“China’s aggregates sector is in the process of an eye-catching green revolution” g ” p16
Regulars
05 COMMENT
An African path to post-COVID-19 surface mining recovery
50 EQUIPMENT UPDATE
Global OEMs’ new equipment launches and applications
52 EVENTS
All the key events in the quarrying & aggregates world
Features
19 CRUSHING & SCREENING
Creating a 2020 crushing & screening premium
24 LOADING
Quarrying-suited, new-generation excavators & wheeled loaders make for an eye-catching global loading machine sector
28 HAULING
Big new ADT & RDT truck launches, & how sustained investment is boosting Terex Trucks’ growth
32 WASHING – PART 2
A major global wash plant premiere, & how state-of-the-art washing solutions are enhancing quarrying operations in the UK and US
35 RECYCLING – PART 2
How recycled building waste can unlock profits for sand & aggregates-producing companies
37 PORTABLE POWER – PART 2
Leading Atlas Copco & Doosan Portable Power figures discuss what’s new in the offhighway portable power world
40 ENGINES – PART 2
High-performing off-highway engines for today and tomorrow
Specials
08 INTERVIEW
GCCA CEO Dinah McLeod says it’s a great time to join the association, given its leading role in coordinating efforts to secure a more sustainable worldwide cement & concrete sector
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GUY WOODFORD
Resurgent South African building materials demand
It was heartening to hear how the South African surface mining and quarrying sector is overcoming COVID-19 pandemic-induced disruption.
Speaking at the recent ‘What is happening in the industry?’ online event hosted by Aspasa, South Africa’s surface mining industry association, Andries van Heerden, CEO of Afrimat, said that building materials demand had been rising monthon-month since June, after what had been a “really, really painful” period for the industry due to the pandemic.
“We are in an industry that has been under pressure. The fact that we are still here shows we have tenacity. The [South African 27 March to 1 May] lockdown did us no favours. It was very, very difficult. For us in Afrimat, I hope we will never see another month like April in my career. For an entire month, we paid our people in full, while costs were running up and no revenue coming in. It was a big, big challenge to make decisions when you have no idea when revenue will return.
was not a fan of Aspasa at all. Since then, we have realised the important role an industry body like that can do. They’ve changed what was seen by a lot of us as a ‘rough-and-ready’ industry through their health and safety and environmental audits. They have helped us become a very widely respected industry among the authorities we work with. We need to support them in continuing their fine work, and I would urge any of us taking part in this event today who are not Aspasa members to become one.”
The Aspasa event also featured a very bullish talk by Dr Roelof Botha, a leading South African economist and economic advisor to the Optimum Investment Group. Dr Botha pointed to South Africa’s V-shaped economic recovery from COVID-19 and the bright fiscal outlook for the Rainbow Nation in 2021 and 2022.
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“Like other major industry players, we have seen a sharp increase in demand for products in June, July, August, September, and October. That’s five months of a very strong resurgence in demand across a lot of areas of the country. It’s showing a good balance between private spending, especially in the rural areas, and rural and provincial government spending on roads and low-cost housing. It is looking a lot better in our business and hopefully yours.
“Looking at corporate action, we’ve noticed that some industry players have put some of their assets up for sale. We know that there are discussions between various players going on behind the scenes. I think it will be a very interesting couple of years seeing how this plays out. There will be some repositioning. We might see some new entrants into the industry.”
Afrimat’s CEO also praised the work of Aspasa for raising surface mining and quarrying industry standards. “Ten years ago, I
The South African government has committed 500 billion rand (US$31.4bn) to a national coronavirus pandemic response. Dr Botha said while there has been a welcome national focus on new infrastructure projects, there has also been careful government management of public debt, leading to a tighter rein being placed on spending in some areas.
In his highly detailed and engaging presentation, Dr Botha also noted the ongoing importance of huge foreign investment into South Africa that began after Cyril Ramaphosa replaced Jacob Zuma as South Africa’s president and as leader of the ANC (African National Congress), following the latter’s resignation in February 2018. Ramaphosa subsequently secured his first full term as president after South Africa’s general election in May 2019.
Given that South Africa is Africa’s biggest national building material product maker, a more buoyant market fueled by national economic growth is a good sign for industry colleagues in the African continent’s 53 other countries. GW gwoodford@ropl.com
VIETNAM CEMENT PLANT INTRODUCES ABB CONTROL SYSTEM
Tan Thang Cement has completed the introduction of a digital control system from ABB at a new cement plant in the Nghe ˆ An province of Vietnam.
The ABB Ability System 800xA DCS (Distributed Control System) is designed to integrate control, electrical and communication systems for optimal visibility into all processes for stable production and the efficient use of raw materials and energy.
Swiss-Swedish robotics and engineering group ABB says the new digital solutions will ensure operational efficiency at the greenfield site, which is 250km south of Hanoi, with reliable electrical supply across the entire production process. Vietnam is regarded as one of the world’s top cement producers, with approximately 100 million tons per year, and the new plant will contribute more than two million tons annually.
The package also includes ABB Ability Knowledge Manager and ABB Ability Expert Optimizer which are integrated with the DCS, as well as basic communication and electrical system infrastructure and equipment.
Hoang Anh Tuan, general director at Tan Thang Cement, said: “The plant has the latest digital solutions to become one of the most modern cement production plants in the region.”
Cummins sets out hydrogen-power plans
Off-road engine manufacturer
Cummins has outlined its plans to grow its fuel-cell and hydrogen production business. The US company says it is combining its powertrain expertise and its fuelcell and hydrogen technologies in a variety of applications, including transit buses, semi-trucks, delivery trucks, refuse trucks and passenger trains. Cummins engines are used in a variety of quarrying machines, such as crushers and screeners, excavators and dump trucks. JCB unveiled the working prototype of a new hydrogen-cell-powered 20-tonne excavator in October.
Amy Davis, president of Cummins new power segment, said that major rollouts of hydrogen fuel cells are first likely to take place in markets such as trains where the powertrain and fuel costs represent 50% of total operating costs - much lower than in
the heavy-duty truck market where the figure is above 80%.
“Demand for electrolysers is growing rapidly with an opportunity to utilise green hydrogen to replace less environmentally friendly grey hydrogen in industrial processes while interest in fuel cells is growing in certain end markets,” said Davis. Electrolysers use electricity to split water and create hydrogen.
Cummins currently has more than 2,000 fuel-cell installations across a variety of on-and off-highway applications as well as more than 500 electrolyser installations.
Company chairman and CEO Tom Linebarger said the production of ‘green’ hydrogen and the adoption of fuel-cell technologies in markets that are served by fossil fuels today will be critical to lowering greenhouse gas emissions globally
and also will enable Cummins to achieve carbon neutrality by 2050.
Cummins says that infrastructure is a current barrier to the adoption of fuel-cell technology, and will require action and engagement from both private industry and government to increase the pace of adoption of hydrogen fuel-cell solutions.
The company’s product offerings in hydrogen technology include PEM (polymer electrolyte membrane) fuel-cell power modules. It also supplies fuel-cell powertrains.
Cummins fuel cells are powering the world’s first hydrogen fuel-cell passenger trains through Alstom, a French rail manufacturer.
Cummins announced this month that it will work with truck and diesel engine company Navistar International on the development of a Class 8 truck powered by hydrogen fuel cells.
The partnership will explore the potential of membrane technology for CO2 reduction
Cemex and MTR partner on low-cost carbon-capture technology
Cemex’s US operations have been awarded a grant from the United States Department of Energy (DOE) to research and develop innovative carbon-capture technology at its Balcones cement plant in Texas.
Cemex is partnering with Membrane Technology & Research
FLSmidth Ethiopia cement plant
FLSmidth has begun its near €100mn contract with Abay Industrial Development Share Company (AIDSC), centred on the operation of Abay’s new greenfield cement plant in Ethiopia.
(MTR) to conduct an 18-month study at the Cemex plant in New Braunfels to explore the potential CO2 emission reduction from installing new membrane technology in the plant’s production process.
The grant will be used to partially fund a feasibility
Located near the city of Dejen, the new state-of-theart facility will play a key role in the development of local infrastructure. Once fully operational, the plant will have a capacity of 5,000 tonnes per day
study to implement this technology and is expected to be a significant advancement towards Cemex’s ambition to deliver net-zero CO2 concrete globally by 2050.
According to MTR, the membrane will act as a semi-permeable barrier through which CO2 can
and will create more than 300 new jobs in the area. The order includes design and engineering, full equipment supply, automation systems, installation and commissioning as well as training and extended supervision.
pass, facilitating carbon capture at a minimal adoption cost.
“With this grant, we will be able to leverage our expertise to define the feasibility of implementing the membrane carboncapture technology in a cost-effective manner,” said Cemex USA president Jaime Muguiro.
LafargeHolcim 3D concrete partnership in China
Building materials provider
LafargeHolcim has started a partnership to sponsor research into concrete and mortars for on-site 3D printing at Southeast University in Nanjing, China.
LafargeHolcim says it is using 3D printing to make construction more efficient while lowering its carbon footprint, aiming to become a full 3D printing solutions provider.
The company has established a network of academic partnerships, working with 40 leading university departments around the world
in fields ranging from materials science to civil engineering to sustainable construction. LafargeHolcim says that many of the PhD students from the network go on to become its employees.
Edelio Bermejo, head of R&D for LafargeHolcim, said: “Our global network of academic partners is critical in helping us think outside the box. We need the brightest minds to help us lead the next frontier of building solutions.”
Professor Yamei Zhang of
Southeast University commented: “My team and I have been working on sustainable concrete and the development of 3D printing concrete technology. The partnership with LafargeHolcim will allow us to take it to the next level.”
LafargeHolcim currently finances two university chairs advancing sustainable construction, one at the Swiss Federal Institute of Technology (ETH) in Zurich, Switzerland, and one at the École des Ponts ParisTech in Paris, France.
Construction aggregates market to reach US$559.8bn by 2027
OMAN TO GET ITS LARGEST CEMENT PLANT
Duqm Cement Projects International (DCPI) has announced plans to build the largest integrated cement manufacturing facility in Oman in the Special Economic Zone at the port town of Duqm.
The Times of Oman reported that the new US$435m plant will have a capacity of 3.5 million tons per year and is likely to provide impetus to the development of downstream industries.
The project is part of Oman’s objective to become a hub for industrial excellence in the region due to its abundant mineral resources, additives, stateof-the-art ports, efficient economic zones and strategic location.
DCPI said in a statement that the plant is expected to be operational by Q1 2023, and will help to meet local demand in the Emirate of Oman. It will also cater to the overseas markets of India, Sri Lanka and East Africa using the port facilities at Duqm.
The value of the global construction aggregates market is projected to grow at an annual rate of 5.2% over the next seven years, according to a new report.
ReportLinker, which published the report, said it has conducted an impact survey to update its figures amid the COVID-19 crisis. It estimates the value of the global market at US$393.6bn in 2020, and this is now projected to reach a revised size of US$559.8bn by 2027, growing at a CAGR
(compound annual growth rate) of 5.2% from 2020-2027.
The sand segment of the global market is projected to record a 5.8% CAGR and reach US$236.6bn by the end of 2027. After an early analysis of the business implications of the pandemic and its induced economic crisis, growth in the gravel segment is readjusted to a revised 5.1% CAGR for the next seven-year period.
The US construction aggregates market is
estimated at US$106.6bn for the year 2020. China, the world`s secondlargest economy, is forecast to reach a projected market size of US$116.3bn by 2027 with a CAGR of 8% from 2020-2027. The markets in Japan and Canada are forecast to grow at 2.8% and 4.7% respectively over the 2020-2027 period. Within Europe, Germany is forecast to grow at approximately 3.2% CAGR.
In the global crushed stone market, the USA, Canada, Japan, China
and Europe will drive the estimated 4.3% CAGR for this segment. The market size of US$132.4bn in 2020 will reach a projected US$177.2bn by the end of 2027, with China remaining among the fastest-growing regional markets. Driven by countries including Australia, India and South Korea, the market in Asia-Pacific is forecast to reach US$74.6bn by 2027, while Latin America is predicted to expand at a 5.7% CAGR from 2020-2027.
It added that the project is also expected to contribute to the development of Oman’s proposed Mineral Railway project by increasing its economic viability. The Mineral Railway has been proposed to support the annual transportation of over 30 million tonnes of mineral commodities from sites in the Al Wusta and Dhofar areas to processing plants and export channels in Duqm and neighbouring Gulf countries.
China is predicted to remain one of the fastest-growing regional aggregates markets
DINAH MCLEOD
Making a sustainability dream a concrete reality
Dinah McLeod became chief executive of the Global Cement and Concrete Association in July this year. She tells Guy Woodford that it’s been a great time to join the key London, England-headquartered association, given its leading role in coordinating efforts to secure a more sustainable worldwide cement and concrete sector
Dinah McLeod, chief executive of the GCCA, has built a highly successful career in the global sustainability sector
Apassion for sustainability has been at the core of Dinah McLeod’s professional career to date, so the recent appointment of the dual British-Canadian national as chief executive of the Global Cement & Concrete Association (GCCA) looks a wise decision.
Most recently a director of ‘The B Team’, an innovative and standard-setting non-profit initiative which was established to improve business practices to enhance the wellbeing of people and the planet, McLeod has also held senior sustainability roles with the Overseas Development Institute, the UK’s largest development research institute, and in the private sector with BT, Novartis and Allianz. She has succeeded Australian national Benjamin Sporton, a former chief executive of the World Coal Association, who had served as GCCA chief executive since its formation in 2018.
“I’m a newcomer to this industry, but I come from a sustainability background. The thing about sustainability people is that they like having an impact. What really excites us is getting the chance to really make a difference. The role of business in achieving global sustainability is my passion. The concrete industry is an emitter of climate impacting emissions – it recognises this. That said, these materials are so crucial to the world. You cannot imagine fulfilling sustainable development goals without cement and concrete at the heart of it. So, the idea of coming to an industry association that represents major companies that are really serious about sustainability and driving down those emissions is very exciting.
“The GCCA itself is also the Best in Class –with a sustainability charter, report measuring, and guidelines on sustainability that members have to abide by.”
Led by the world’s top 40 international cement companies, the GCCA is dedicated to developing and strengthening the sector’s vital contribution to sustainable construction. The association also fosters innovation throughout the construction value chain in collaboration with industry associations, architects, engineers and corporate innovators.
GCCA member companies make up 40% of global cement production. Having secured all the big industry players, including LafargeHolcim, CEMEX, HeidelbergCement, CRH, Buzzi UNICEM, Dalmia Cement, Titan Cement, Vicat and Votorantim, the GCCA is now looking to work more closely with medium- and ambitious small-sized sector companies.
“The concrete industry is very well known but often misunderstood. Once you start finding out that after water, concrete is the most used material on earth, that all our community infrastructure is made of it, you become obsessed by it. My role is talking to the outside community about the importance of our industry to the world while also ensuring global sustainability.”
In September, the GCCA launched a joint industry ‘2050 Climate Ambition’ with
“I didn’t even have a chance to get my feet under my desk when the GCCA launched a quite incredible 2050 Climate Ambition statement”
an aspiration to deliver to society carbonneutral concrete by 2050. The ambition statement identifies the essential levers that will be required for achieving carbon-neutral concrete: reducing and eliminating energyrelated emissions; reducing process emissions through new technologies and deployment of carbon capture, more efficient use of concrete; reuse and recycling of concrete buildings; and harnessing concrete’s ability to absorb and store carbon from the atmosphere.
GCCA member companies are currently developing a 2050 concrete roadmap which will set out the detailed actions and milestones that the industry will enact to achieve its ambition. The roadmap is due to be completed towards the end of next year. The 2050 Climate Ambition builds on the longtime climate commitments and sustainability progress of GCCA member companies and affiliate associations worldwide.
“I didn’t even have a chance to get my feet under my desk when the GCCA launched a quite incredible 2050 Climate Ambition statement,” says McLeod. “The reception for it has been amazing. We’ve had lots of media interest and got the chance to engage at the very highest levels of policymaking. An example of this is when the GCCA was one of only two private enterprise voices, the other being the president of Microsoft [Brad Smith], invited by the UN secretary-general to join a distinguished panel discussing environmental issues.
“The cement and concrete industry is one of the most competitive industries in the world, yet when the senior people from our member companies meet up on GCCA business, they are very cordial. They just come and talk with each other to advance our important work. But I have seen the competitive edge at times in practice when it came to sustainability, but that is great, channelling a rivalry to encourage progress
“The concrete industry is also conservative. When the leaders running our member companies commit to supplying carbonneutral concrete by 2050, it’s more than just words. They won’t commit to something they don’t think can be delivered.”
While the COVID-19 pandemic has limited her ability to get out on GCCA-member company work sites and travel for face-toface dialogue with senior member company executives, McLeod has been drawing on the “world-class” expertise of GCCA’s senior management team as she settles into her chief executive role. “I’ve learned an enormous amount from our vastly experienced GCCA team, and there are experts among our member companies who have been very generous with their time. I have also been very bookish in my reading about the industry, and I look forward to getting out on site as soon as possible.”
September’s big 2050 Climate Ambition statement launch was followed on 6-7
This year’s GCCA annual conference was broadcast to an online audience of almost 500 senior executives
October by the GCCA Annual Conference, staged virtually due to the COVID-19 pandemic.
Just under 500 senior executives, including cement and concrete industry CEOS, experts and vital stakeholders gathered online for what was the association’s third annual conference, staged under the central theme of ‘building the sustainable world of tomorrow’.
Moderated by renowned broadcaster Gavin Esler, the conference featured a keynote presentation from Dr. Timur Gül, head, Energy Technology Policy Division of the International Energy Agency on industry transition to a low-carbon future. Other key contributors over the two days included Pratima Rangarajan, chief executive of OGCI (Oil & Gas Climate Initiative) & Climate Investments, and high-level stakeholder organisations including WeMeanBusiness, and the IUCN Global Business and Biodiversity Programme, as well as cement and concrete industry CEOs.
Delegates also discussed health and safety, best practices and reporting, thought leadership and resilience, and the role of innovation in building a more sustainable future world.
“The GCCA did something extraordinary. We held a major conference fully online, and it felt quite natural. It was great to have Gavin Esler moderating, and there was a nice mix of technology and humans in a TV studio and online.
“Because of the unique circumstances we find ourselves in, we were able to broaden the conference’s audience beyond our working groups. We’ve got our key 2050 Climate Ambition statement, and the conference was a key opportunity to continue the dialogue over how we get there.”
McLeod notes the particular importance of health and safety in the modern cement and concrete industry, citing conversations on the subject with Albert Manifold, GCCA president and chief executive of Irish building materials giant CRH. “Albert has repeatedly said to me that COVID-19 has put a spotlight on health and safety. He said, ‘Focus everything on this issue. The health and safety of our employees, our facilities and interactions with the wider world are of number one importance to our industry’. It’s been great to hear the stories of people in our industry also downing tools and helping in their local communities.
“Like in other industries, COVID-19 has had a significant effect on the cement and concrete industry. Because of the industry we have, we see a bounce back. Construction is 13% of the world’s GDP (gross domestic product). Construction is also going to be one of the tools to help
us emerge out of this dreadful pandemic and build towards a recovery. This is an industry which will play such an important role over the long-term.”
Created by GCCA and launched at the association’s annual conference in Singapore in October 2019, Innovandi – the Global
Cement sacks at a HeidelbergCement plant ready for transportation to customers. Pic: HeidelbergCement
A passion for sustainability is driving Dinah McLeod’s work within the GCCA
After water, concrete is the most used material on earth
TRANSFORMING THE WAY YOU WORK.
WORKING IN UNISON.
The ALLU Transformer is a hydraulic screener that screens/ mixes and separates fine material from coarse material. The remaining coarse and hard soils can be crushed with an ALLU Crusher unit. All materials can be processed to the desired fragment size and sorted for further use
Especially in demolition contracting, the simultaneous use of the ALLU Transformer screening unit and the ALLU Crusher have proven to be useful. Approximately 70% of the material can first be screened with an ALLU Transformer, and the remainder crushed with an ALLU Crusher. The total capacity of the machines is increased exponentially, and more material is being utilized
Cement and Concrete Research Network –staged in June 2020 its initial ‘Kick-off Week’ of online workshops, aimed at accelerating global collaboration on cement and concrete research.
The week brought together 40 scientific institutions from across the world and 30 leading industry players from across the cement and concrete sector, including cement and concrete manufacturers, concrete admixture specialists and equipment suppliers. Over the week, the Innovandi industrial and academic partners set headline themes for future research projects to improve sustainability and decrease CO2 emissions.
“We are looking to continue to grow Innovandi and we welcome companies from the supply chain to also join us on this important mission,” stresses McLeod.
Innovandi aims to build on the cement and concrete industry’s progress to date, which includes achieving a 19.2% reduction in CO2 per tonne of cementitious product since 1990. Additionally, the proportion of alternative fuels used is now 9.5 times greater than in 1990.
“The GCCA’s role, through Innovandi and other platforms, is to facilitate information transfer. We are not talking about getting companies to share their industrial secrets. We want a policy framework where this playground for innovation allows and facilitates more research and development.
For example, can Innovandi help develop carbon-capture technology and access research funding? It’s more about providing a home for everyone that is doing research. We need bright new engineers to come into our industry and create technology that enables us to go forward.”
Originally from Vancouver, Canada, McLeod, who is married and a mother of two teenage children, has lived and worked in London for many years. She holds a master’s degree in Public Administration from Princeton University’s Woodrow Wilson School as well as a BA (Hons) from Columbia University.
She began her career as a social protection specialist at the World Bank, where she worked on community-based financing and social infrastructure projects for marginalised and vulnerable groups. She was also a policy advisor at the UK Prime Minister’s Strategy Unit.
Expanding on her key role as GCCA chief executive, McLeod continues: “What I see as one of my fundamental roles is to say to governments and international public policymakers that we need partnerships at every level, municipal and global, so we can achieve our very challenging ambition. We need to invest in carbon-capture technologies, in policies that promote the circular economy and go on highlighting the importance of the cement and concrete industry in global climate resilience.
“People won’t have decent homes and schools without concrete. It’s been a fundamental building block for thousands of years. There are simply no alternatives at scale with anything like the performance benefits of concrete, nor need there be. It allows us to build at a cost that is sustainable and at a carbon point that we are committed to driving right down.”
Global sustainability will be at the forefront of delegates’ minds at next year’s United Nations Climate Change Conference, also known as COP26, being held in Glasgow, Scotland, from 1 to 12 November 2021 under the presidency of the UK government, with assistance from the Scottish government. McLeod and her GCCA team are talking to government figures about how its work and 2050 Climate Action statement can feed into the global showpiece event.
The GCCA’s new chief executive can always count on a great deal of domestic support for her sustainability work from her husband, who is an astrophysicist, and her teenage children. “Teenagers tend to have a very sophisticated view of sustainability, led by environmental concern.”
A highly enjoyable hour’s conversation with McLeod has covered much ground. Achieving global sustainability is an almighty challenge, but one she, her team and her GCCA-member company colleagues are very much signed up to and determined to deliver. AB
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Ambitious Sibcem eyes growth despite COVID-19
A COVID-19-induced economic recession in Russia has tested the resilience of the country’s giant construction materials industry, with product demand varying greatly since Russia’s peak construction season began in May. Eugene Gerden caught up with Valery Bodrenkov of Sibirskiy Cement, one of Russia’s largest building material producers, to find out more about the state of the domestic market and the company’s growth plans
Valery Bodrenkov, Sibcem’s first vice president, is optimistic about the long-term health of Russian building materials demand
Valery Bodrenkov believes the Russian building materials market is in pretty robust shape. The Russian government has introduced quarantine measures in a bid to restrict the spread of the coronavirus, leading to the suspension of several big investment projects in the sector. But Sibirskiy Cement’s (Sibcem) first vice president says his company and other major producers remain optimistic due to the demand for aggregates, concrete and other materials for construction works.
Established in 2004, Sibcem is a Russian vertically integrated holding company that combines companies producing cement and construction materials based on it. The firm’s product range includes 24 types of cement, over 30 nomenclatures of concrete mixtures, fine-grained concrete and mortars, and more than 40 chrysotile cement products.
“Annually, Sibcem enterprises are capable of producing nine million tonnes of cement, 1.8 million m³ of concrete mixtures, 606,000m³ of mortars, 15 million m² of roofing, 3.4 million m² of flat sheets, 800 kilometres of conventional pipes,” explains Bodrenkov.
“Currently, the holding company’s share of the Russian cement market is about 8-9%. Providing a consistently high quality of manufactured construction materials, the company successfully participates in the implementation of projects for the construction of residential complexes, industrial enterprises, social and transport infrastructure facilities.
“At various times, Sibcem’s products were used for the construction of strategically important facilities for the Siberian Federal District - the Boguchansk hydroelectric power plant, the Boguchansk aluminium plant, the Kuyumba-Taishet oil pipeline, the fourth bridge across the Yenisei in Krasnoyarsk, the Northern bypass of Novosibirsk, the Krasnogorsk water-lifting unit in the Omsk region, the third bridge across the Ob in Novosibirsk and many others.”
Bodrenkov emphasises Sibcem’s strong track record of supplying construction materials for large-scale infrastructure projects. They include high-quality products for Novosibirsk Arena’s indoor ice sports palace in the city of Ulan-Ude in east Siberia; and the fourth bridge across the Ob River in Novosibirsk, southern Siberia. Sibcem is currently supplying building materials for Novosibirsk’s under-construction eastern and northern bypasses, along with the Yurubcheno-Tokhomskoye natural gas field in Krasnoyarsk Krai, east Siberia, and the Vankor cluster (Suzunskoye, Tagulskoye and Lodochnoye oil fields), also in Krasnoyarsk Krai.
Commenting on Sibcem’s cement production facilities, Bodrenkov says: “Sibcem currently has five cement plants - Topkinskiy Cement, in Topki, in the Kemerovo region; JSC Iskitimcement, in Iskitim, in Novosibirsk region; Krasnoyarskiy Cement in Krasnoyarsk,
Krasnoyarsk Territory; JSC Angarskcement in Angarsk, in Irkutsk region; and Timluy Cement, in Kamensk, in the Kabansky district of the Republic of Buryatia. The Iskitim and Angarsk plants were only incorporated into our group in June 2020. Consolidation of these plants will allow Sibcem to accumulate financial and material resources necessary for the development of each asset.”
In addition to cement plants, a network of concrete production facilities trading as Sibirskiy Beton operates in the Sibcem holding-company structure (subdivisions are located in the Siberian cities of Novosibirsk, Krasnoyarsk and Kemerovo). These include the Volna integrated plant, which produces chrysotile cement products in Krasnoyarsk, and the Gornaya Company offering consumers fractional limestone and mineral powder made at its facilities in Tatarsky Klyuch, in the Zaigraevsky district of the Republic of Buryatia in eastern Siberia.
“2.2 million tonnes of cement was manufactured at Sibcem’s five cement plants, which is 4% more than in the first half of 2019”
Sibcem also has several non-production assets. ZapSibCement LLC sells cement and products for Gornaya Company, and KuzbassTransCement LLC operates railway transport. The Sibcem holding company also includes the Sibcemservice repair company and the Sibirskiy Cement Trading House, which carries out procurement activities.
Despite still relatively healthy building materials demand and the very promising longer-term outlook, Bodrenkov says there are no current plans to increase Sibcem’s plant footprint. “This is due to a significant excess of demand oversupply in the Russian market. For several years in a row, the country’s cement plants have been loaded on average by only 50%. Under present circumstances, Sibcem’s priority remains the technical re-equipment of enterprises. The main areas of this activity are the modernisation and reconstruction of existing production facilities, increasing the level of their environmental safety, and the introduction of automated control systems for technological processes.”
Between 2007 and 2019, Bodrenkov says that Sibcem invested more than 20 billion rubles (US$261.4 million) excluding VAT on all assets (including JSC Angarskcement since 2012, and JSC Iskitimcement since 2013). Additionally, repair costs within all Sibcem assets for the same period amounted to about 16.6 billion rubles ($217.29 million) excluding VAT (including JSC Angarskcement and JSC Iskitimcement since 2015).
Commenting on whether sanctions imposed on Russia by Western countries have affected Sibcem’s trading, Bodrenkov says: “Up to 40% of Sibcem’s investment costs depend on foreign supplies. As such, the company depends on the exchange rate of the national currency. Its decrease led to an
BELOW: Sibcem’s Krasnoyarskiy cement plant
increase in the cost of equipment necessary for the holding to carry out repair campaigns and implement investment projects. Sibcem does not experience any other consequences from the sanctions, since the company sells a regional product - cement - which is profitable to supply only within Russia and the Eurasian space.”
Does Bodrenkov see Sibcem expanding its existing building material exports? “Some of our cement is shipped to Kazakhstan, and some of our chrysotile cement products produced by the Volna integrated plant are exported to Tajikistan, Uzbekistan and Mongolia. We do not plan to enter the European Union market. Cement is a heavy and rather cheap product. As such, its transportation more than 1,000 kilometres from where it is produced is, in most cases, economically impractical.”
Looking in detail at Russian construction materials demand and the impact of the COVID-19 pandemic, Bodrenkov says that while manufacturers have been affected by the introduction of restrictive coronavirusfighting measures, the disruption varies greatly depending on the region and type of materials.
“According to the investment and
consulting company CM PRO, in January-June 2020, about 25.1 million tonnes of cement were manufactured in Russia, which is 4.9% less compared to the same indicator of 2019. Cement consumption over the same period decreased by 6.1% - to 24.9 million tonnes.
“According to our analysts, the main market for shipments of Sibcem products, which includes ten regions of the Siberian federal district, as well as Buryatia and the Trans-Baikal territory, increased by 0.6% yearon-year between January and June 2020 to 2.4 million tonnes.
“During the same six-month period, 2.2 million tonnes of cement was manufactured at Sibcem’s five cement plants, which is 4% more than in the first half of 2019. Despite the fact that the company completed this period making a profit, it was very difficult.”
Bodrenkov says the Russian government introduction of restrictive measures aimed at combating COVID-19 had led to many of its construction company customers having to significantly adjust their working practices.
“At the end of March and in the first half of April this year, many of our clients were forced to suspend their activities, which reduced the pace of construction of facilities
and production volumes. Usually, the beginning of the second quarter is the start of high construction season in Siberia, but this year the cement market of the federal district literally collapsed, with demand down 20% compared to the level of April 2019. It should be emphasised that the market recession was stopped thanks to the measures taken by the Russian government on behalf of the president Vladimir Putin, who several times personally held meetings on the adoption of urgent measures to support the construction industry.
“In May and June, after the resumption of work on construction sites, the decrease in cement sales was won back. However, now that the deferred demand has been made up for, we have again detected a decline in sales. Compared to 2019, in 2020, the volume of cement consumption in Siberia could fall by 7-10%.”
Bodrenkov says the national construction and building materials industries have benefited significantly from the Russian government’s preferential mortgage programme, which includes mortgage interest-rate subsidies of up to 6.5% per year for homeowners. He also points to the helping hand offered by increased government lending on preferential terms to low-margin construction firms, and greater funding for home construction within the framework of the dangerous housing resettlement programme.
Bodrenkov stresses that while many small- to medium-sized companies working across many different industrial sectors have received financial support from the Russian government during the pandemic, Sibcem is not planning to seek support from the government.
Looking further ahead, Bodrenkov is heartened by the Russian government’s infrastructure building, and industrial development plans up to 2035, which he thinks will lead to a significant increase in cement consumption. “The Manufacturing Industry Development Strategy, in particular, provides for an increase in consumption of 90 million tonnes of cement per year to 2035,” he notes.
“Sibcem, as a key producer of the ‘bread for construction’ in the Siberian macroregion, is preparing for this growth by having a growth strategy spanning the next 15 years. The task of company shareholders and management is to actively modernise the plants that are part of the holding, to bring the technologies used to a global standard. For the 2020-2024 period, Sibcem is set to invest more than 17 billion rubles ($222.75 million), excluding VAT into the business.
“We are deeply convinced that government assistance to the construction industry should be in the shape of the consistent implementation of national projects and federal target programmes in housing, industrial and infrastructure construction in the volumes approved by the RF budget for 2020-2022. At present, work in these areas does not stop.” AB
Topkinskiy Cement is based in Topki, in the Kemerovo region of southwest Siberia
Sibcem operates five cement plants. Pictured is Topkinskiy Cement’s facility in the Siberian town of Topki
Global equipment market – a case of “China and everywhere else”
Aggregates demand has surged in China with the government investing heavily in infrastructure projects to drive economic growth. Liam McLoughlin reports on how the country is bouncing back from the COVID-19 pandemic
China was the first country to go into a lockdown after being hit by the COVID-19 pandemic in late 2019, but was also the first major economic and industrial power to emerge from restrictive measures.
This has enabled its aggregates and construction equipment sectors to be looking at healthy figures for 2020 at a time when most other nations in the developed world are faced with market contraction.
The pandemic exerted some negative effects on the Chinese aggregates market at the start of 2020 but government measures have helped facilitate a fairly swift return to ‘normal’, according to Zhai Zijian, international trading department manager at Shanghai-based aggregates and quarrying equipment manufacturer SBM.
“Aggregates demand surged in the middle of 2020, because the government put a lot of investment into infrastructure to improve the economy,” Zhai says.
His views are echoed by Chris Sleight of management consultancy Off-Highway Research. Speaking at the online congress held by European construction equipment manufacturers association CECE in October, Sleight described the current global market for equipment such as excavators, loaders and haulers as being “China and everywhere else”.
He added: “The Chinese government
has gone very hard on stimulus. The main mechanism of this has been at a provincial level. The central government has allowed provincial governments to issue a lot more bonds, with the stipulation that those bonds have to be spent on infrastructure, agriculture and environmental protection - things which fortunately have a component of equipment sales to them.”
Estimated construction equipment sales in China totalled over 312,000 units in 2019 – the highest level since 2011 - and previously this had been projected to fall by 9% in 2020.
“So instead of the peak [in equipment sales] in China taking a gentle downturn this year, we are seeing quite a spike - a 14% rise is what we think at the moment.”
He added that this projected rise represents “a very, very good level” for the Chinese market, particularly when set against a projected 16% fall in total global equipment sales in 2020.
The Chinese government appears set to maintain the measures that are helping equipment manufacturers for the rest of this year, but it is not clear how long after that the stimulus measures will continue.
The country has been through “a hard time” since the pandemic struck, says David Zhao, editor of China Aggregates Net (CAN), which specialises in independent Chinese aggregates market analysis and statistics.
He adds that China’s COVID-19 pandemic coincided with the Spring Festival, a traditional long holiday when almost all construction and quarries stop working. This year the festival ran from January 24 to February 2.
“During every Spring Festival aggregates production in China will be sharply down, and the pandemic extended that short period to around half month,” says Zhao. He adds that aggregates production in the country began to recover by late February.
“On 1st April, all quarries who report their price to China Aggregates Net had restarted
Shunxing Quarry in Guangdong Province, which is operated by Gongsheng Group
Zhai Zijian, international trading department manager at SBM
work or were ready to restart, except some quarries in Hubei Province,” Zhao adds.
He says that the Chinese aggregates sector has now fully recovered from the pandemic with the remaining quarries in Hubei Province around the capital Wunan re-opening in April and May.
“The virus itself cannot affect this sector now, but we are ready to deal with any small waves of COVID-19 in the coming winter,” he adds.
To guarantee the necessary raw materials supply for reignition of the country’s economic engine, Zhao says that central and local government have introduced policies to make sure quarries can restart work smoothly, including quicker approving and more strict quality supervision.
China Aggregates Association (CAA) president Hu Youyi said that, after the COVID19 pandemic, the state has promoted the construction of “two new and one heavy” (‘two new’ equating to new infrastructure and urbanisation construction, and ‘one heavy’ referring to major construction of transport and water conservancy projects).
Hu added that there is a huge demand for aggregates and relevant equipment, aggregates prices continue to rise, and the income of enterprises continues to grow rapidly. Hu said today is the best era for the development of the aggregates industry in China. The central state and local governments have issued many documents to promote the high-quality and healthy development of the aggregates sector.
China’s aggregates industry has entered what Hu described as the “golden era” which is full of opportunities and challenges. More and more players are rushing into the aggregates industry, and there are more and more new, modern large-scale production bases, said Hu.
The CAA says that Chinese aggregates prices are remaining at a generally high level in most parts of the country. Giving figures for September, the association says the selling (ex-factory) price of natural sand (2.3mm-2.8mm) in Shanghai is 95 yuan (€10.93) per tonne, and manufactured sand (2.8-3.3mm) is 92 yuan (€10.58). The price of Dongting Lake sand (2.0mm-2.5mm) in the Yangtze River is 122.5 yuan (€14.09), and the price of manufactured sand (2.8-2.5mm) is 88.5 yuan (€10.18).
The price of crushed stone in Guizhou and Guangxi Province has generally risen. In Guizhou it has increased to 35 yuan (€4.03), while the price of crushed stone (10mm-30mm) in Guangxi has risen to 90 yuan (€10.35).
Crushed stone and manufactured sand prices in Jiangmen, Guangdong Province and Jining, Shandong Province have declined. The price of crushed stone in Jiangmen is 92 yuan (€10.58), while the price in Jining fell to 70 yuan (€8.05). The price of manufactured sand in Jining fell to 75 yuan (€8.63).
The CAA said that the price of aggregates in various parts of China varies greatly due to differences in demand and output.
bauma
CHINA
organisers say the 2020 event
has
managed to retain an international flavour despite travel restrictions
“In these difficult times, bauma CHINA 2020 gave the entire industry a reason to enter the coming fiscal year with confidence and hope”
The levels of post-COVID recovery in the aggregates sector varies by region, according to SBM’s Zhai.
“Some provinces are developing and have many construction projects this year, and the local demand for aggregates and sand will be high,” he says. “On the other hand, some provinces have already undergone development, and there are only small projects. In my opinion this gap will become bigger due to the pandemic, and more investment will take place in developing areas.”
In the first half of 2020 the Chinese government decided to cut tax on companies across all industries by 50% for the rest of the year. Zhai says the government may introduce more measures that benefit enterprise in early 2021.
In terms of which types of aggregates and quarrying equipment are most in demand among Chinese operators, Zhai says it is difficult to make generalisations as the country is so large and each province has different materials, requirements and regulations. He adds that the main unified development trend across the Chinese quarrying sector is towards energy saving and the adoption of an environment-friendly approach.
CAN’s Zhao says that current government policy is leading to increased demand for sand making machines and mobile equipment in the aggregates industry.
“From central and local government to quarries, manufactured sand is now a hot topic in China,” he adds. “China has determined to reclaim abandoned quarries along the most important rivers and city clusters, [so] mobile crushing and screening equipment has a good opportunity.”
An indication that the Chinese market is returning to something like normal was given by the staging of the major bauma CHINA 2020 construction, quarrying and mining machinery exhibition in Shanghai from November 24-27. Organiser Messe München says that more than 2,800 exhibitors attended from 34 countries and regions, despite the COVID-19 crisis and the latest travel restrictions. After four show days the event had been visited by around 80,000 trade delegates.
In spite of the circumstances, bauma CHINA organiser Messe München said the event was able to keep an international flavour and retain 300,000m2 of exhibition space.
“The huge area occupied by international exhibitors such as Caterpillar, Volvo, Bauer, Terex as well as pavilions by Germany, Italy and Spain show the continued international confidence in China’s growth and development,” said Messe München, adding: “In these difficult times, bauma CHINA 2020 gave the entire industry a reason to enter the coming fiscal year with confidence and hope.”
Su Zimeng, chairman of the China Construction Machinery Association, commented: “bauma CHINA 2020 is a very important event for the industry, and it was held when China has achieved major strategic results in COVID-19 prevention and control. The economy is showing a stable recovery. It is also the most successful construction machinery exhibition in the world held this year.”
Bin Qi, regional director - eastern, northern & western China of Terex (Changzhou) Machinery, Shanghai Branch, USA added: “In this special time, the successful opening of bauma CHINA has brought confidence
to the industry, manufacturers, investors, and all those who are concerned about the construction machinery industry. The results exceed our expectations, and the visitors are highly professional.”
Thanks to a sophisticated safety and hygiene concept the 10th international edition of bauma CHINA could be held at the Shanghai New International Expo Centre (SNIEC).
Stefan Rummel, MD of Messe München, said he was satisfied with the result: “There is far-reaching demand for innovative technologies, intelligent and low-emission machines, and vehicles with integrated digital solutions. Hand in hand with our partners we therefore made everything possible and provided the industry with a platform even in times of crisis.”
Messe München says that key Chinese accounts such as XCMG, Sany, Zoomlion, Shangdong Lingong, Zhejiang Dingli even increased their exhibition space this year.
“We were able to showcase our high-end machinery and core technologies,” according to an XCMG representative. “And we could meet many new and old customers and make deals.”
Shi Weizhi, deputy general manager of Zoomlion sales marketing company, commented: “In such a difficult situation, taking part in this exhibition allowed us to demonstrate our technological strength and new products to the industry, customers and the public. We will definitely participate in the next edition of bauma CHINA, and even expand our booth.”
In addition to the on-site event, bauma CHINA offered a range of online solutions, especially for international participants who could not travel to China. On the online platform, “bauma CHINA Community”,
everyone could virtually participate in bauma CHINA 2020, from their home or office.
The participants could search for exhibitors, exchange company information, get to know products, participate in events digitally and thus gain new market insights. Exhibitors and visitors had the opportunity to communicate via live chats or video conferencing. The organisers say this meant participants were able to generate greater reach and build their social networks in the
“For domestic Chinese aggregates equipment manufacturers the overseas market is huge”
Zhai Zijian, SBM
construction equipment industry.
The bauma CHINA Community is estimated to have had over one million online visitors. Rainer Hirsch, member of the executive board of Herrenknecht said he was impressed by the newly-launched service: “bauma CHINA provided the online platform to build a communication and interaction bridge that breaks the limit of time and space between exhibitors and participants, who are not able to visit the on-site event. The combination of offline and online greatly facilitates communication and helps to achieve cooperation deals.”
The Chinese domestic market in aggregates and other industries can be a
difficult place to do business for foreign players, particularly if they lack a good local partner, but CAN’s Zhao says there are opportunities for non-Chinese companies.
“Quarries in China now have a relatively longer lifespan and larger productivity, which drives the owner to buy more reliable, long-service-life equipment,” he says. “A wellexperienced non-Chinese company can seize that. The challenge for them is that Chinese companies have noticed this trend and are working hard on it.”
The Belt and Road Initiative (BRI) presents ongoing business opportunities for Chinese aggregates equipment manufacturers.
The government set up the BRI trade and infrastructure agenda in 2013 and it extends to nearly 70 countries.
SBM’s Zhai Zijian says: “For domestic Chinese aggregates equipment manufacturers the overseas market is huge, and most of countries among the Belt and Road are developing. Aggregates demand is high in those nations. It seems like a win-win business for China and other countries.”
In terms of major developments in the Chinese quarrying and aggregates sector over the next 12 to 18 months, CAN’s David Zhao highlights a trend for state-owned companies buying quarrying rights and taking part in the Chinese construction aggregates industry.
As part of its greener quarrying initiative linked to environmental commerce and tourism, the Chinese government has closed tens of thousands of smaller environmentally harmful quarries in the country. This, and a more diligent approach to granting new quarry licences, based on meeting tougher green production and site restoration criteria, has seen the number of Chinese quarries fall by around 40%, from over 300,000 to 180,000. AB
CHINA EQUIPMENT SALES (UNITS)
A 2020 crushing & screening premium
Investment in a premium mobile crushing & screening plant is paying off for a top Polish quarrying firm, while two major global market manufacturers have launched new models. Guy Woodford reports
When it comes to producing large amounts of accurately sized aggregates, most large production quarries have chosen a stationary solution. For one Polish quarrying company, this was not a viable option. Instead, VWV turned to a multifaceted selection of Sandvik tracked mobile plant supplied by the Swedish manufacturer’s dealer in Poland, Grausch i Grausch Maszyny Budowlane.
Based near Wroclaw in the south-west of Poland, and with its registered office in Czarny Bór, VWV was established nine years ago and now employs approximately 100 people.
Dealing primarily with the extraction and production of a wide range of granite aggregates, the company has in a relatively short period become renowned for the high quality of its products and the professionalism of its service. The
granite quarries and mines in the southwest of Poland. From these operations, it supplies aggregates of the highest quality to construction and infrastructure companies throughout the country.
VWV’s quarrying, mining and production take place at the Strzegom quarry in Marcinowice, in the district of Swidnica, in Dolnoslaskie province, and at the Gebczyce quarry in the town of the same name, in the Strzelin district of Lower Silesia. The Strzegom quarry is located 30km from the A4-Bielany Wrocławskie motorway junction and the no.35 national road. The latter fact has proved to be vital in providing rapid distribution of aggregates to customers throughout the country and the local area. The national rail network is also easily accessed from the Sobótka Zachodnia station, further facilitating easy distribution throughout Poland. VWV also has its railway rolling stock fitted with a dedicated excavator
The Gebczyce quarry is located 8km south of Strzelin in Lower Silesia. Its location on the eastern periphery of the Lower Silesian Voivodeship also enables convenient, easy and cheap transport by both road and rail of any aggregate produced. Due to the location and the convenient locations of the road and rail infrastructure, both quarries are ideally placed to service the requirements of Polish construction and infrastructure industries, supplying aggregates throughout Poland and beyond.
The granite found in the Strzegom quarry is a magma rock, which has a fine- and medium-grained structure, with a light grey colour. The aggregates obtained from the granite deposits at the quarry possess excellent absorbability, compressive strength, abrasion and frost resistance, making them ideal for use in a wide variety of construction applications, including road, rail, general building works and hydro-technical
In south-west Poland, VWV has acquired a multifaceted Sandvik tracked mobile plant solution supplied by Grausch i Grausch Maszyny Budowlane
The Sandvik QA451 triple-deck Doublescreen at VWV’s at Strzegom quarry
Similarly, aggregates from the Gebczyce quarry are also granite and possess a rarely found and unusual geological structure, providing notable technical and strength benefits. The rock itself is from the Strzelin Massif and is a deep magma, light grey with a fine-grained structure, which makes the aggregate have high compressive strength, low abrasiveness, and possess a high level of resistance to frost. The attributes of the rock make the aggregates produced useful in landscaping and decorative construction projects such as walls, ponds and rock gardens.
To be able to react to the ever-changing requirements of the construction industry, as well as to modernise its equipment fleet, VWV has continually updated the equipment it uses. Often working in conjunction with leading Polish equipment dealer, Grausch i Grausch Maszyny Budowlane, this has seen during the last four to five years a vital boost to the company’s production capabilities.
Through a significant investment project undertaken in both equipment and resources at both the Strzegom and Gebczyce quarries, VWV is now able to call upon a fleet of approximately 30 Volvo and Doosan excavators and loaders as well as over 50 Scania and Caterpillar haul trucks. In addition to this fleet of tracked and wheeled machines, the company also has its dedicated railway trucks for the direct and convenient transport of aggregates to national railway infrastructure. However, before they can be transported, aggregates need to be produced.
When upgrading its crushing and screening capabilities, VWV management opted for a Sandvik tracked mobile plant supplied by Grausch i Grausch Maszyny Budowlane. The plant was chosen due to its ability to offer more flexible production
of aggregates, while also maximising the quarry’s resources by being able to go directly to the rock. The Sandvik solution also met key VWV requirements of a crushing train offering primary and secondary crushing capabilities and screening and scalping units that are accurate enough to produce sized aggregates that can be shipped to customers direct from the quarry, without the need for further processing.
The sellable aggregates produced by VWV are 0-4mm, 4mm - 31.5mm, 31.5mm -50mm, +50mm and a 100mm – 500mm. To ensure these product fractions, two Sandvik crushing and screening train now operate consisting of a QJ341 primary jaw crusher, a QH331 Hydrocone crusher and a QA451 triple-deck Doublescreen. The latter model can produce four accurately sized products working perfectly with the high productivity of the jaw and cone crushers. The second
importance to proper planning encompassing what our customers want to achieve, and how best to meet these requirements.
Grausch has a hard-won name for excellence in Poland, and the Sandvik mobile crushing and screening equipment is seen as the very best equipment of its kind available on the market.”
With its new equipment in place, VWV is able to supply over 500,000 tons of aggregates each year to a variety of customers. Although road and rail construction are the mainstays of the quarry’s business, a new customer has been taking a sizeable proportion of the aggregates from both quarries. Poland’s largest river, the Vistula, is the scene of a new dam which is also set to be the home of an 80 MW hydroelectric power plant. The project will cost more than €470mn, according to Poland’s environment ministry, and is located near the village of Siarzewo. With a project of this size as well as satisfying the requirements of its existing customers, the plant upgrade could not have happened at a better time for VWV.
Rubble Master says its new RM 120X crusher is the first machine showcasing its new RM NEXT product philosophy to go into full production.
The debut RM NEXT crusher follows on from a prototype RM NEXT machine showcased at bauma in Munich, Germany in April 2019. The RM NEXT-based RM 120X crusher will be followed by an RM NEXTbased screen in 2021.
“We have received valuable input for this operating concept from our customers around the world”
Gerald Hanisch
“With this philosophy, we are once again setting standards in user-friendliness,” says Gerald Hanisch, founder and owner of Rubble Master, enthusiastically. As the first NEXT philosophy crusher, the RM 120X combines enhanced safety with maximum performance and flexibility. However, the company remains true to its proven service and intuitive GO! operation concept, which it continues to expand.
In a nutshell, RM NEXT focusses on four points. Extended service is one of them, which includes both the standard five-year warranty - an industry first - and the annual service.
Rubble Master says the new RM 120X crusher is the first machine based on its new RM NEXT product philosophy to go into full production
UNPARALLELED
TAKE RECYCLING TO UNPRECEDENTED LEVELS
Ammann focuses on technologies that incorporate high percentages of RAP – and considerabl y reduce operating and materials costs in the process. These technolo gies aren’t baby steps – they’re signi fi cant advances that can greatly impact your business. And they ’re PROVEN technolo gies that are in use at hundreds of plants around the world.
Ammann RAP products include:
• Counterflow dr yers that enable use of 100 per cent hot rec ycled material
• Parallel-fl ow dryers that can use up to 60 per cent hot recycled material
• Middle ring dryers for the use of up to 40 per cent recycled material
• Various cold addition systems for the use of 25 to 40 per cent recycled material
• Retrofi t options to start or improve your recycling efforts
Ammann’s experience gained during the installation of countless recycling systems worldwide will ensure you find the right solution. We have the cost-saving technology, and it’s yours for the asking.
Simplicity is ensured despite the additional features, equipment options and configurations that have been developed based on customer requirements.
“Operating a RM 120X still involves only a few buttons. The built-in screen is only used to display information and has no sub-menus. We have received valuable input for this operating concept from our customers around the world, and the controls and display meet the specifications on job sites 100%,” says Hanisch.
The RM Group has always been one of the pioneers in terms of safety. Gerald Hanisch’s vision has now become a reality. With RM NEXT and the comprehensive operatormachine interface, the operator no longer has to enter the danger zone while operating the machine and can see light signals indicating both the status and current workload of the crusher from the excavator cab.
An additional focus was on the optimisation of material throughput. Here, the world market leader implements job-specific crushing equipment for the respective material and real-time analysis. This reduces running costs and increases turnover. The optimisation starts with the machine configuration, which is why five main application cases have been developed with the necessary equipment options. Also, the performance indicator on the machine and the RM GO! SMART can be used to detect and implement any potential improvement immediately.
“When we started developing RM NEXT, we always had our entire product range in mind. In future, an important role will be played by networking different products in operation at the same job site. However, we can only make this happen if all the products work according to the same philosophy,” explains Hanisch. That is why intensive work is currently underway to network RM machines that work together. This will mean that the throughput of the screen can be adjusted in future to match the utilisation of the crusher. Machines downstream from the crusher can also stop automatically if the crusher is currently not processing any material. These optimisations are designed to increase efficiency and save running costs.
The new Terex Minerals Processing Systems’ (Terex MPS) high-capacity, all-electric wheeled crushing systems are said to be designed to deliver and built to last. Quick to set up and dismantle, and easy to operate, the new wheeled crushers’ claimed exceptional portability, productivity, efficiency and quality deliver real advantages over other systems in labour savings, power, maintenance, plant relocation costs and time.
The Terex WJ3042 is a high-performance wheeled jaw crusher plant. Incorporating the aggressive Terex JW42 jaw crusher and a heavy-duty vibrating grizzly feeder, the
Terex WJ3042 gives optimum production in a range of applications. Plant installation is assisted with hydraulic legs. Its compact size, quick set-up times, ease of transport and simple maintenance make the Terex WJ3042 ideal for quarrying, mining, demolition and recycling applications.
The Terex WC1150S Cone-Screen plant is a high-performance, medium-sized wheeled crushing-screening system. At the heart of the plant is the 225kW Terex TC1150 cone crusher with a modern automated control system. Its innovative crushing action is said to provide excellent capacity, high reduction and good product cubicity for the production of high-quality aggregate and
Terex MPS’ WJ3042 is said to be a high-performance wheeled jaw crusher plant
sub-base materials. A level sensor over the cone crusher regulates the feed to ensure the cone chamber is choke fed, essential for maximum production, manganese life and optimal product shape. The large onboard 6’x20’ three-deck screen allows for sizing product from a single plant. Plants come with hydraulics for simple and easy installation of the plant.
The WJ3042 and WC1150S are available as standalone plant or as part of a multiplant system with product conveyors for a complete crushing and screening solution. All plant and conveyors are made to fit in standard containers for easy transport overseas or on the road; the entire system with conveyors can be transported in nine containers. Once on-site, each assembled plant can be transported in a one-piece tow. Hydraulic screen lift and hydraulic support legs reduce cranage and tools required for plant set up and relocation.
Aggregate material in France’s northwestern corner is often shipped to the mainland from nearby tiny Ushant Island in the English Channel - La Manche, in French.
But one enterprising company, JeanJacques Perhirin, in Kéranchas, recently bought two MB Crusher’s units - a BF70.2 crushing bucket and an MB-S14 screening bucket - and began recycling debris.
The two powerful units now work close to another powerful unit, the 53m-high Phare du Créac’h. Built in 1863, it is one of Europe’s most powerful lighthouses. A short distance away the MB Crusher BF70.2 is mounted on a Hitachi 170W to reduce brick and concrete. With the MB units operating apace, the company says that it is saving natural resources as well as avoiding the cost of bringing in aggregate by sea.
Also, the compact MB Crusher attachments make it possible to work in restricted spaces. They are now able to make their own aggregates, by sifting rubble to separate the smallest portion and then reducing the larger pieces with the jaw crusher. Et voilà! Aggregate for paving, foundation and fillings. AB
An MB Crusher BF70.2 on a Hitachi 170W excavator is reducing waste brick and concrete in France’s most northwesterly point
Loading up a range of applications
Companies are deploying new loading equipment in a diverse number of activities including Portland Stone operations, waste recycling and concrete production. Liam McLoughlin reports
Albion Stone has taken delivery of a new Volvo L150H loading shovel for its Portland Stone extraction operations in south-west England.
The wheeled loader joins two existing L150s that Albion Stone acquired in 2014 and 2016, and will operate at the Jordans and Bowers mines on the Isle of Portland in Dorset.
The new arrival will take over the primary duties of extracting and rehandling blocks of Portland Stone from the mine face, as well as conveying them to the stock yards and designated block-cutting areas of the works.
“Our original machine has clocked up over 10,000 hours, so we considered it was time to replace this with a fresh machine and put the older unit onto secondary duties,” says Albion Stone operations manager Dan White.
Unlike the two older units that had to be supplied with reduced height operators’ compartments, the new L150H has been supplied with a conventional cab. White says that, since those machines were delivered, Albion Stone has made a significant investment in its drilling operations inside the mines to increase the roof horizon and maximise production capability.
“This means we can now utilise a conventional loading shovel without a significant amount of modification,” says White. “Furthermore, having such a reduced cab height meant our operators had a
restricted field of view, so using a standard cab means better visibility and, ultimately, a more conventional machine to sell on if we so wish in the future.”
The new L150H features a hydraulic quick hitch, to facilitate the easy change-over of the existing attachments from the previous machines. These include a 3.8m³ spade nose rock bucket for cleaning up, as well as heavy-duty 1,500mm block-handling forks that are capable of handling blocks weighing anything from seven to 12 tonnes. Whilst the L150H has plenty of breakout torque to prise the majority of part-sawn blocks from the mine face, there is the occasional need to encourage some more awkward blocks away from the face; particularly from the mine roof.
To counterbalance the weight of the blocks, the machine has been fitted with Goodyear RL 5K wheel and tyre assemblies, with the rear pair being water- and glycolballasted and an optional block-handling counterweight. Other safety features for working underground include an Ardent twin-agent fire-suppression system, fire resistant hydraulic oil, Pyrojacket-sleeved fuel lines, a double pole battery isolator and a Chelwyn valve to meet mine regulations, while also reducing the risk of fire. The operator’s compartment benefits from a heavy-duty bar-type screen guard and additional LED work lights.
Powered by a 13-litre, 227kW Stage V
engine, the 26-tonne L150H benefits from powertrain components designed by Volvo. This combination coupled to other fuelsaving devices, such as the Volvo ‘Eco pedal’, encourages the operator to run the machine at its optimum rpm in the engine’s torque curve. ‘Optishift’ with torque converter lock-up also makes the L150H a highly efficient and productive loading shovel for its size class.
Albion Stone has been involved with the Portland Stone industry for nearly three quarters of a century, quarrying the Oolitic Limestone that is reputed to be 145 million years old from the Basebed, Whitbed and Roach seams for over thirty years.
In recent years, the company has switched its extraction operations from quarrying to mining. This process has made a significant reduction on its environmental impact, making Portland Stone an economical yet sustainable choice that compares favourably with many alternative construction materials. The extracted material is highly desired for prestigious buildings, and features in many famous edifices – for example, in London where recent projects include the new Chelsea Barracks, Green Park Underground Station, the Bulgari Hotel and Eagle Place, Piccadilly.
German waste-handling company BTU Hartmeier has been operating a new Hyundai HL960A wheeled loader in its fleet since the start of 2020.
Albion Stone uses three Volvo L150H loading shovels for the extraction and rehandling of Portland Stone
The 19-tonne HL960A is powered by a Cummins QSB6.7 Stage V (168 kW) engine, and features a tipping bucket with 7m3 highlift and 3.3m3 capacity.
Hitachi Construction Machinery is planning to launch the ultra-large EX2000-7 hydraulic excavator in October 2021.
The EX2000-7, suitable for small-to medium-sized mining and quarrying operations, is remodelled from the EX1900-6 and the manufacturer claims it consumes up to 19% less fuel while maintaining the same productivity.
Hitachi CM says the EX2000-7 has high durability of structural parts achieved by the design employed on the current EX-7 series machines and it can incorporate support services for repair works and inspections based on ICT (information and communication technology) and IoT (the Internet of Things). It is also said to achieve higher fuel efficiency due to features including an entirely new hydraulic circuit and the addition of a work-mode selection function.
At an operating weight of 193 tonnes, the EX2000-7 is one of the smaller Hitachi EX-7 ultra-large excavators.
The EX2000-7’s impressive 19% fuel saving has been achieved through a range of newly designed, energy-efficient features that have made the engine more compact while retaining productivity. Hitachi says that, when compared with its predecessor the EX1900-6, the EX2000-7 can save as much as 460 tons of CO2 emissions per year per machine.
An all-new hydraulic control system has been developed and, for the first time, employed for an ultra-large hydraulic
excavator which allows more precise management of the hydraulic oil flow in each control valve throughout the digging and loading cycle.
In the EX2000-7’s new hydraulic circuit, the oil flow rate to each cylinder (for boom, arm, or bucket) and swing motor is independently controlled for each operational pattern such as excavation, swinging or dumping and the load to the front-end attachment optimises energy efficiency of the system. Thus, fuel consumption is kept as low as possible.
Hitachi’s
new 193-tonne EX2000-7 ultra-large hydraulic excavator
BTU Hartmeier has its headquarters in Unterschleissheim, which is just north of Munich. The group was founded in 1996 and is split into two divisions, Waste Disposal and Service. The Waste Disposal division works at Unterschleissheim and the Service division at Augsburg and in total employs 120 staff. The company disposes of waste from construction sites in a radius of 50km around Munich and ensures that the recycling of waste materials and recyclables is correctly classified. The company’s annual output is 130,000 tonnes, and in the region of 7,000 containers and skips are needed to manage this volume of materials.
A large fleet of construction machines work on loading and feeding the crushers on the 15,000m² treatment site in Unterschleissheim and at further sites, in and around the area, belonging to the group. The company has four Hyundai wheeled loaders which have been operating since 2010.
Johann Hartmeier Jun., whose responsibilities include the fleet of twenty construction and transfer loading machines and 80 trucks, said he opted for the new Stage V machine from Hyundai because of its power, fuel consumption and ergonomics.
“The superb, rapid service from Hyundai Construction Equipment service partner Fischer & Schweiger was another deciding factor in the purchase,” he added. “Features on the machine include solid rubber tyres, which make for easy working in often sharp-edged recycling material. The high-lift tipping bucket is also required for loading high-edged and walking-floor semitrailers. The tipping height of the high-lift bucket is 4,200mm.”
The machine will be in use for around 2,500 operating hours per year. Hyundaiauthorised dealer Fischer & Schweiger from Zusmarshausen near Augsburg provides service care on all of the company’s wheeled loaders and some of its transfer loaders.
Hyundai Construction Equipment Europe (HCEE) says it launched the new A-series at the bauma 2019 show due to the sustained strong demand for large wheeled loaders in the European market.
BTU Hartmeier is operating a new Hyundai HL960A wheeled loader
Two Liebherr wheeled loaders are helping to meet the demands of increased production at concrete batching company Ready Mix Tees Valley.
One of the L 550 XPower loaders is operating at Ready Mix Tees Valley’s newlyopened plant on the banks of the River Tees in north-east England, and another at a new company facility in Leeds.
Ready Mix Tees Valley MD James Greenwood says the reliability of the L 550 XPower is enabling the company to cope with the increased production.
“We had used a number of shovels for stocking the [Tees] plant since we started operations,” he said. “Both manufacturers’ products had caused us some issues with reliability and build quality. That was something we couldn’t afford with the increase in production from the new batching plant.”
Liebherr GB’s wheeled loader product specialist Michael Atkinson and area sales manager Carl Longhorne suggested a trial of an L 550 XPower at the Tees plant, and Ready Mix Tees Valley was impressed by its fuel consumption of less than six litres per hour, cab comfort and productivity.
Tees Valley has joined forces with another local family-owned firm Shire Aggregates, which occupies part of the large yard area. It imports aggregates by ship from around the UK which are then screened, with more than 80% used by Tees Valley for concrete production.
Tees Valley claims to be the largest concrete supplier in the area, producing 50,000m3 last year.
As well as the two loaders, Tees Valley has bought four HTM 905 Liebherr mixers, mounted on Mercedes-Benz chassis and provided by Northside Truck & Van which has a rolling-stock mixer truck programme with Liebherr.
The mixers are highly specified and include user-friendly features such as remote grease points, sub-frame covers and the Litronic EMC Controller.
The company was launched in 2008 when James gave up his position with a major pharmaceutical company to invest
in concrete. Tees Valley now operates two depots on the banks of the Tees, in addition to the new Leeds facility.
Caterpillar has launched the new 963 Track Loader in Europe, a replacement for the 963K model.
Cat says the new crawler loader combines the versatility to dig, load, carry and fill with up to 10% better fuel efficiency, more productivity and cab and controllability improvements. The 963 meets EU Stage V emission standards, provides power of 151kW (202hp) and has an operating weight of 20,358kg.
The loader features an updated cab with suspension seat and adjustable armrests/ controls, an intuitive 254mm touchscreen dash display and a standard high-definition rear-view camera. The Slope Indicate feature is designed to make operation easier by showing machine mainfall and cross slope right on the display.
There are two steering/control options. The joystick option provides familiar controls for operators experienced with skid steers/ compact track loaders, and the more traditional V-lever/foot pedal controls can also be chosen. With either control scheme,
that produces 15% more peak torque than the previous model for more power to the ground under load.
Cat says that up to 10% fuel consumption reduction is achieved with the Auto Mode that will adapt the engine speed to the load. Eco Mode uses even lower speed for further reduction in fuel consumption in lighter duty applications. Power Mode will keep engine speed high to feel readily available power at all times. An optional Performance Series bucket is claimed to boost productivity by up to 20%, while an optional Fusion Quick Coupler enables fast attachment changes. A variety of buckets, forks and other tools can be shared among track loaders, wheeled loaders and other Fusion-compatible machines.
Doosan Infracore Europe has launched the new 43-tonne DX420LC-7 crawler excavator.
The DX420LC-7 is powered by the new Scania DC13 Stage V-compliant diesel engine, providing 257 kW (344.4 HP) of power.
Doosan Infracore says the Scania engine uses super-efficient DOC/DPF+SCR aftertreatment technology to offer a new solution
One of Tees Valley’s two Liebherr L 550 XPower loaders in operation
The new Caterpillar 963 is designed to work effectively on slopes
3-10% better fuel efficiency (m3/l) than the previous DX420LC-5 model.
There are now four power modes available, which is intended to simplify the operation of the new DX420LC-7 excavator compared to the more complex choice of eight power modes and SPC combinations in the previous generation machine. The operator can set the power mode (P+, P, S or E) in both one-way and two-way working modes.
Doosan Infracore says that, by bringing together the SPC3 system and a new Doosan Mottrol main control valve, the new DX420LC-7 also offers 2% more productivity than the DX420LC-5 in company tests, ensuring the best digging, swing and tractive forces together with the best lifting performances for this size of machine.
The new cab in the DX420LC-7 model features a touch-enabled colour LCD gauge panel with 30% larger 20.32cm size screen.
A stereo system is integrated in the cab’s gauge panel (with Bluetooth streaming function), in addition to a keyless start system, enhanced interior cab design, improved air conditioning/defrost performance, seat heating (2-step), 360o cameras, and LED-type cab-space lamp.
Optional cab features include ultrasonic detection of obstacles, LED lights, side protection, catwalk and air compressor.
As standard, 360° cameras provide full visibility around the excavator and allow the operator to see a top-down view of the area outside the machine. The camera array comprises a front camera, two side cameras and a rear camera. The camera display is separated from the gauge panel.
Mecalac Construction Equipment UK has been running a promotion for telematicsbased fleet management across its portfolio of MCR, MWR, MTX and 15MC excavators.
Operators were offered the chance to equip their latest models with telematics functionality and a two-year subscription to MyMecalac Connected Services for less than £400. The offer lasted until 17th October 2020.
Launched earlier this year, MyMecalac Connected Services is designed to help operators minimise downtime and optimise
productivity through real-time equipment data. It provides detailed insight into fuel consumption, unit productivity, service reminders, maintenance alerts, remote diagnostics and geofencing capability.
The Mecalac MCR excavators can switch from compact tracked excavator (with a top speed of 10 km/h) to loader (with 360° rotation capability) within seconds. Available in three variants – 6MCR (0.49m2 bucket capacity), 8MCR (0.53m2 bucket capacity) and 10MCR (0.75m2 bucket capacity) – each unit is powered by a 55kW engine.
Japan-based Kobelco is this year celebrating nine decades since it created Japan’s first electric mining shovel in 1930, an innovation that would go on to have a significant impact on both the business and the worldwide loading-equipment sector.
One of Kobelco’s most important innovations to date has been the development of hybrid technology. It claims
to be the first major excavator manufacturer to instigate hybrid development in 1999. This forward-thinking led to the reveal of a hybrid excavator (HE-01) in 2007, followed by sales of the hybrid excavator 80H (8-tonne class) in 2010. Demand for a larger category hybrid machine was realised with the S–200H-9 8217; Kobelco’s first 20-tonne class hybrid excavator, before the SK210HLC-10 was launched in 2017 – which Kobelco says is the world’s first hybrid excavator to use lithiumion technology.
A major milestone for Kobelco in the last decade was the reestablishment of the Kobelco Construction Machinery Europe (KCME) headquarters in Almere, the Netherlands, in 2013. Over the past seven years, the company says this important base has provided an efficient and responsive service and full aftersales support for its European customers across 64 dealers and 270 outlets in 60 countries. AB
The Doosan DX420LC-7 excavator offers improved fuel efficiency
Mecalac has launched a telematics offer across its excavator range
Upgrading ADTs for greater performance
Major manufacturers are unveiling new dump truck lines with a range of enhanced features including maximised ground clearance, greater cab visibility, and heavier duty parts to increase durability. Liam McLoughlin reports
Liebherr has launched the TA 230 Litronic articulated dump truck (ADT) which the German manufacturer says means it now provides a full line of earthmoving equipment. The new TA 230 Litronic, which was unveiled in a digital presentation, is primarily designed for overburden transport, the mining industry, and larger infrastructure projects. Its optimal structure gauge means it can also be used for special applications such as tunnel construction.
The TA 230 Litronic features a newly designed front-end area, creating maximum ground clearance for performance in challenging off-road environments. For example, the powershift transmission is positioned safely and compactly under the operator’s cab. In addition, the exhaust gas after-treatment is safely installed behind the operator’s cab in a space-saving manner, whereby a large slope angle could be generated.
The newly designed, solid articulated swivel joint creates excellent off-road capability and allows independent movements of front and rear end to enable maximum manoeuvrability. The robust and positive-locking swivel joint with tapered roller bearing is suitable to meet the shear stresses arising during use, withstand maximum loads and provide optimal force distribution.
The front and rear axles of the machine are secured via sturdy A-rods at the articulated swivel joint and at the rear end. The focus was placed on maximum ground clearance during the development process. Both the front axle suspension with A-rods and shock absorbers at the articulated swivel joint and the position of the separate and oscillating A-rods of the rear axles at the rear end provide maximum ground clearance.
A powerful 6-cylinder construction machinery engine with 12-litre displacement and 265 kW/360 hp is installed in the new TA 230 Litronic, which complies with Stage V exhaust emissions standards. A robust drivetrain with automatic 8-speed powershift transmission is designed to ensure optimal force distribution.
With the actively controlled longitudinal differential locks, automatic traction control is also available for the TA 230 Litronic. As soon as slip occurs at an axle, the torque is transferred to the axle or axles with traction.
Liebherr says the new dump truck provides enormous pulling force, even in the most difficult ground conditions and on challenging gradients. It adds that maximum safety is guaranteed thanks to optimal adhesion.
The large trough of the new TA 230 Litronic can carry a 28-tonne payload and a range of improvements have been made for quick and efficient loading, unloading
and safety. The front of the trough is straight and the sills are low so that loading with a wheeled loader is easily possible across the entire length. A weighing system shows the current payload during the loading process on the display in the operator’s cab. An optional loading light on both sides at the back of the operator’s cab shows the loading level outdoors. To accelerate the release of material during unloading, the inner edges of the new trough are tapered. During transportation the long chute at the end of the trough is designed to ensure minimal material loss. The trough volume can be increased with the optional tailgate.
The newly developed operator’s cab of the TA 230 Litronic features panoramic windows without any struts, in addition to a short and inclined bonnet to ensure the driver always has an optimal view of the driving, working and articulating area of the machine. A touch display with integrated rear camera also increases transparency in the rear area. In the soundproof cab ergonomically arranged control elements facilitate intuitive operation of the machine.
In addition to a hill-start assist, a speed assist is also available. With the hard stop function, the end-position damping of the trough-lifting cylinders can be activated or deactivated by a button. The trough lift is limited for work in a height-critical area with the aid of the height limit.
The new Liebherr TA 230 Litronic dump truck offers the option of extra-powerful LED headlights that can illuminate the entire working area
oriented machine design. The dump truck automatically performs the daily check itself through the use of sensor technology. The machine runs through an inspection catalogue at the start, where levels of engine oil, coolant, the central lubrication system are checked with any deviations being shown on the display in the operator’s cab.
The standard version of the TA 230 Litronic has an empty vehicle weight of 24,600kg, a payload of 28,000kg, a maximum trough capacity with tailgate of 18.1 m³, engine power (ISO 9249) of 265kW/ 360hp, and a maximum driving speed of 57kmph (forward) and 16kmph (reverse).
Indonesia-based PT Manado Karya Anugrah says a fleet of Volvo Construction Equipment (Volvo CE) machines, including 16 haulers, that it has been using since last year is delivering exceptionally profitable operations.
PT Manado Karya Anugrah, a coal mining contractor, has been using the machines since April 2019 at its coal mine in East Kalimantan.
The fleet consists of 10 R60D rigid haulers, six A40G articulated haulers and three EC750DL excavators and PT Manado says the machines are proving profitable due to their high productivity and uptime.
“Conditions at our site are tough and we know we can count on the productivity and reliability of Volvo machines to give us the lowest cost per tonne,” said Rafiuddin Djamir, owner of PT Manado Karya Anugrah.
The site has medium to high gradients with limited room for manoeuvring, and the
“Our operators particularly like the speed of the machines during a climb,” said Djamir. “They feel the machines have more power than others.”
The machines provide a high level of uptime and work 22 hours per day in two shifts, seven days a week. “The Volvos have a high availability for work, and we appreciate the machine features and dealer support behind this advantage,” Djamir said.
The fleet is served by PT Indotruck Utama, Volvo CE’s distribution partner in Indonesia. “So far there have only been a few minor issues but with the total support and quick
Manado Karya Anugrah
Sulawesi, also owns Volvo L260H wheeled loaders.
Since Volvo Group acquired the off-highway truck product line from Terex Corporation in 2014 and formed Terex Trucks as a division of Volvo Construction Equipment, the Swedish manufacturing giant has invested around £35m in transforming the Scotlandbased company’s articulated dump trucks. The investment over the last six years has seen substantial improvements to the quality and performance of the Terex Trucks TA400 and TA300 ADTs, as well as heavily investing both in the factory at Motherwell and in systems, employees, distribution network and
The Liebherr TA 230 Litronic’s cab features panoramic windows without any struts
operates 16 Volvo CE haulers at East Kalimantan in Indonesia
Volvo CE has also committed to spend a further £10m-plus on improvements over the next two years, reinforcing its commitment to the Terex Trucks operation.
In 2014, Volvo CE took the long hauling heritage and product knowledge of Terex Trucks and combined it with its expertise, experience and financial backing to start an ongoing product renewal programme which has seen the launch of a new generation of Terex Trucks ADTs.
One of the key changes is a new drop-box on the TA400 – which now has heavier-duty parts as well as better lubrication lines and materials to improve durability. It also has two-stage gearing for tailored performance in all haul conditions, whether the operator’s requirement is for severe traction or high speed. There is also a new transmission on the TA300 with eight forward gears and four reverse gears, which is designed to help deliver a 5% improvement in fuel efficiency, a 5 km/h increase in speed to 55 km/h, an extended 4,000 hours oil change period and enhanced performance when compared with the previous model.
The hydraulic system on the trucks has also been upgraded – magnetic suction filters reduce the risk of component failure from environmental contamination, while
improved over-pivot hose routing boosts performance in severe working conditions. Steering cylinder cushioning has been improved, with the intention of making operators more comfortable and reducing stress on components. Hydraulic oil replacement intervals have also been extended to 4,000 hours, with the TA400 transmission oil change now at 6,000 hours, helping to reduce operating costs.
Work has also been done to enhance life for the operator, with upgraded instrumentation, controls, layout, cab-sealing, heat-shielding and a highperforming HVAC (heating, ventilation and air conditioning) system – all increasing operator comfort, safety and productivity. Additionally, the introduction of telematics is helping owners to protect their trucks by monitoring location, performance, productivity and maintenance needs.
“Because the articulated dump truck is the only product Terex Trucks develops, we’re able to focus all our attention on this machine – and that’s exactly what we’ve been doing over the last few years,” said Paul Douglas, MD of Terex Trucks. “We’ve listened to our customers and, with the help of their feedback, they are now reaping the rewards of these investments and enjoying
lower operational costs, higher uptime levels, fuel efficiency savings, extended service intervals, faster fault detection, top-quality customer service and industryleading parts availability.”
Since the Volvo CE takeover, improvements have also been made at the Terex Trucks production site. New tooling and machinery include large welding robots, computer programmed CNC (computer numerical control) machines and heat-treatment capabilities, while factory enhancements include new work compartments segregating key areas, re-laid floors and a new LED lighting system.
Since the end of last year, Terex Trucks has been working with the Molson Group – the UK’s largest distributor of capital equipment – to strengthen its presence and reinforce its commitment to customers.
“Our partnership with the Molson Group is a big benefit to our customers,” said Douglas. “They are an experienced dealer with a strong reputation for service and support and they have a 360-degree product offering, meaning that customers can now buy our trucks together with complementary machines, such as excavators, from a single source.” AB
“Magnetic suction filters reduce the risk of component failure from environmental contamination”
The HydroScrub 200 was officially unveiled at a live launch webinar on Tuesday 17 November that took viewers through critical features of the product and how it efficiently and effectively caters for various applications, allowing you to wash more and waste less.
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All comes out in the advanced wash
The pace of change in the aggregates wash plant market has been rapid in recent years. The latest example of this is Terex Washing Systems’ (TWS) new HydroScrub 200 — a state-of-the-art new addition to the company’s Greenline range of products specifically tailored to work in wash recycling applications.
Described as TWS’s “most versatile machine to date”, and the end result of a two-year research and development project, the HydroScrub 200 uses the core principles of a high-performance log-washer with new features that offer dynamic adjustment and control, ensuring a flexibility that enables the customer to adjust parameters to optimise performance and suit various types of feed material.
Comprising of hydro flotation water injection, integrated pre- and post-screens, a high-volume trash removal screen, and single-pass processing for various feed materials, the HydroScrub 200 is said to be ideal for wash recycling applications. These can range from construction and demolition (C&D) muck away applications—where the challenge is liberating the valuable aggregates and light organics from tough to break down fines and insoluble clay—to ‘high volume lights’ applications, where the level of attrition required to clean aggregates is lower, but high volumes demand more water to create the hydro separation required to float these off effectively.
Barry McMenamin, business line director -
An eye-catching premiere and how other premium plant is having a hugely positive impact on major quarrying company operations. Guy Woodford reports
Terex Washing Systems, said: “We recognise that not only is there a huge growth in the wash recycling sector, but there is everincreasing diversity in the range of materials end-users need to wash. The HydroScrub 200 offers the convenience of having one machine that can be easily adjusted to process different feed materials and provides opportunities for expansion in the range of customers you can provide a service for and expansion in terms of the volume of material they can process. It is the epitome of what we strive to offer through our Greenline range of products: balanced, end-to-end processing systems that enable our customers to wash wisely.”
wisely.
The new HydroScrub 200 is said to use the core principles of a high-performance log-washer with new features offering dynamic adjustment and control
sustainabil
Independent, family-owned business Longcliffe Quarries is fast approaching its milestone centenary celebrations. To mark the occasion, it has committed to a series of ambitious sustainability targets and has partnered with CDE, a leading manufacturer of wet processing technologies, to help realise its environmental objectives and strengthen its position as a champion of sustainability in the UK’s quarrying sector.
Founded in 1927, Longcliffe Quarries is the largest independent supplier of calcium carbonates in the UK. By 2027, it hopes to achieve zero-carbon quarrying operations.
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The Derbyshire, central England-based business produces over one million tonnes of high-quality calcium carbonate powders and granules every year, quarried from pure limestone deposits at its Brassington Moor quarry.
Calcium carbonate forms the basis of many everyday products. Longcliffe Quarries managing director Viv Russell says it has “many applications” and that the company produces over 100 products for a vast range of “critical industries”.
Longcliffe Quarries’ calcium carbonate products are vital components in animal feeds and pet foods. Its powders and granules are also supplied into the glass, plastics, and pharmaceutical industries and many more.
Russell also explained, proudly, that sealants – or cure activators – produced by Longcliffe Quarries are used in fluoroelastomer docking seals on the International Space Station.
“We are quite a wasteful industry,” Russell states, adding that Longcliffe Quarries generates “about 300,000 tonnes of waste per year.”
In pursuit of its environmental commitments, the business sought to address the high volumes of waste generated at Brassington Moor quarry.
Moor quarry.
its quarry by-product, material described as having a higher clay content. But feasibility studies and material testing to demonstrate market demand for products recovered from this stream highlighted the potential for Longcliffe Quarries to realise its commercial objectives without sacrificing its sustainability credentials.
David Kinloch, CDE’s regional manager in the UK and Ireland, says the partnership with Longcliffe Quarries began several years ago.
“Following intensive testing in our lab, we demonstrated through on-site plant trials how CDE wet processing technology could process Longcliffe’s by-product into a very clean and high-value revenue stream.
“It was after a procurement process through which CDE proved its technical capability that workshops were launched in partnership with Longcliffe to co-design what would eventually become its first-ever wet processing plant.”
CDE operates an innovative co-design approach which involves working closely with its customers to design customised wet processing solutions tailored to meet their specified commercial and environmental objectives.
Kinloch said this design process included integrating the plant into the existing setup at Brassington Moor quarry.
“One of the more unique aspects of this particular plant was how it integrated with Longcliffe’s existing primary crushing setup. We introduced overland belt conveyors to
charter product to the CDE wet processing plant.”
The resulting 220 tonnes per hour stateof-the-art wet processing plant represents the single largest investment Longcliffe Quarries has ever made.
Engineered to maximise product yield from heavy clay-bound feedstock, the plant features CDE’s signature AggMax modular logwasher setup for scrubbing and sizing.
It also incorporates CDE’s patented EvoWash classification and dewatering system which offers greater efficiency compared to more traditional washing methods.
Central to the system and to address the availability of clean water on site is CDE’s AquaCycle thickener which allows for up to 90% of the process water to be recycled and recirculated back into the system, offering near-total independence from fresh water supplies.
Exceptional water management means the CDE wash plant requires only a small top-up water supply resulting in a highly efficient system extending significant operational savings to Longcliffe Quarries.
Previously discarded clay-bound material is now being processed through the wet processing plant creating new, high-value revenue streams.
High-quality single-sized aggregates and sand grades are among the key products being recovered, which is maximising available reserves and supporting Longcliffe Quarries to realise its environmental targets.
It’s a win-win scenario, as Russell explains.
“We’re recovering up to six different products from heavily contaminated material. The CDE plant is producing a very, very clean product and one that we’re now able to turn into a higher value industrial material.”
This has led to a significant 12% reduction in the quarry’s load and haul fuel usage and follows an almost 70% reduction in net emissions recorded at the quarry since 2014/15.
Russell says the quality of the washed aggregates has created new commercial opportunities for Longcliffe Quarries.
“We’re now supplying into both the ready-mix and decorative markets as a direct result of the quality of material output from the plant. We’re processing high volumes of low-grade feed and turning that into saleable products.”
He adds that addressing the impact on the environment will produce a competitive advantage.
“As we move towards a more circulardriven economy, it’s vital that the industry continues to adapt. Our investments in renewable energy and this wet processing plant demonstrate our commitment to sustainability.
“In hard economic terms, if planning permission is to be granted, then we want to be seen as the supplier of choice. Yes, the steps we are taking now offer immediate returns, but longer-term they also position Longcliffe as a socially responsible business committed to the Derbyshire Dales.”
James Thorne, chief executive officer of the Institute of Quarrying, says technology is reshaping how the industry operates.
“There’s been a massive change in technology, and I think that’s really exciting. We’re only going to see more of that. The industry has always adapted to changes and utilised technologies coming in to its benefit to make it better and more efficient – and safer.”
He believes the Longcliffe Quarries wet processing plant will generate significant interest from across the industry.
“Projects like this are the future. It makes sense to do these kinds of things, and I think the industry will view this with real interest, particularly when you look at the big picture
Some of Longcliffe Quarries’ product being processed by the company’s cutting-edge CDE wet processing plant
Longcliffe Quarries’ 220 tonnes per hour state-of-the-art CDE wet processing plant represents the single largest investment the company has ever made
Viv Russell (left), Longcliffe Quarries managing director, pictured with David Kinloch (right), CDE’s regional manager in the UK and Ireland
of the issues we’re facing as a society.”
The integration of technology and IT in the plant, Russell says, has impressed the team at Longcliffe Quarries.
“Due to the IT related to the plant, if we’ve got an unforeseen problem then CDE often knows about it before we do. That gives us the confidence and reassurance that we are working for the right team.”
It features CDE CORE, a suite of smart technology tools that offers plant operators greater control over their plant and access to real-time data on how their plant is operating to maximise plant uptime and throughput.
“We want the plant to be running and producing products and so too does CDE. This exemplifies the partnership and shared ethos of both companies.”
Kinloch concludes: “The plant, a fully optimised turnkey solution, will provide Longcliffe with the capacity to utilise available resources to their fullest potential by extracting maximum value from previously disregarded by-product material due to its high clay content. This will facilitate the company’s growth and further strengthen our shared purpose for a sustainable future.”
Luck Stone is the largest privately held, family-owned and -operated producer of crushed stone, sand and gravel in the United States. Its 28 sites across Virginia, Maryland, Georgia and the Carolinas provide consistent, quality aggregate materials that serve as the foundation of roads, bridges and buildings.
At each new site Luck Stone develops, the firm extends its core operating principles of economic development, environmentally sound practices and values-based leadership. The company is committed to being a good neighbour and providing a positive impact on the communities in which it operates.
In 2002, Luck Stone purchased its Bull Run Plant in Chantilly, Virginia., to serve the growing Northern Virginia market. Started in the 1950s, the quarry was a low-volume, eight to 10-conveyor operation when Luck Stone began expansion efforts to meet the market demands. It moved a road to access more reserves and grew the site to approximately 70 conveyors that transport trap rock from the quarry through the crushing and wet processing plants to the stockpiles.
The expansion efforts also included upgrading their asphalt sand processing plant to increase production.
“The main driver for the expansion of the sand plant here was just the demand in the market for sand products that needed to be clean,” said Craig Wiant, assistant plant manager at the Bull Run site. “At those volumes, we can’t afford to make a pile and let it decant before we sell it, so we really needed to be able to make it on the fly, ready to ship.”
The Bull Run Plant has a lot of stock turnover, so its sand needs to be ready to ship. The company wanted a solution that would put the product on the ground as dry as possible.
“It’s really critical to us to have a lot of
sand-making capacity but also to have a lot of sand on the ground that’s ready to sell,” shared Wiant.
As part of the expansion of its sand plant, Luck Stone replaced a much smaller sand screw with two McLanahan twin 44” x 33’ fine material screw washers to more effectively remove fines from its asphalt sand.
Luck Stone also wanted to include dewatering capabilities in its new wash plant, something it didn’t have in the old plant. Dewatering screens have been proven to produce final products that are at least 10% drier than fine material screw washers. When the two are used together, they provide a greater level of dewatering. Luck Stone followed each fine material screw washer with a McLanahan VD18 dewatering screen for additional moisture removal before stockpiling.
“The screw classifiers clean the material so it’s within our customer specs and above,” Wiant said. “Then, the addition of the dewatering screens allows us to produce the product at a moisture content that’s ready to ship.”
To keep valuable solids in closed circuit, the screen throughs collect in low-profile sumps underneath the dewatering screens and are pumped back to the screw feed via McLanahan slurry pumps.
The McLanahan fine material screw washers and dewatering screens help Luck Stone produce a clean, drip-free asphalt sand for its customers.
“Our customers really want to see the percent passing the 200 mesh at a two or less, especially for asphalt mixes,” said Wiant. “We can typically put it in the pile at about 1.5% passing the 200.”
Not only does the McLanahan equipment help Luck Stone meet the strict specifications required of its final product, it also allows it to produce a drier sand. The moisture content of the sand coming off the dewatering screen is as low as 7%.
“Depending on weather and setup, we usually see somewhere between 7 and 9% moisture coming off,” explained Wiant. “It allows us to sell our material much quicker, so it doesn’t have to sit in the pile and decant. It’s pretty much ready for sale as it comes off the stacker.”
Wiant said they’ve been really happy with the McLanahan systems at the Bull Run Plant.
“The McLanahan screws and dewatering screens have been incredibly reliable,” Wiant said, “so our quality has been great. They provide a really clean product, which is what our customers demand, and they’ve been reliable since we put them in.”
With the increase in infrastructure projects in Northern Virginia, the McLanahan fine material screw washers and dewatering screens will continue to help Luck Stone meet the needs of its customers.
“Being able to provide a clean sand at low moisture to our customers allows them to build projects with the longevity to serve the surrounding community,” said Wiant. AB
As part of its sand plant expansion, Luck Stone installed two McLanahan twin fine material screw washers to more effectively remove fines from its asphalt sand
Not only is McLanahan helping Luck Stone meet its strict final product specification, its washing solution also allows the firm to produce drier sand
Mapping the way forward for use of recycled building waste
CD&E waste accounts for a large percentage of all waste produced across the European Union. With the use of the appropriate technology these resources can be recovered to a high specification and returned to the construction sector to boost the circular economy. Liam McLoughlin reports
It is estimated by European Union data body, Eurostat, that construction and demolition (C&D) waste accounted for 36% of the total waste produced in the EU-27 countries in 2018, while quarrying and mining was responsible for a further 26.3%.
According to figures from the Department for Environment, Food & Rural Affairs, the UK generated 221 million tonnes of total waste in 2016, with CD&E (construction, demolition and excavation) activities accounting for an eye-opening 62% of that total, compared with 12% from household waste.
These large CD&E waste resources can be recovered to a high specification and returned to the construction sector to further the circular economy, according to Eunan Kelly, head of construction and demolition waste recycling at Northern Ireland-based wet processing plant manufacturer CDE.
Kelly stresses the importance of the right technology, and the right processes to unlock the concrete potential in recycled materials such as sand & aggregates.
He adds that, when supported with the appropriate processing practices and technology, sand and stone resources recovered from CD&E activities are suitable for high-value construction and infrastructure projects.
“In the materials processing industry, we’re having to speak out in defence of recycled sand and aggregates and lobby for attitudinal change to encourage
greater acceptance and adoption of recycled materials,” says Kelly.
“We’re often told it’s not possible to produce structurally sound concrete from recycled sand and aggregates or it’s unfeasible to replicate the water-to-cement ratio with recycled products to produce a durable concrete.”
He adds: “These are arguments our industry is faced with regularly, and misconceptions that we at CDE move to challenge.”
Research is currently on-going to identify alternatives to sand and aggregates in concrete production. Some of the research centres around the use of woods, shredded-up vehicle components, and other unnatural concrete constituents. Kelly asserts that such research seemingly disregards the largest waste stream – from CD&E - and fails to recognise the fact that much of the material in this stream originates from the natural constituents of concrete, therefore lending itself perfectly to producing concrete.
“To combat depleting natural sand and aggregate resources we should better utilise the abundant incoming CD&E waste stream,” says Kelly.
Kelly says that, when it is being appraised, concrete produced from recycled sand and aggregates is unfairly pitted against higherstrength concrete produced using virgin aggregate, such as granite or basalt, and natural sand. He adds that not all granite or sandstone deposits display the same strength characteristics and therefore selective end-use logic is applied.
The same is true for sand and aggregates recovered from CD&E waste. Given the variability of rock geologies and other man-made aggregates, such as brick and bound concrete, Kelly says the same end-use logic must be applied.
He adds this should not undermine the potential of concrete produced from recycled materials. It is a case of identifying the strength of concrete that can be produced from recycled sand and aggregates and then pinpointing suitable applications for the product. “Current wet processing technologies deployed by CDE around the world can produce washed sand and aggregates that when used in the production of similar strength concrete are comparable in cement consumption,” says Kelly.
“Low-strength granite or gritstone would not be used to construct a multistorey building, but we can identify suitable concrete-strength applications for their use. Similarly, with CD&E material, we may never use it to construct that same multi-storey building, but there are still many applications for which it is suitable.”
Thompson Recycling, based in Scotland, is an example of a company using C&D waste to produce a wide range of products for the construction sector. With the support of CDE technology, the firm is able to replicate the grading of local virgin sand deposits to provide the local construction market with a viable and creditable alternative to natural resources.
Current concrete-strength specifications allow for recycled aggregates to be used in
Construction group Sheehan creates 20,000 building blocks a day from 100% recycled aggregates with help from CDE technology
the appropriate proportions to produce the required strength. Kelly says the majority of concrete produced is C40 strength or below. Approximately 75% of all concrete used globally is non-structural which he says begs the question, why are structuralgrade aggregates being used to produce non-structural concrete?
“Surely we would use the appropriate material provided it gives us the appropriate outcome,” he adds. “In so many cases, globally, CDE customers are producing competitive concrete for these non-structural – but still high-value – construction projects, with some applications successfully achieving beyond C45.”
Soaring urbanisation presents a global challenge to meet the demands of the construction industry, and Kelly says that recycled materials are an effective solution when supported by the most appropriate technologies and practices.
It is anticipated that, by 2050, over two-thirds of the world’s population (68%) will be living in urban settings, according to data from the United Nations, rising from around 55% of the population today.
Currently, an estimated 40-50 billion metric tonnes of primary aggregates – crushed rock, sand, and gravel – is extracted every year, and GAIN, the Global Aggregates Information Network, in its global outlook to 2030, estimates aggregates production will rise to 60 billion tonnes per year over the next decade to support growth in urban populations.
CDE customer Velde Pukk AS plays a significant role in meeting the material demands in Stavanger, Norway, in the face of a construction boom. Utilising high-quality recycled aggregates and its on-site concrete batching plant, Velde Pukk AS supplies the construction industry with a CE-certified concrete from 100% recycled sand and aggregates.
“The recycling sector will continue to grow and it will gradually become more competitive,” says Kelly. “CDE is working with its customers to stay ahead of that curve and to adopt efficient and sustainable technologies that are future-ready. Those customers who have integrated wet processing technology into their plant are reaping the commercial advantages of superior end products and are facilitating sustainable construction by recovering high-quality recycled materials.”
Robust debate is needed in the South African construction industry to map a way forward for the recycling of demolition material on the country’s construction sites, according to national surface mining industry association ASPASA.
The association says that little research or planning has been released to plot a way forward with recycling, and complexities exist that will need to be resolved before industrywide use of the practice becomes viable.
ASPASA director Nico Pienaar says it will need close cooperation between all parties concerned to be successful. This includes the civil engineering fraternity that will be required to compile standards for recycled aggregates, quarries which have the equipment required to crush and screen material, as well as the demolition industry and recycling experts who will need to apply certain processes to prevent contamination of the material.
“Recycling of building material for any other purpose than backfill is a complex business,” says Pienaar. “It requires complete separation of materials such as clay bricks, steel, glass, wood and other construction materials in order to guarantee the strength and durability of structures built with recycled constituents.”
Pienaar says that perhaps more significant is the correct grading of recycled materials that will change depending on the type of load and the construction site. It may even be necessary to have a new breed of specifiers
who are qualified in the assessment of structures to be demolished, and paths for the recycling and grading of material.
He adds that successful projects are already in operation in other parts of the world where incentives exist and legislation requires the use of a certain percentage of recycled materials.
However, without similar market requirements and incentives, the recycling of building rubble may prove to be too costly or specialised for the local market to grasp. South Africa has an abundance of suitable sands and aggregates and Pienaar says that price-driven market forces are likely to render recycled materials uncompetitive.
Even if a successful industry is launched, Pienaar states that the market in even the most advanced recycling countries is only about a 20% substitution and the construction industry will still need to be supported by a strong, healthy and profitable quarrying industry.
“New legislation around the use of recycled materials will need to be devised, as will permitting, and standards need to be introduced to ensure quality construction in future,” says Pienaar.
Pienaar is therefore encouraging other government, professional bodies, companies and individuals to make contact with ASPASA to begin setting up the process of establishing a forum to drive the way forward. “With space running out in the country’s landfills, the time to act is now,” he adds.
Ease of transport and high performance swung the purchase of a Rockster R900 impactor by Martin Meier Erdbau in Germany’s Upper Palatinate area.
Demolition business, earthworks and transport have been Meier’s specialties since the company’s founding in 1977. With 16 employees and a fleet of around 50 construction machines and trucks, the Bavarian company is extremely well positioned. Up until the purchase of the Rockster R900, recycling construction waste from bridges and buildings had been outsourced.
But the number of demolition projects has been increasing steadily over the years, and the disposal of construction waste has become more and more expensive. Martin Meier Erdbau bought the R900 mobile crusher so demolition material could be recycled anywhere and anytime.
Transport is also easy with the unit’s dimensions of 9.6m in length, 2.5m in width and 3.2m in height, and a weight of only 25.5 tonnes. AB
Eunan Kelly (right), head of construction and demolition waste recycling at CDE, with Tommie Thuresson, plant manager for Swedish recycling and landfill specialist DA Mattsson
Martin Meier Erdbau uses a Rockster R900 mobile crusher to recycle demolition waste
Making the right quarrying portable power trade-offs
Rodolfo Reimberg, vice-president marketing Portable Air at Atlas Copco, assesses quarry operators’ choices between investing in a mobile compressor powered by an electric motor or a diesel engine
In some quarrying and mining locations, site conditions dictate the use of either diesel or electric compressors because of their specific constraints. Where there is no electric power available, diesel becomes the only solution. Where the noise or emissions requirements are very high (e.g. in confined spaces), then electric compressors are mandatory.
All other cases require an assessment of the trade-offs related to the application. Factors to consider include trends in legislation, the total cost of ownership (TCO), safety, noise and emissions, the robustness of outdoor conditions and portability. Over the last few years, electric compressors have developed to such an extent that their benefits tend to exceed those of diesel compressors in most cases.
This article explores the trade-offs between diesel and electric compressors and highlights the areas where electric compressors could help quarry operators unlock new benefits.
Any new diesel compressors must meet the current emissions standards. In Europe, this means Stage V, which came/will come into effect in 2019 and 2021 depending on the engine size. Stage V aims to reduce CO2 and NOx and requires exhaust after-treatment to comply.
But regulators raise emissions standards
continuously. Even though Stage V has only just come into force, Stage VI is already under discussion. New regulations are likely to push the costs of diesel compressors upwards as manufacturers develop new technologies to keep up with the changing standards.
Electric compressors have zero emissions. They consume energy and therefore, do contribute to the carbon footprint of a site. But their contribution is lower than that of a local diesel engine on site.
The total cost of ownership is the sum of all expenses associated with a piece of equipment from purchase until resale as a used item. It includes capital cost, energy utilisation and maintenance. Each of these is discussed separately below in a comparison between diesel and electric technology.
At this stage, the market for used diesel compressors is more established than for electric models. However, as the electric market grows, the resale values should reflect a similar trend to diesel models.
Diesel compressor costs are increasing due to improvements in technology required by rising emission standards. A diesel compressor costs about 25% more today than it did five years ago. The efficiency improvements can offset some of this cost compared to older models.
Electric compressors have fewer
variables contributing to their manufacturing cost. Developments in technology are performance-driven because they have zero emissions. For example, the Atlas Copco E-Air VSD range has a unique in-housedesigned permanent magnet motor for optimal performance and minimal dust ingress.
However, purchase price is not the primary consideration when it comes to choosing which technology to adopt. The purchase price of a new portable compressor accounts for less than one-third of the total cost of ownership. Other costs like energy consumption and maintenance play a significant role.
The primary operating cost of portable compressors is due to its energy consumption. Trade-offs between diesel and electric models depend on the difference between fuel costs and electricity costs, which is illustrated by the following calculation:
A diesel-driven compressor rated at 250 CFM (7 m³/min) consumes 13.2 litres of fuel per hour. Assuming an average fuel cost of €1 per litre, the diesel compressor has an operating cost of €13.2 per hour. On the other hand, an equivalent electric compressor connected to the grid consumes 38kWh of electricity. Taking an average European electricity cost of €0.25 / kWh, the electric
Atlas Copco’s E-Air 250 electric mobile compressor
compressor has an operating cost of €9.50 per hour.
The electric compressor solution seems cheaper than diesel, but costs vary from region to region. These calculations must be updated for local contexts.
Compressor efficiency has a direct impact on energy consumption and therefore operating cost. A more efficient compressor consumes less energy to produce the same amount of air.
Diesel air compressors use generalpurpose diesel engines. They lack the efficiency of a driver that matches the compressor characteristics for optimum performance. However, the bigger the diesel engine, the more efficiently it runs. Large diesel air compressors, therefore, have very high energy efficiencies.
Electrically driven compressors have motors specially designed for compressor service. The permanent magnet motor used in Atlas Copco’s e-Air range of compressors is the most efficient type of motor in the market. They prevent dust ingress and have an excellent performance across a wide operating range.
It is important to note that Tier 4 diesel engines represent the latest technology and the highest levels of efficiency. Older Tier 2 and Tier 3 models are not as efficient as newer Tier 4 engines. Therefore, electric compressors offer even more benefits over Tier 2 or 3 models compared to Tier 4 models.
Rodolfo
Reimberg, vice-president marketing Portable Air at Atlas Copco
“Electrically driven compressors offer substantial benefits over diesel compressors in terms of maintenance”
Electrically driven compressors offer substantial benefits over diesel compressors in terms of maintenance. Electric motors don’t have removable engine parts, so the only maintenance task is to regrease bearings. Costs of spares, labour hours for servicing and ease of maintenance tasks are all in favour of electric motors over diesel engines.
The simplicity of the electric solution over diesel also affects the service interval requirements. Diesel engines need servicing every 500 hours, although newer models could extend this interval up to 1,000 hours or two years. Electric motors can run for 1,500 or even up to 2,000 hours between services. Maintenance costs for a diesel compressor average at €1 per hour, although these costs are reducing with newer machines.
Electric air compressors have a 50% lower operating cost than diesel compressors based on energy use and maintenance savings.
One question that gets regularly asked is whether electric air compressors can withstand the harsh outdoor conditions found in quarry or mining applications. Diesel compressors have a long track record of service in these environments. They have hard-hat hoods, spillage-free frames and C3-certified bodywork. But electric compressors do not have as much history of outdoor use.
Electric compressors have the same protective features as portable diesel compressors. All components of the motor and compressor are subject to extreme endurance testing. The permanent magnet motor is designed for harsh operating conditions. Its potted windings and watercooled inverter keep dust away from sensitive components. Atlas Copco e-Air range of compressors are IP 66-rated and run in ambient temperatures up to 500C.
Diesel compressors have a proven history of operating in rugged outdoor conditions, and electric compressors are designed with these same conditions in mind. They are certified to meet the requirements just as diesel compressors do.
Electric motors eliminate some significant safety risks associated with diesel engines. They remove the need for storing large volumes of combustible fuel on site. Even with the best safety procedures and culture, the presence of diesel still constitutes a risk of fire. This risk is not only associated with storage; it applies to the transport of diesel to the quarry and then the compressor location on-site.
Diesel engines generate heat. Exposed engine parts, exhaust pipes and silencers can cause injuries to workers. Best practices and safety awareness can minimise injuries as far as possible - but the nature of a diesel engine means that these risks remain.
Electric motors eliminate fuel and its associated risks. They do not generate as much heat as diesel engines, making the site safer for workers.
Electric air compressors are superior to diesel models in terms of noise. Tier 4 diesel engines meet the latest environmental regulations, but this still does not bring them close to the levels of electric motors. Electric air compressors have noise levels as low as 62 dB, which is equivalent to a normal conversation. Their lack of noise makes them suitable for sensitive areas like enclosed areas or near to public spaces.
Stage V compliance ensures that modern diesel compressors have impressive emissions performance. However, electric compressors have zero emissions. Electrical energy from the grid still results in a contribution to the carbon footprint of the project. However, that footprint remains below the emissions of a diesel-driven compressor on site.
One of the primary considerations in terms of portability is the ability to tow a compressor without special licences. The cut-off weight limit for standard licences is 750kg in Europe. Diesel compressors meeting these requirements can deliver up to 5m³/ min FAD, but electric compressors can reach up to 7 m3/min. This means that you can service a greater range of applications using an electric compressor without the need for special towing licences.
Diesel compressors have the advantage of being more quickly manoeuvrable on site because they have no electric cables. However, electric models tend to be lighter and smaller for the same air capacity making them easy to move around.
Choosing between electric and diesel portable air compressors requires some consideration of the pros and cons of each. Factors like TCO play a significant role in the final decision, but safety, noise and emissions are also important.
Advances in diesel engine technology have led to significant gains in efficiency and emissions. Most of these advances are driven by changes in legislation like the Stage V emission requirements introduced in Europe in 2019 and 2020. Regulations will continue to change, and diesel technology will continue to improve. However, electric compressors already comply with future legislation due to their zero emissions.
Some applications only allow for one type of compressor. For example, remote quarries, without access to electricity, can only be serviced by diesel-driven compressors. On the other hand, only electric compressors can service low-noise and emission environments.
However, where there is a choice of compressor technology, the advantages of electric compressors tend to outweigh those of their diesel counterparts. AB
High-performing off-highway engines for today and tomorrow
While off-highway machine engine technology is evolving, leading manufacturers are finding their current state-of-the-art engine range in high demand among quarry fleet operators. Guy Woodford reports
Due to the economic challenges of alternative solutions, quarrying and construction equipment will continue to rely on diesel for some time yet. Today, only diesel power can match intense duty cycles with a combination of energy efficiency, work capability, flexibility, reliability, durability and economical operation.
With a continued emphasis on diesel power throughout the sector, Cummins has pushed the evolution of diesel technology with its ultra-clean Stage V engines –Performance Series. This range delivers on average 10% more power and 20% more torque across the 75-321kW range when compared to Stage IV predecessors. These engines are smaller, lighter and simpler than ever before, emitting near-zero NOx and particulate matter (PM) emissions levels using innovative after-treatment technology.
The latest four-cylinder B4.5 Performance Series engine powers Hydrema’s innovative 912G articulated dump truck. The high power-to-weight ratio of the B4.5 enables the truck to operate on steep gradients and in challenging conditions, with its compact configuration allowing ease of access when being serviced.
Hyundai’s new 20-tonne excavator is also powered by the B4.5 Performance Series. The HX210A delivers more than 10 per cent higher power and nearly 20% more torque compared to previous machines, all while using less fuel.
The popular B6.7 Performance Series engine is used in key installations for the quarrying industry such as excavators and wheeled loaders. Producing over 30% more torque than its predecessor and 5% more power, the B6.7 has enabled OEMs (original equipment manufacturers) to replace engines of higher displacement, reducing costs with no impact on productivity.
Wheeled loaders from JCB and Hyundai are some of the many machines that use the
B6.7 engine across the sector. For example, the Cummins-powered JCB 456 has increased power compared to the previous model and is also more efficient. For Hyundai, the B6.7powered HL955A has higher torque at low rpm for improved productivity, with lower fuel consumption and servicing costs.
Building on the strength of the performance series, Cummins has looked to increase further the capability of its engines with power unit packaging and the addition of new rear-engine power take-offs (REPTO). Cummins’ power units are available from 75 – 503kW and come as a single, complete and ready-made package. This comprises an engine, exhaust after-treatment system, radiator and cooling system, plus auxiliaries such as mounting feet, hoses and an air cleaner. More than 60% of the content is pre-approved, making the machine integration process simpler and quicker.
The dual REPTO technology is currently available with B6.7 and L9 engines (pictured above) and power units, and complements their standard PTO capability used for items such as hydraulic pumps. Fitted with the dual REPTO, the L9 will have a total drive capability of 560Nm, making the engine capable of driving additional pumping capability. Integrated into the flywheel housing, the system is compact and has a minimal impact on engine packaging. The added weight is approximately 100kg.
Equipment manufacturers will be able to efficiently drive more from the engine without the need for additional add-on systems. Powering hydraulic pumps for machine functions such as steering systems to fans reduces installation costs and complexity, for a more integrated solution.
An Anaconda J12 jaw crusher using a Cummins L9 Performance Series engine with dual REPTO
An example of this can be found in the Anaconda J12 Jaw crusher, using a Cummins L9 Performance Series engine with dual REPTO. It is a reliable and economical solution, capable of working in the harshest crushing conditions.
Whilst diesel remains a firm focus, Cummins continues to invest in alternative power solutions such as hybrid, fully electric and hydrogen fuel cells. The aim is to develop the expertise to provide the most appropriate power source for the customers’ needs.
Cummins engines are capable of running in a range of hybrid configurations; mild, parallel and series. The right solution depends on the machine type and its duty cycle. All configurations will drive reductions in running costs and emissions. For widespread adoption, the savings made need to cover the additional cost of the chosen hybrid technology.
For full electric requirements, Cummins has acquired technology companies Brammo, JMBS and EDI. This has led to industrial projects with OEMs such as Hyundai and XCMG. Working collaboratively, Cummins has developed power for 3.5-tonne electric excavators using eight Cummins battery modules connected in a series configuration producing total energy of 35kWh.
Recently, Cummins has invested in hydrogen fuel-cell technology with Hydrogenics, Loop energy and NPROXX. This is to grow the company’s capabilities in fuel-cell and hydrogen production, storage and transport. The fuel-cell technology is currently being tested in trucks and rail applications and will likely be brought into off-highway use once it is sustainable and cost-effective.
The growth in potential power solutions means that digital technologies become an important tool to manage fleets of equipment on construction sites. Cummins has developed connected solutions to support its latest and future generations of power. From
remote equipment diagnostics, calibrations to power generation and electrified charging support, Cummins connected technologies enable real-time digital applications to keep customers operating at peak performance with less downtime and more streamlined services.
On a fitted power unit, Cummins Connected Diagnostics provides fault alert notifications, including issue descriptions and service recommendations, as well as live monitoring through an accessible web portal, mobile app and via email alerts. Any issues which arise can be managed in the most efficient manner to maximise machine availability and minimise unplanned costs for the site manager.
Cummins can also now use Connected Software Updates to offer over-the-air programming, ensuring the longevity and flexibility of engines anywhere in the world in real time. This software enables remote engine control module calibrations to be
TM420 telescopic wheeled loader which is designed for concrete batching plants in the aggregates sector - its range of OEM Mobile- and IPU-variant engines are also well suited to a number of quarrying applications. Existing JCB OEM customers already supply the quarrying market with products such as dewatering pumps, drill rigs and crushing and screening equipment – all powered by JCB Power Systems engines.
The IPU versions are perfect for quarrying applications due to the high-power density of the engines, with their robust design withstanding the environmental factors that are seen in these applications – such as dust and vibration. JCB Power Systems can also offer tailored, complete installation solutions, reducing the engineering demand on OEMs. These include fully mounted and integrated after-treatment and wiring harnesses on the lower output models and completely assembled DEF (diesel exhaust fluid) tank modules for engines above 56kW.
A JCB Stage V 430 IPU-variant engine
Rubble Master’s latest RM 100GO! (pictured) and RM 120GO! units are powered by John Deere Tier 4 Final/Stage IV engines
encountered in this environment. JCB’s air filtration systems have integrated pre-cleaners to aid longer service intervals and are also scavenger-compatible, which can further minimise downtime.
Each unit is supported by a Europewide engine distribution network that specialises in engine sales and support, providing a further level of local support to OEMs and customers. JCB Power Systems can also offer an extra level of integration flexibility with the capability of additional components, engine assembly dress modifications and specialist installation design and testing.
The quarrying market is demanding ever more complex installations, operational flexibility and robust engineered solutions and JCB Power Systems works closely with its customers to develop a true partnership. This extends to a full powertrain solution, with ongoing support and goes beyond the typical component sales model. This offering is further bolstered by the JCB Drivetrain division and its range of axles and transmissions - completing a full OEM solution for mobile applications.
Recycling has clear value for the planet, but Rubble Master makes sure it creates value for businesses as well. The Austrian company specialises in impact crushers that turn mobile rubble recycling into a revenue-generating activity for companies of any size. And its latest RM 100GO! and RM 120GO! units, powered by John Deere Tier 4 Final/Stage IV engines, are literally ‘crushing it’ in a myriad of applications — and opening up new opportunities.
Rubble Master has used John Deere engines since 2005. “We’re pioneers in our field and aim to have a global impact; we see these same qualities in John Deere. John Deere has a good reputation and a highquality product that has proven reliable for us, even in tough applications, for over a decade,” says Gerald Hanisch, Rubble Master CEO.
Originally designing solutions for entrylevel crushing, Rubble Master has never stopped developing its product line. But it always combines simplicity and productivity with power and output, comments Heinz Jank, research and development manager. “Our mobile compact crushers offer great weight-to-size ratio and excellent throughput capacity. Yet they can be operated with the touch of a button, without in-depth technical knowledge. Combining reliability, productivity, and efficiency to keep operating costs very low is critical to creating value in the competitive recycling sector.”
The company’s drive for excellence has resulted in some industry surprises. “We demonstrated that a Rubble Master impact crusher can even process hard stone — usually the job of a jaw or cone crusher. And, in certain applications, a single Rubble Master crusher can do the work of two other crushers processing material,” explains Shaun Montgomery, sales manager.
“Customers are astounded by what the RM 100GO! can process, in materials as well as throughput,” Montgomery continues. The RM 100GO! has a throughput of up to 250 tonnes per hour, but weighs only 29 tonnes. This star of the Rubble Master range can crush mineral materials, including construction and demolition (C&D) waste, concrete, asphalt, glass, coal, natural rock, and even reinforced concrete for production of high-quality construction materials. The RM 100GO! is available with a John Deere PowerTech Plus Tier 3/ Stage III A or a 235kW PSS 9.0L Final Tier 4/ Stage IV engine, depending on the customer’s location and application.
Offering outstanding performance, high output, and excellent final aggregate quality, the RM 120GO! has catapulted Rubble Master into a new league. “Customers asked for a bigger version of our crushers to compete with other heavier crushers,” says Montgomery. “But of course, we gave it our own spin, designing a unique machine from the first brushstroke to the final design.”
The flagship of the company, the RM 120GO! has an output of up to 350 tonnes per hour. As it weighs only 35 tonnes, it can still be transported on a flatbed trailer. Handling numerous applications, the RM 120GO! has even opened up a new market for Rubble Master: the mining sector.
The RM 120GO! features new solutions, including a release system that ensures an even more homogeneous final aggregate in regular operation and impact plates that enable the operator to switch between recycling and natural stone applications quickly. Customers can choose between a PowerTech Plus 9.0L Tier 3/Stage III A or 286kW PSS 9.0L Final Tier 4/Stage IV engine.
“Our reasons for using the John Deere engines are similar for both the RM 100GO! and RM 120GO!,” concludes Jank. “The dynamics of a crusher require a good engine response to maintain a constant speed at a highly fluctuating load. These engines deliver that.”
Rubble Master sees John Deere engine distributor Hamilton AG in Lauterach as a true, long-term partner. “They always provide us with detailed technical information on the engines and about the Final Tier 4/Stage IV powertrain technology. They show great flexibility in scheduling engine approvals and warranties. We are pleased to work with John Deere and Hamilton AG and are looking forward to a long, mutually beneficial relationship.”
Another Rubble Master innovation is the RM GO! SMART software tool that saves customers downtime and unnecessary costs. Integrating mobile devices such as smartphones and tablets in the infrastructure of Rubble Master impact crushers, the system enables remote maintenance regardless of network coverage. All required machine parameters are displayed, allowing customers to monitor machine performance and carry out troubleshooting routines easily.
Deutz, the German diesel engine maker for the off-highway machine industry, has officially brought a new assembly line on stream at its Cologne site.
On assembly line five, the production processes for Deutz’s successful 2.2, 2.9 and 3.6 engine series now benefit from a new set-up, making them more streamlined and increasing overall capacity. Diesel, gas, and bi-fuel engines will now be assembled in Cologne.
The new production line is located where the 2011 model series used to be made before those operations were moved to Ulm. It has been designed to optimise the flow of materials. Fully automated guided vehicle systems, for example, are used to transport materials directly to the material staging areas at the assembly line. The materials for the workstations are then pre-assembled and moved to the appropriate stations.
LEFT: Dr Frank Hiller, Deutz CEO, speaking at the official bringing on-stream of Deutz’s assembly line five at the firm’s site in Cologne,
The new final assembly line also helps to minimise process risks. A high production rate is achieved thanks to a flowing system, enabling work to take place at more than 70 assembly stations where the pre-assembled components and modules are put together. Another priority for the assembly was an end-to-end quality concept, which includes the monitoring of all threaded connection processes, the use of cameras to document critical assembly steps, and support from collaborative robots for individual processes.
The engines are subsequently checked using a cold test that is integrated into the value stream. The introduction of cold testing for engines with a capacity of fewer than four litres brings lasting reductions in busy machine time and fuel consumption at the plant.
Virtual simulation of the processes and movements enabled the production processes to be optimised for employees too, taking particular account of ergonomics and health & safety aspects.
“We are delighted to have brought on stream our new ultra-modern assembly line at our Cologne site. The process-driven design of the line will enable us to use our internal resources even more efficiently and therefore to considerably increase our performance,” says Deutz CEO, Dr Frank Hiller.
Swedish off-highway machine engine giant Volvo Penta is highlighting how quarry fleet operators’ engine choices, and how they are used, have a big impact on machine uptime. As such, the manufacturer is suggesting five ways to maximise engine productivity and efficiency.
1. Finding the right size
When it comes to industrial engines, the right size very much depends on the application you’re working in. An engine that’s too small will result in average loads that are too high, and you’ll struggle to perform the equipment’s intended tasks. This will lead to increased wear on the engine and its components. However, if it’s too big, the equipment won’t run efficiently. That’s
why it’s crucial to work with your engine manufacturer to find the right size for your application and usage to maximise uptime. At Volvo Penta, we work with our customers to
perform simulations on factors such as speed and torque trace, and calculate an accurate description of how the engine should be sized for its workload.
2. The engine after-treatment system can make all the difference
Stage V emission legislation requires off-road engines up to 560 kW to have a diesel particulate filter (DPF) which captures and stores soot. Active regeneration – the process of burning off this soot – can cause significant downtime as it requires the engine to stop. This can be minimised by choosing the right diesel engine and exhaust after-treatment system (EATS) concept to suit your specific needs.
The intervals between regenerations can vary greatly between engine manufacturers and their EATS concepts. At Volvo Penta, we have a “Regeneration Zero” vision, which means that we’ve minimised the need for active regeneration as much as possible by maximising the use of passive regeneration. Here, the soot accumulated in the DPF is burned off during normal machine operation, without the need for frequent active standstill
regener togethe cu and pro
regeneration. Through an optimised engine and EATS that work seamlessly together, we’ve increased uptime to keep customers’ machines operational and profitable.
3. Get th need it If somethin aftermarket dow that providers wh at hand and c vital.
3. Get the right support when you
If something goes wrong, getting aftermarket support quickly is crucial to reducing downtime. Choosing an engine supplier that works with competent service providers who have the right spare parts at hand and can reach you quickly is vital. Things to discuss with your engine manufacturer include dealership coverage areas, call-out service, product registration, service agreements and oil analysis.
manufacture areas, call-ou service agree
4. Training operators to ensure correct
4. o usage
Operating your engine with maximum efficiency is key for longevity and uptime. Pushing the engine too hard and operating at too high RPM (revolutions per minute) can result in increased wear on components and higher fuel consumption. That’s why it’s important to train operators, so they know the ideal RPM and engine loads for their application. This prevents downtime, and the cost savings will quickly repay the investment.
5. Using connectivity to improve uptime Connectivity can increase uptime. Engines and components can generate vast amounts of data that can be used to analyse performance and report active or predicted faults. The data transmitted will also help to identify inefficiencies and will allow technicians to assess and diagnose an engine fault before going out to service it. Connectivity is already showing huge potential for improving uptime and will continue to grow in the coming years as suppliers, OEMs, technicians and operators are exploring how data can be used to establish new ways of working. AB
The Volvo Penta Stage V engine and EATS work seamlessly together to deliver maximum uptime
A D13 Volvo Penta engine in an aggregates crusher
Lowering carbon emissions
Reducing carbon emissions from the energy-intensive cement and concrete production sectors will help stop climate change – Mike Woof, Guy Woodford & Liam McLoughlin report
Key moves are being made in the battle to reduce the effects of climate change. The cement and concrete production sector, which is highly energy-intensive, is seeing significant steps being made by some of the biggest players in the market.
CEMEX, Heidelberg Cement and LafargeHolcim have all announced developments that will help to lower CO2 emissions from this industry, which will assist in the battle to limit, and even halt, climate change. All three big industy players have pledged to become carbonneutral by 2050.
For its part, CEMEX says that it has invested over US$280 million since 2013 in technology to measure, control, and mitigate the gas and particle emissions in its operations.
Through this continuous investment, the company has introduced international standards consistent with the world’s strictest emissions regulations throughout its operations.
As a result, by the end of 2019, CEMEX achieved significant emissions reductions when measured against its 2005 baseline, the year when the company initiated its investments to improve its air quality. As of 31 December 2019, CEMEX has reduced dust emissions by approximately 90%, sulphur emissions (SOx) by almost 60%, and nitrogen oxides (NOx) by close to 50%.
The company has signed an agreement with Carbon Clean to develop an efficient carbon-capture solution by 2021.
UK-headquartered Carbon Clean provides low-cost modular carbon dioxide capture and separation technology, aimed at developing a carbon-capture solution for the cement industry that lies below the line of US$30/ tonne cost of CO2 captured.
The partners say the aim is to develop technology that allows for the economically viable capture of CO2 emissions in the cement industry on an industrial scale.
As part of the agreement, both companies will further develop and adapt Carbon Clean’s third-generation modularised carbon-capture
technology for the cement industry. Carbon Clean uses an integrated modular system that works using rotating packed beds (RPBs) to intensify the carbon-capture process. This technology could provide a significant reduction in both capital cost and equipment size compared to conventional capture technologies.
The technology will be tested for the first time in the cement industry at a CEMEX facility by deploying an industrial-scale pilot during the first quarter of 2021. The partners say the technology has the capacity to capture up to 100,000tonnes of CO2/year at a cost lower than US$30/tonne of CO2 captured.
Furthermore, CEMEX says that it expects its European operations to reach the target of a 35% reduction in carbon emissions from cementitious materials by the end of 2020, a decade ahead of CEMEX’s 2030 global commitment outlined in its Climate Action strategy announced earlier in 2020. The company has launched its Vertua carbonneutral concrete in the UK and France, which
CEMEX is working on a project for cement production using solar energy
will be gradually available in other countries where CEMEX operates.
CEMEX and Synhelion meanwhile announced that they have developed a technology to decarbonise the cement manufacturing process based on solar energy. Synhelion, based in Switzerland, is a pioneer in sustainable solar fuels and process heat.
The radical approach is based on replacing the use of fossil fuels in cement plants with solar heat, and capturing 100% of the carbon emissions, to be used as feedstock for fuel production, enabling cement manufacturing to achieve a net-zero level. This is made possible by the unprecedented temperature levels of solar heat provided by Synhelion’s technology and its pioneering process to turn CO2 into synthetic drop-in fuels, such as kerosene, diesel, and gasoline.
This solution offers a comprehensive approach to decarbonising the cement industry. Following the research collaboration completed in spring 2020, CEMEX and Synhelion will phase in the implementation of the technology. A pilot installation will be incorporated into an existing CEMEX cement plant by the end of 2022 and extended to a fully solar-driven plant.
Meanwhile, HeidelbergCement has plans for the Brevik cement production facility in Norway through its Norecem subsidiary. Brevik is to implement an industrial-scale carbon-capture and storage (CCS) project.
Giv Brantenberg, general manager HeidelbergCement Northern Europe and chairman of the board of Norcem, said: “We have been developing this project since the first desktop studies in 2005 and have interacted well over many years with the Norwegian authorities and our supportive partners.”
“Europe is on track to become the first region to reach this net-zero ambition, building on its €148.51 million investment roadmap launched in 2019”
The Norwegian government shortlisted Brevik for an industrial-scale CO2-capture trial at the beginning of 2018. On 5 September 2019, a memorandum of understanding on the capture and storage (CCS) of CO2 was signed by HeidelbergCement and the state-owned Norwegian energy group Equinor. The Norwegian government is expected to provide the bulk of the project funding.
The company has joined the SBTi (Science
Based Targets initiative) “Business Ambition for 1.5°C,” and says it is signing the pledge with intermediate targets for 2030, validated by SBTi. It adds that this commitment builds on its green construction solutions, including ECOPact concrete and Susteno circular cement.
For its 2030 goals, LafargeHolcim is further lowering its target for CO2 intensity in cement to 475kg net CO2/tonne of cementitious material. Europe is on track to become the first region to reach this net-zero ambition, building on its €148.51 million investment roadmap launched in 2019.
LafargeHolcim is also partnering with SBTi to develop a roadmap for aligning climate targets to a 1.5°C future in the cement sector.
By 2030, LafargeHolcim says it will: accelerate the use of low-carbon and carbon-neutral products such as ECOPact and Susteno; Recycle 100million tons of waste and by-products for energy and raw materials; Scale up the use of calcined clay and develop novel cements with new binders; Double waste-derived fuels in production to reach 37%; Reach 475kg net CO2/tonne of cementitious material; Operate its first net-zero CO2 cement production facility.
In addition to its pledge to reduce scope 1 and scope 2 emissions, LafargeHolcim will expand its actions to include scope 3 emissions. The company says this will cut transportation and fuel-related emissions by 20%.
HeidelbergCement will use its Norcem Brevik cement plant in Norway to trial industrial-scale carbon-capture technologies
LafargeHolcim adds that it will increase the use of recycled materials in its products and processes while recovering materials at the end of their life cycle. In 2019, the company recycled 48 million tonnes of waste.
The company says it will develop and deploy advanced technologies, preparing the next step of its net-zero journey. This includes piloting over 20 Carbon-Capture Usage and Storage (CCUS) projects across Europe and North America.
In addition, the Canadian clean technology company CarbonCure has announced an investment co-led by Amazon and Breakthrough Energy Ventures (BEV) will be used to tackle the carbon footprint of concrete.
CarbonCure is to use the investment to accelerate its product roadmap and geographical expansion in a bid to remove 500 million tonnes of CO2/year from the concrete industry by 2030. The investment is expected to help Amazon, and other companies meet The Climate Pledge, a commitment to net-zero carbon by 2040.
Other companies involved in the investment include Microsoft, BDC Capital, 2150, Thistledown Capital, Taronga Ventures and GreenSoil Investments.
And Blue Planet has developed a carbon-
capture and utilisation system to permanently remove carbon dioxide that it says is economically viable and can be deployed at Gigaton (GT) scale. It adds that the financing round was comprised of “leaders in the war against climate change”.
In strength, performance and cost, Blue Planet claims that its CO2-sequestered aggregate is equivalent to that of standard quarried aggregates.
The startup says it will capture carbon dioxide emissions from bioenergy, natural gas and coal-fired power plants, steel mills, cement plants, and refineries, as well as directly from the atmosphere. The process converts captured CO2 to carbonate for mineralisation as a synthetic limestone (CaCO3). The synthetic limestone is claimed to be able to replace extracted limestone in concrete, permanently sequestering the captured CO2
Blue Planet says the rock market represents one of the largest potential sinks for CO2 at over 50 GT every year, making its solution to reducing global carbon levels scalable and economically viable.
The company’s proprietary process creates synthetic limestone sand and gravel that can be used to make carbon-neutral and carbonnegative concrete, with the same structural
integrity of conventional concrete. By offsetting the carbon footprint of the cement in concrete, Blue Planet says its aggregate compensates for the cement component’s carbon footprint, making the concrete a net-carbon storage sink.
The process also creates upcycled concrete aggregate as a by-product, reducing the need for further extraction processes.
Blue Planet says that most carbonreduction schemes are not permanent and instead allow the captured carbon dioxide to re-enter the atmosphere at some point. The production and distribution of synthetic aggregate for concrete are said to make the operations profitable, and the plants can be financed, owned and operated without subsidies.
Blue Planet’s first plant is being constructed in Pittsburg, California, adjacent to a natural gas-fired power plant and the Sacramento Delta, for barged-material transport of raw materials and finished goods. Blue Planet concrete has already been incorporated into Terminal 1 at San Francisco International Airport (SFO), which the company says establishes a model for costneutral public procurement of low-carbon building materials for carbon mitigation. AB
For its 2030 goals, LafargeHolcim is further lowering its target for CO₂ intensity in cement to 475kg net CO₂/tonne of cementitious material.
Pictured is a laboratory at the group’s R&D Centre in Lyon, France
With its new Metso Rapid 350tph plant, ASG achieves more than 100,000 tonnes of production on average per month
ASG AIMS HIGHER WITH METSO
In India, Aman Sethi Group has achieved its higher production goal by investing in Metso’s high-capacity crushing solutions. Guy Woodford reports
To cater to the huge Indian demand for aggregates, Aman Sethi Group, which has been associated with Metso for more than two decades, opted to go with Metso’s newest addition to its rapid fleet: a NW120 Rapid jaw crushing unit and a NW330GPS Rapid cone crushing & screening unit. With this, Aman Sethi Group became the first proud owner of the 350 tonnes per hour (tph) Rapid plant by Metso. They are easily able to achieve more than 1 lakh tonne (100,000 tonnes) of production on average per month, and they have been delighted with the expert service support from Metso over the years.
With the changes in the government quarry rules and the rising demand for good quality aggregates, there was a need for a solution that could deliver quality aggregates and even enhance production volume with the lowest downtime. Seeing this need, Metso was well equipped to launch its newest product in the industry, the 350tph Rapid plant, with higher production capacity, lower operating costs and advanced automation.
Aman Sethi, proprietor of Aman Sethi
Group, said: “If we talk about Bihar or even other states, the mines are auctioned by the government and are usually given on a five-year lease to the mine operator. The key here is to mine as much as possible in the given time frame. Even the markets are booming, so the operators need to go for two or even three crushing plants in one mine to produce more; this is a challenge, due to the space constraints in a mine area. This clearly signalled the need for a higher capacity plant that can operate in less space and deliver more in a limited time period.”
He continued: “Our decision to go with Metso Outotec’s 350tph Rapid plant was good, as we are able to get more than 1 lakh tonnes of production in a month, on average, and this plant has occupied almost the same space that a 250tph plant would occupy. Hence, we are producing more in the same amount of space. I feel that this plant has the capacity to deliver even more than 1.25 lakh tonnes (125,000 tonnes) per month with constant feed from the quarry.”
Manjeet Chawla, director of Aman Sethi Group, said: “We have always been trying new things or new opportunities, and if Metso Outotec was involved, we would take a chance. We went ahead and took
the new higher capacity plant from Metso Outotec, and in record time it was installed, commissioned and we were in production.
This being a Rapid plant, I think we saved a lot of time in installation and commissioning – and that one month of extra production gave us a head start.”
Deepak Raina, DGM, Aggregate Sales, Metso India, said Aman Sethi Group’s new Rapid 350tph plant had given the group the ability to achieve higher production capacity, low operating costs and even better support.
“The Metso-supplied crushers have advanced automation, which increases the productivity of the machines and reduces the fuel consumption of the equipment. The quarry lease had already started, so the requirement for a quick setup of the plant was only possible with Metso’s Rapid range. Its setup time is minimal, and it can be easily moved from one location to another.”
Aman Sethi Group has been in the aggregates business for more than two decades and has been operating in Haryana, Odisha, West Bengal, Rajasthan, Bihar and other states.
Seeing a rising demand for quality aggregates, they opted for the best equipment available in the industry. The aim was for a
The NW330GPS Rapid cone crushing & screening unit being put to work by ASG
“The Indian market is one of the biggest markets for aggregates and we are one of the biggest mine operators in north India”
solution that could not only deliver quality aggregates but also deliver quantity with efficiency. The company founded by Som Prakash Sethi in 1975 is currently led by his son, Aman Sethi, who believes in quality products and services.
“As we were gradually increasing our business, we saw that there is a lot of demand in the market for quality aggregates that are not flaky. We witnessed the shortage of quality material and the Government’s increasingly stricter laws for the mining industry, making this business more challenging. So, we decided to go with Metso. Their quality equipment produces quality aggregates and long-term sustainable solutions that suit the mining industry – and that was precisely the need of the hour.”
The company has gradually expanded its foothold in the market and has adjusted to the changing requirements of the industry. From operating more than 300 local crushers in one zone at one point in time, the company has slowly moved to plants offering high capacity, optimum life, high uptime and the lowest cost of operating. As one of the largest producers of aggregates in the industry, the company has been regarded as a trendsetter by many other players in the industry.
“We bought the first crusher, a C125 jaw crusher from Metso, in 1997; the best part is the crusher is still operating in one of our quarries 20 years later. Seeing the
crusher operating even after 20 years gives us confidence in the Metso brand and its equipment,” said Chawla. He added: “The Indian market is one of the biggest markets for aggregates and we are one of the biggest mine operators in north India. Initially, we operated more than 300 local crushers in our quarries, as there were frequent breakdowns, and the demand was not fulfilled. Buying that first crusher from Metso changed the perception, as production quality was good, crusher uptime was high, and we were able to meet the growing market demand for aggregates.
“Any equipment can have problems, but the key in our business is how fast the problem is solved. Metso has been delivering the best service, and this has enabled us to lead from the front in this industry,” said Chawla.
The cost of a shutdown is very important to any mine operator, and the aim is to minimize it or find a solution to the issue as quickly as possible. Metso, with its wide service network spread across India, has lived up to customer expectations and has delivered quality service to its customers.
“Service plays a vital role in this crushing business, so the plant’s proper upkeep and preventive maintenance is a must. Metso’s service experts have been able to reduce these shutdowns by training our people on how to operate the plant and even educate us on inventory planning so that the maintenance is quick.” He added: “We only buy genuine spares from Metso; this way, we do not face any shutdown due to a faulty spare. I am happy with the services provided by Metso and – just like other companies –we have confidence in Metso’s quality and brand services. We have ten more projects coming up, and I am happy to share that all my future orders will go to Metso only.” AB
Aman Sethi, proprietor of the Aman Sethi Group
Manjeet Chawla, director of Aman Sethi Group
Metso-supplied crushers and screens to ASG come with advanced automation, increasing the efficiency and productivity of group plants
The new Metso Rapid plant gives ASG higher volumes of quality aggregates, while also reducing production downtime
Aman Sethi Group is the first Indian owner of a 350tph Metso Rapid plant
Productive vibrating screen from Haver & Boecker Niagara
Haver & Boecker Niagara offers the Niagara XL-Class vibrating screen, which combines advanced exciter drive technology with a wide body to offer producers high-capacity screening action at up to 15,000 tonnes per hour.
The German-based manufacturer says that the XL-Class is the largest exciterdriven machine in the industry and is suitable for high tonnage rates, such as iron ore and oil sands applications. Each XL-Class machine is custom-designed to its specific application using finite element analysis (FEA) to predict the structural behaviour of a vibrating screen.
“Haver & Boecker Niagara is dedicated to using innovative technological solutions to enhance customers’ daily processes,” said Eduardo Iizuka, Haver & Boecker Niagara chief engineer of product development. “Our ability to optimize the XL-Class to perform at peak efficiency, according to exact application requirements, provides a reliable, low-maintenance screening solution for our customers.”
The Niagara XL-Class screen is suitable for high-tonnage applications
Haver & Boecker Niagara strategically engineers the XLClass vibrating screen using FEA, which predicts high stress areas and natural frequencies. The FEA analysis equips engineers with the appropriate information to understand the machine’s expected performance, determine where to reinforce critical areas of the vibrating screen and reduce the weight of oversized components, resulting in an optimised vibrating screen. Haver & Boecker Niagara then customises each XL-Class to perform at maximum productivity according to a producer’s specific application requirements.
Epiroc breakers assist in blast-free quarrying near World Heritage site
Birla Cements’ operation near the city of Chittorgarh, in Rajasthan, northern India, is home to the world’s largest fleet of 17 giant HB 10000 heavy breakers. The company runs a fleet of HB 10000s in its limestone mining works.
Headquartered in Kolkata, Birla Cements is part of cement production group M.P. Birla. Chittogarh, where Birla Cements’ limestone mining operation is situated, is home to the historic Chittor Fort UNESCO World Heritage site.
Due to its status, no conventional mining activities are allowed within a radius of 10km of Chittor Fort. Therefore, Birla Cements opted for blast-free mining using rig-mounted heavy hydraulic breakers for primary rock excavation. For this purpose, they invested in a total of 17 Epiroc HB 10000 heavy breakers, and a further five HB 10000’s are on order.
In 2015 Birla Cements was looking for a reliable breaker
which could work for 3,500 hours without major breakdowns. Epiroc introduced them to the HB 10000, a machine legendary for its sheer breaking power. The power generated in a single impact between piston and working tool is said to correspond to a weight force of around 760 tonnes. And impact frequency is up to 380 blows per minute.
However, to optimise the HB 10000 for the specific task of primary rock excavation,
the customer discussed certain upgrades with Epiroc’s design engineers. These included features like double ContiLube II for enhanced lubrication, easyto-fix split wear bushings and modified flange seals to withstand the high temperatures. Epiroc’s patented Intelligent Protection System (IPS), a fully automated, state-of-the-art system that provides simpler, more efficient, and more economical operation, was implemented as well.
Cat’s new fully mechanical D6 GC
Caterpillar has added the fully mechanical D6 GC to its bulldozer line-up. The vehicle offers 158 kW (212 hp) of nominal net power and operating weight ranging from 21,630 to 22,710 kg (47,686 lb to 50,067 lb).
powershift transmission and Caterpillar exclusive torque divider are designed to ensure that more useable power gets to the ground for solid all-around performance in a wide variety of applications.
analogue dash display add to the simplicity and ease of operation.
The D6 GC comes with either open (canopy) or enclosed cab, both with integrated roll-over protective structure (ROPS/FOPS) for comfort, excellent visibility and added safety. The suspension seat includes a built-in retractable seat belt, and the cab is available with air conditioning for added operator comfort.
The elevated sprocket is designed to help make maintenance easier with modular components that are easy to remove/install for service. Segmented sprockets are easy to replace.
The undercarriage is optimised with strong structures for stability and durability. The twopiece track roller frame has a maintenance-free recoil system, and the sealed and lubricated track helps prevent internal wear and maximise bushing life.
Epiroc breakers in action at limestone works near Chittor Fort
The D6 GC dozer can be used in a variety of applications
Maptek updates modelling software with fragmentation analysis
A powerful fragmentation analysis tool is a centrepiece of the new Maptek PointStudio 2020 geospatial modelling and reporting software, just released to customers. Better understanding of fragmentation can account for phenomenal downstream cost-efficiencies, with implications for many aspects of an operation, according to Maptek’s group product manager mine measurement, Jason Richards.
“Sub-optimal fragmentation is immediately associated with inefficient excavation and haulage,” said Richards. “Undue damage to crusher parts is another impact. Excessive energy usage, crusher downtime due to wear and tear outside of planned maintenance and delivering out-of-specification product are directly linked to operational performance.”
PointStudio Fragmentation Analysis is designed to allow KPIs (key performance indicators) to be
achieved consistently. Individual rocks can now be modelled from scanning of muck piles and draw points to provide accurate fragmentation S-curves from blasting or caving operations.
The new tool allows blast engineers and surveyors to quickly assess the condition of blasted rock, ideally before the material heads to the crushing process. Oversize rocks can be isolated for more effective haulage and processing.
Richards said that a simple scan > analyse > report workflow provides a table where rocks outside of spec can be identified and dealt with before the material gets anywhere near the plant.
“A unique feature allows editing rocks or fines in the 3D view and characterising any that are not correctly defined,” he added.
Maptek states that visual and tabular reporting is understandable at a glance so rock can be fed with optimal dimensions for crushing.
Key role for Ammann plant at Chinese asphalt producer
An Ammann mixing plant is helping Hangzhou Road & Bridge Group reduce emissions and change perceptions at its asphalt production centre in China’s Zhejiang province. Having already purchased an Ammann UniGlobe 320 asphalt-mixing plant in 2011,
bought an ABA 320 UniBatch asphalt-mixing plant from Ammann in 2017 for use at the facility in Hangzhou, the capital of Zhejiang province.
“This asphalt-mixing production centre has raised the standard of the entire industry,” said Jerry Shang, Ammann China
Engcon offers locking system as standard Engcon is now offering its Quick hitch Standard Control (QSC) safe locking system as standard on all tiltrotators with Engcon’s control system.
The Swedish company says that, from October 1, the previous system for controlling the bucket lock under the tiltrotator on excavators has been replaced by Engcon’s standardised locking panel.
The previous system for controlling the excavator bucket lock under the tiltrotator will be replaced with Engcon’s standardised locking panel, directing the driver’s actions by means of an alert system to ensure correct positioning. Engcon says this simplifies the handling of the bucket lock with the hitch control function being standardised, regardless of the make and model of the excavator. It adds that this minimises the risks of dropped or swinging tools.
”We usually compare it to the fact that the accelerator and brake pedals would have different placements in a car depending on which car brand it is,” says Martin Engström, product manager at Engcon. “In short, if a driver who changes from one excavator to another and can operate it in the same way, the risk of making mistakes with serious consequences is greatly minimised.”
In addition to the standardisation of the locking procedure, Engcon says it is also impossible to activate the bucket lock under the tiltrotator while the bucket is hanging in midair – a safety function that it claims is unique to its locking solution.
region director. “It has changed people’s impressions that making asphalt is messy and dirty – instead of a modern, clean, factory-style approach.”
The ABA UniBatch and the UniGlobe are at the core of the centre, which has a very small footprint and is located in the densely populated subdistrict of Renhe. This makes the minimisation of sound levels of the utmost importance, and both Ammann plants utilise cladding to reduce emissions, sound and dust levels. Hangzhou Road & Bridge must comply with strict governmentmandated environmental standards, and Ammann says its plants help businesses meet such emissions challenges.
The safe locking system minimises the risk of accidents
Aggregates Business travels the globe attending conferences, events and equipment shows, keeping you informed of the latest offerings. Come and join us for a chat at any of the events below.
JUNE 2021
22-24 Hillhead 2020 Hillhead Quarry, Buxton, Derbyshire, England
JULY 2021
07-10 EIG 2021 Exeter, UK
These dates were correct at the time of going to press, but please note that the COVID-19 pandemic means some events may be rescheduled with little advance notice
