ Conventional High Speed
Fixed Shaft

CYBAS-i Cone Crusher

Continuous Improvement Process

◼︎ Worn liner profiles measured periodically

◼︎ Achieved profile analyzed in conjunction
with machine performance data
(PSD & Tph)

◼︎ Design can be optimized to suit
changing plant requirements or
material properties

◼︎ Liner optimization generally
takes the form of:

◼︎ Changes to machined profile
◼︎ Changes to MSI design (Qty, thickness, geometry, …)
◼︎ Changes to inlet groove geometries
◼︎ Changes to liner material types

CYBAS-i Cone Crusher

Where
En = Net power consumed (kW)
Q = Feed rate to the crusher (t/h)
P80 = Pass 80% of product size
Fe = Equivalent pass 80% of feed
size when feed is scalped
Wi = Work index

Note:
F80 is replaced with Fe when the feed is scalped.

Fe = F80 / [ 1-{(Fc / F80 )1/√2 } /2 ]√2
F80 = Pass 80% of feed size
Fc =

Total power required
Et = En + Eo

Where
E0 = Einstalled / 8
Einstalled (kW)

Power Calculation

Power Reduction due to MSI Liners, Spherical Bearing, and Curved Crushing Chamber

Typically, HAZEMAG Cone Crushers require less power. As an example, The CYBAS-i 1500 is normally fitted with 400HP, due to this MSI, Spherical Bearing, and Curved Chamber. Typical Conventional High Speed Cones would require 500 or even 600 Horsepower.

CYBAS-i Cone Crusher

Track Stock Levels | Track Change Outs | Prompt Order Placement | Ensure Stock Availability

◼︎ Increase Down Time Between Shut Downs

◼︎ Increase Crusher Availability

◼︎ Reduce Time for Shut Downs

CYBAS-i Cone Crusher

Remote Monitoring

Industrial plants are widely spread apart, sometimes even across countries and borders.

With telecommunications, connecting to plants distributed around the world are possible, both wired and wirelessly. This also allows further remote applications such as remote management and condition monitoring.

Integrated Management and
Engineering Systems

Monitoring and analysis of operation
trends and performance

Optimization of the equipment and
process performance

Support to site through expert group

Using leading edge Techologies and tools