ABI Sept-Oct 2020 by Prime Creative Media

INTERNATIONAL

SEPTEMBER/OCTOBER 2020

| Vol.8 ISSUE No.5 | www.AggBusiness.com

High-performance screen media

PONSI BLY

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INTERVIEW Bheki Mthembu: PPC’s next steps in uncertain South African cement sector p10

DRILL RIGS, TOP HAMMERS & BREAKERS A high-quality drill rig for major China limestone mine p28

WATER RECYCLING, MANAGEMENT & FILTRATION Innovation in washing plant technology leads to big commercial gains p31

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F OO T P R

I N T E D & PO S

An assessment of its bottom-line-boosting potential p19

DUCE OU

CONTENTS

INTERVIEW

“As the cement industry, we remain optimistic that if these strategic objectives of the government materialise, the construction sector will rebound, creating many jobs and contributing to a q quick uic turn of the economy” ” p10

INTERNATIONAL

SEPTEMBER/OCTOBER 2020

| Vol.8 ISSUE No.5 | www.AggBusiness.com

Vol.8 ISSUE No.5 September/October 2020

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 New and proven crushing and screening plant is proving itself in largely unreported as well as traditionally strong markets

10 INTERVIEW PPC’s Bheki Mthembu discusses the current state of the South Africa cement industry, the industry’s future and the role of technology in the ‘new normal’

PONSI BLY

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I N T E D & PO S

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INTERVIEW Bheki Mthembu: PPC’s next steps in uncertain South African cement sector p10

Specials

An assessment of its bottom-line-boosting potential p19

Hi-tech solutions for optimised drill and blast in quarries and surface mines

39 BLASTING & ATERNATIVES

High-performance screen media

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More than 1,400 delegates attended the 7th China Aggregates Industry Technology Conference, emphasising the size and importance of the country’s giant aggregates sector

F OO T P R

Rotary cutter heads are making an increasingly strong case for their deployment in quarries globally

05 COMMENT

35 ROTARY CUTTER HEADS

DRILL RIGS, TOP HAMMERS & BREAKERS A high-quality drill rig for major China limestone mine p28

Regulars

DUCE OU

WATER RECYCLING, MANAGEMENT & FILTRATION Innovation in washing plant technology leads to big commercial gains p31

COVER STORY: Premium screen media from MAJOR during a customer material processing application. The Canadian-headquartered global market manufacturer has highlighted the beneﬁts of investing in high-performance screen media for quarry operations

13 MARKET REPORT India’s aggregates sector has been rocked by COVID-19, but huge demand remains as the country continues to implement its huge national transport infrastructure programme

23 LOADING Next-generation, quarrying-suited excavators and high-performing wheeled loaders are creating an eye-catching global loading machine market

16 QUARRY PROFILE A leading Tunisian sand product supplier has successfully ventured into a new industry thanks to the purchase of a bespoke CDE wet processing solution

26 HAULING A new Doosan articulated haul truck has become a reliable workhorse for a Bavarian clay and loam pit operator

28 DRILL RIGS, TOP HAMMERS & BREAKERS Premium drill rigs, top hammers and breakers are in demand on quarry and surface mine sites globally

31 WATER RECYCLING, FILTRATION & MANAGEMENT Investing in quality water recycling, ﬁltration and management solutions is a must in modern quarrying

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43 HYDRAULIC HAMMERS IN AFRICA

Rapid technological advancements in hydraulic hammers in recent years have ensured proper operation and enhanced breaking efficiency

46 CHINA BELT & ROAD INITIATIVE IN THE MIDDLE EAST COVID-19 continues to play havoc with China’s ongoing multi-billion Belt & Road Initiative (BRI) projects in the Middle East

43 AGGREGATES BUSINESS INTERNATIONAL September/October 2020

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COMMENT

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EDITOR EDITOR E EDITO DITO

Strength in numbers

he size and importance of China’s huge aggregates industry would have been quickly apparent to any delegates running late at the start of the recent two-day 7th China Aggregates Industry Technology Conference. They would have entered a vast room at the event’s hotel venue in Shijiazhuang, Hebei province, to be greeted by more than 1,400 people eagerly awaiting the start of proceedings on 28th August 2020. Hosted by the China Aggregates Association, the high-profile conference was sponsored and co-organised by many leading companies in the China building materials and off-highway machinery sectors. They included Hebei Jiuzhou Mining Co., Ltd., Shanghai Sanme Mining Machinery Corp., Ltd, Jiangsu Shanbao Group Co., Ltd., Northern Heavy Industries Group Co., Ltd., Shibang Industry & Technology Group Co., Ltd., Wuxue Minben Mineral Resources Development Co., Ltd., Shenyang Shunda Heavy Mining Machinery Manufacturing Co., Ltd., Henan Liming Heavy Industry Technology Co., Ltd., Nanchang Mineral Systems Co., Ltd., Comps Compressor (Shijiazhuang) Co., Ltd., and Guangzhou Leimeng Machinery Equipment Co., Ltd. Hu Youyi, president of China Aggregates Association, delivered a keynote speech titled ‘Scientific Development and Innovative Development of the Aggregates Industry - Establish a Modern Aggregates Industry System’. The comprehensive address covered relevant state documents of the aggregates industry, future economic trends and aggregates industry development trends, market demand for aggregates, innovation in the aggregates industry, the construction of a modern aggregates industry, the development model of the aggregates industry and the issues enterprises should pay attention to. President Hu pointed out that after the COVID-19 pandemic, the state has promoted the concept of “two new and one heavy” (‘two new’ equating to new infrastructure and urban construction, and ‘one heavy’ referring to major construction of transport and water conservancy projects). Hu noted that there is a huge demand for aggregates and relevant equipment in China, and that national aggregates prices continue to rise,

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alongside the rapid growth in income of industry enterprises. Hu said today is the best era for the development of the aggregates industry in China. The central state and local governments, noted Hu, have issued many documents to promote the high-quality and healthy development of the aggregates industry. China’s aggregates industry has entered what he 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, stressed Hu. In his speech, CAA’s president introduced the future economic and development trends of the aggregates industry. He highlighted the importance of artificial intelligence, super-highspeed rail, efforts to build larger sand dredgers and mining excavators, 3D-printed buildings and bridges, aerial construction factories, cutting-edge demolition machines, green transport and other key innovations. Hu also introduced many aspects of constructing a modern aggregates industrial system, including policies and regulations, regional planning and design, quarry planning and design, scientific research, technology development, standards and specifications, quality inspection and monitoring, enterprise inspection rooms, a certification and accreditation system, corporate credit-rating evaluations, aggregates industry science and technology awards, appraisal of scientific and technological achievements, education and training, statistical analysis of industry data, information research, industry development trend research, the construction of a big data platform in the sand and gravel industry, intelligent manufacturing, and smart mines. Other conference highlights included Li Huajian, postgraduate tutor and researcher at the Chinese Academy of Railway Sciences, giving a talk headed ‘Considerations on the Status Quo of High-Quality Manufactured Aggregates Production and Application Technology’.The 7th China Aggregates Industry Technology Conference was undoubtedly a reminder of how China is not only the biggest aggregates market in the world, but also one of its most advanced. GW

gwoodford@ropl.com AGGREGATES BUSINESS INTERNATIONAL September/October 2020

NEWS

ASPASA WANTS TO CRUSH CORRUPTION Surface mining industry association ASPASA has thrown its full weight behind the Minerals Council South Africa’s call for visible leadership in the eradication of corruption. Representing mainly smaller surface mines, the association accounts for a large portion of the overall number of mines in the country and has a large and well-established member base. It is an active participant in council matters, as well as actively engaging all levels of government and labour bodies.

Nico Pienaar, ASPASA director ASPASA director, Nico Pienaar, says the industry and the economy, in general, are being hamstrung by corruption and illegal mining that threatens the existence of the formal mining industry. Smaller mines feel the brunt of such corruption more quickly as they have limited resources and are often less resilient than larger mines. “The Minerals Council said it supports President Ramaphosa’s zero-tolerance approach and called for the President and the law enforcement authorities to act urgently against those within his government, and those businesses and other citizens who have looted public funds, including funds intended to ease the impact of COVID-19,” said Pienaar. “Corrupt practices breed larger-scale corruption and needs to be stopped at its roots to reinforce morality in the industry.”

CEMEX: ‘Operation Resilience paves road to a better future’ M exican building materials giant CEMEX has revealed the framework of ‘Operation Resilience’, its medium-term strategy, that incorporates the challenges of the COVID-19 pandemic and lays out a plan to enhance EBITDA (earnings before interest, taxes, depreciation and amortisation) growth over the next three years. During an open dialogue with top management, CEMEX announced that despite significant COVID-19 disruptions, it expects EBITDA for the full year 2020 to grow approximately 4%, on a likefor-like basis for foreign exchange, over the prior year. This performance results from the decisive management actions as well as better than anticipated market conditions. With increased visibility and higher EBITDA expectations, CEMEX says it is comfortable in rolling out its medium-term strategy. Operation Resilience consists of the following components: • Enhancing EBITDA margin through operational performance and disciplined cost containment: New 2020 cost reduction target of $280 million while targeting additional savings in 2021-2023. Targeting a consolidated EBITDA margin of at least 20% on an “as is” portfolio basis.

CEMEX CEO Fernando Gonzalez • Optimising the company’s portfolio for higher growth with lower risk: Undertake strategic divestments to streamline portfolio and deliver while seeking attractive,

bolt-on investment opportunities in the company’s footprint; construct a portfolio more weighted towards the USA and Europe; focus on vertically integrated positions in attractive metropolises and develop urbanisation solutions as a core business. • Achieving investment-grade capital structure to promote future growth: Utilise EBITDA growth, free cash flow, and divestiture proceeds to improve capital structure and achieve a target net leverage of at least 3.0x by 2023. • Recognising sustainability as a competitive advantage: With a proactive Climate Action strategy, advance towards its 2030 carbon reduction goal and the company’s ultimate vision of a carbon-neutral economy. “Operation Resilience lays the foundation for our future. It allows CEMEX to optimise its portfolio for profitable growth while securing its position as a leading, vertically integrated heavy building materials company with a focus on four core businesses: cement, ready-mix [concrete], aggregates, and urbanisation solutions,” said Fernando A. Gonzalez, CEMEX’s CEO. “We will concentrate on developing sustainable urbanisation solutions which meet the needs of growing metropolises while we ourselves progress towards achieving our long-term decarbonisation goals.

Hitachi marks 70 years of excavators Hitachi Construction Machinery Co is celebrating seven decades since the start of full-scale production of its excavators. The company’s ﬁrst mechanical excavator – the U05 – was developed by Hitachi Ltd and used to help rebuild post-war Japan. Hitachi had developed this excavator with in-house technology in 1949 and fully entered the construction machinery market in 1950 with the mass production of its successor, the U06. To mark the 70th anniversary there will be various online and printed materials featuring legendary Hitachi machines of the past. The Hitachi Construction Machinery (HCM) subsidiary was established in Japan in 1970, followed by its European subsidiary, Hitachi Construction Machinery (Europe) NV (HCME) in the Netherlands in 1972.

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

In Europe, HCME has evolved into a multinational organisation, with production facilities in the Netherlands and supported by an extensive dealer network. In addition, Hitachi Construction Machinery Group also introduced “JCMG” (Japan Construction Machinery Global) as a certiﬁcation of quality assurance to customers. HCM says the JCMG mark symbolises its desire to deliver high-quality construction machinery to global customers. The mark has been placed on HCMbranded products since January. Hitachi has recently introduced the next-generation Zaxis-7 medium and large excavators.

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NEWS

Cement producers are expected to shore up balance sheets in the near-term

DEUTZ MAKES FURTHER PROGRESS WITH CHINA STRATEGY Deutz is continuing to make good progress with its growth strategy in China. Now that Deutz and diesel engine maker Beinei’s new factory for contract manufacturing has been completed, local production of the 2.9 and 6.1 engine series can commence in early 2021 as planned. Engines for aerial work platforms, forklift trucks, and smaller construction equipment will be made at the site in the port city of Tianjin, which will serve as the production hub for the Asian market (see pic: Deutz). German off-highway machine diesel engine manufacturer Deutz’s joint venture with China’s largest construction equipment manufacturer Sany is also progressing well and has already proved proﬁtable this year. The objective is to raise the annual production volume of approximately 7,000 achieved in 2019 to around 20,000 engines in 2020.

Cement producers focus on consolidation post-COVID

ement industry companies are less likely to enter new markets through mergers and acquisitions (M&As) in the near future and will look to consolidate their positions in existing markets, according to an analyst at Bank of America. Christopher Reynolds, senior operations project analyst at Bank of America, said there has been a conservative and decelerated approach to large M&As in the sector since 2014, and this is likely to continue in the near-term in the wake of the global pandemic with companies shoring up balance sheets and focusing on

self-help measures. “I don’t have a crystal ball but I think we will see continued portfolio refinement and an opportunistic approach to smaller acquisitions,” he said. “We may however see disposals as people look to trim leverage positions and strengthen the balance sheet.” Speaking during a webinar hosted by the World Cement Association, Reynolds added that regional manufacturers have started to account for a greater share of the market over the last decade. In 2010 the four major global players (HeidelbergCement, LafargeHolcim, CEMEX and CRH)

had a 62.5% share of the market in terms of revenue as a percentage of total sales, compared with 37.5% for regional players. By 2019 this had switched to regional players accounting for 59.3% of sector revenue compared with 40.7% for the global players, with the expansion of Chinese cement manufacturers being the main driver of regional sales growth. COVID-19 has led to a downward revision of broker forecasts for sales and income in the sector, with net income predicted to be down in the range of 18% to 56% at the four major global players in 2021.

SDLG stages virtual factory tour amid travel restrictions The LG936 wheeled loader was among products showcased The Deutz-Sany assembly plant in Kunshan produces engines for trucks, construction equipment, and concrete pumps. This joint venture, established in 2019, has allowed Deutz to consolidate and build on its position as an experienced technology partner in China. The two joint venture partners are currently building a new engine plant in Changsha, which is scheduled to be completed at the end of 2021. Deutz and Sany had received subsidies of around RMB 300 million (approx. US$37 million) from the city of Changsha to fund the project.

China-based SDLG has conducted a live-streamed tour designed to showcase its smart manufacturing process and highlight the reliability of its range of wheeled loaders, excavators and graders. With many countries’ borders still closed amid COVID-19 and

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

the need for safe social distancing, SDLG offered the virtual tour over three live-streamed virtual events. “Since it’s hard for our customers and dealers to visit us in China, we wanted to bring SDLG to them, so we offered virtual tours of our smart manufacturing process and

shared how we build SDLG’s equipment to offer reliability in action,” said Wang Xiaohui, general manager of SDLG Import and Export Company. The event was live-streamed via SDLG’s online shop at SDLG. en.Alibaba.com and was offered in five languages: French, Spanish, English, Russian and Arabic. SDLG business manager Zhang Shuai took participants on a virtual tour of the company’s assembly line for wheeled loaders and excavators. Zhang also offered an in-depth look at the company’s research and development facilities, test yard and parts warehouse. Products highlighted during the event included the LG936, L958F and L975F wheeled loaders; the G9190F motor grader; the E635F and E680F excavators; and the B877F backhoe loader. Over 3,000 people watched the live stream event and it garnered some 22,100 likes on the website.

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INTERVIEW

Bheki Mthembu, head of the Inland Business Unit at PPC

Unpacking the impact of COVID-19 on SA’s cement industry The impact of COVID-19 on the South African cement industry has been devastating, with Bheki Mthembu, Head of the Inland Business Unit for Africa’s largest cement producer, PPC, describing it as the ‘ﬁnal straw’ on an industry already in survival mode prior to the pandemic. He discusses the current state of the industry, the cement sector’s future and the role of technology in the ‘new normal’. By Munesu Shoko

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

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INTERVIEW

hat the cement industry in South Africa is in dire straits due to the COVID-19 pandemic is no overstatement. While almost all sectors of the economy have been hit hard, Bheki Mthembu acknowledges that the cement industry is one of the worst-hit industries during the current pandemic. According to Mthembu, the industry was already in survival mode pre-COVID-19 and the outbreak of the pandemic pretty much served as the “final nail in the coffin”. The business environment pre-COVID-19 was already tough, with the industry operating at almost half of its capacity, with the importation of cheap cement from Asia undercutting local manufacturers by at least 45% exacerbating the situation. “Prior to COVID-19, the cement industry in South Africa was already at ‘rock bottom’, with most of the cement producers having to halve their capacities. We also had to fight against the importation of cheap, substandard cement into the country, while calling to order the so-called cement blenders who were taking shortcuts as far as their quality and subsequent prices were concerned,” explains Mthembu. To provide some context, figures from The Concrete Institute show that South Africa has become a net importer of cement with total imports increasing by 139% since 2016. A total of 350,441 tonnes (t) of cement arrived in South Africa during the second quarter of 2019 – the most since the third quarter of 2015. Most of the cement landed at Durban at the time – the 260,909t that arrived there was an 85% increase on the first quarter of 2019. Combined with unprecedented low levels of demand due to slowed economic growth, the industry was already facing a survival crisis pre-COVID-19. The COVID-19-influenced hard lockdown, dubbed Alert level 5 of South Africa’s tiered approach to fighting the

pandemic, saw the complete shutdown of the cement sector and the construction industry at large, leaving cement producers with absolutely no revenue during the month of April. While Alert Level 4 regulations allowed the cement manufacturers to operate at 50% capacity levels, the construction industry was still completely shut, leaving cement manufacturers in a precarious position. The start of Alert Level 3 in June offered some reprieve for the industry, with Mthembu noting some recovery, notably driven by the retail sector.

“We remain optimistic that if these strategic objectives of the government materialise, the construction sector will rebound” “We have seen a notable recovery of the market due to some small-scale building and renovation activities currently going on. Thus, the retail sector has been a bit positive for us in June and July. However, there is very little happening on the large construction projects front,” says Mthembu. One inherent advantage that PPC has over some of its competitors is its wider geographical footprint. To give an idea, under Alert Level 4 of the lockdown, government allowed cement operations to operate at 50% of their capacity. Thus, a cement producer with only two sites, for example, operating at 50% of its capacity, is nowhere near PPC’s 50% capacity across eight factories around South Africa, says Mthembu.

Digitalised and highly automated production in the cement sector is more important than ever to gain a competitive edge

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PPC’s extensive geographical footprint, he says, also means that the company can still operate sustainably in the event that one of the operations records a positive COVID19 case, which according to government regulations, necessitates immediate closure for deep cleaning and disinfecting purposes. “We can, therefore, navigate the challenges posed by COVID-19,” he says. While COVID-19 has had a devastating impact on the economy, Mthembu believes it has also served as a wake-up call for the government, highlighting the need to prioritise infrastructure development as the path to economic recovery, as well as to fight social ills such as the lack of water sanitation and housing. In an environment where people are obliged to social distance and continuously wash hands to curb the spread of the virus, Mthembu notes that the call is impossible in areas like townships where, for example, a family of seven has to share a two-bedroom house, and the provision of potable water is erratic. To this end, the government has gone on record to say there is a need to drive housing and water infrastructure aggressively. Apart from the need to prioritise social infrastructure, Mthembu believes that the government also understands that the quickest route to resuscitating the economy post-COVID-19 is via infrastructure development. “In June the government hosted the Sustainable Infrastructure Development Symposium, where President Cyril Ramaphosa made promising commitments to prioritise infrastructure development to support structural transformation, creation of jobs and economic recovery,” he says. The symposium notably reflected on a number of projects that have been identified by the National Infrastructure Fund. The fund has finalised a list of projects worth ZAR700billion (£30.8bn) over the next 10 years.

PPC is the biggest cement producer in Africa

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

INTERVIEW

PPC owns Pronto readymix in Gauteng, South Africa Mthembu is of the view that as South Africa works towards overcoming the social and economic fallout of COVID-19, the development of key infrastructure will play a critical role in building the economy and creating jobs. Infrastructure development can be the catalyst that places the country on a new growth trajectory, he says. “As the cement industry, we remain optimistic that if these strategic objectives of the government materialise, the construction sector will rebound, creating many jobs and contributing to a quick turn of the economy,” he adds. Looking ahead, Mthembu is of the view that the more pressing concern for cement manufacturers post-COVID-19 will be the increased pressure to rapidly ramp up production in an effort to recoup output lost during the lockdown. Like many, Mthembu believes that technology and innovation will play a central role in the future of the cement industry. In such a highly competitive environment, conventional business approaches will lose their place, he reiterates. Mthembu is a proponent of innovation and modernisation, key values shared by his company, PPC. PPC understands that modernisation of its plants is critical to building and sustaining the momentum needed for long-term development. “Technology in future will play a central role in the cement industry. Robotics and instrumentation, for example, will take over the role of labour in manual operations where you have people loading and unloading cement bags, for example. In Africa you still find that this task is largely done manually, which, in the current operating conditions, makes it difficult for people to social distance due to the labour-intensive nature of these functions,” he reasons. Mthembu believes that the current situation creates major challenges for cement companies, not only in South Africa, but across the continent, and shows that digitalised and highly automated production is more important than ever when it comes to gaining a competitive edge.

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

“This is the only way that companies can react to current and future challenges with the required degree of flexibility,” he says, adding that just as important as the tools are the staff operating these new technologies. Automatic and digital processes, he says, will be made possible by a pool of well-trained and skilled people who understand the complexities of the technology. Thus, the key benefit of the approach to modernisation, he says, is skills transfer, equipping current and future generations with critical skills related to advanced cement manufacturing technology, as well as technical sales and distribution. From a productivity perspective, Mthembu says new technology helps cement manufacturers with the much-needed efficiency and higher throughputs than older technology. “Technology plays a significant role in driving efficiency, allowing cement producers to run at a lower cost per tonne,

which helps with the paying back of the capital investment quite faster.” Additionally, Mthembu believes that post COVID-19 cement producers must be more concerned about two main objectives – a smaller carbon footprint and lower energy consumption, especially considering that a carbon tax introduced in 2019 on the South African cement industry’s activities will definitely increase the industry’s production costs. Many of the cement industry’s industrial production techniques need a revamp. Cement production is one of the most polluting and energy-intensive processes, and the demand for a better way is only equalled by the demand for the product itself. “New technology will be the best of both worlds for the industry; it will help the industry meet its sustainability goals, while reducing operating costs significantly through energy-efficient plans,” concludes Mthembu. AB

PPC’s Mooiplas quarry in Centurion, Gauteng, South Africa

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MARKET REPORT

LSC Infratech’s sand producing technology acquired from Weir Minerals, Bangalore, is a key feature at the company’s Bharatpur crushing facility in Rajasthan

Challenging times for Indian aggregates sector Led by a renewed government push to develop road and railway infrastructure, demand for aggregates in India continues to remain strong. However, a continuing shortage of ﬁnance for the acquisition of newer plant, a dearth of plant operators due to COVID-19, and forthcoming elections in many states are hindering aggregate sector growth. Tough regulations around commercial quarrying and the Indian government’s growing preference to work with steel slag as an alternative material to aggregates for road construction are further challenges facing aggregate product producers. Partha Pratim Basistha reports

he Indian Infrastructure sector is yet to fully overcome the negative impact of COVID-19 that led to nationwide lockdowns, resulting in the largescale stalling of construction projects. This has had an adverse effect on cash flows, with the main contractors and plant and machinery owners delaying planned purchases of newer crushing and screening plants, excavators and rigid dump trucks. An extended monsoon in India, coinciding with the third-quarter lifting of the country’s tough lockdown measures, has also contributed to the subdued demand for aggregates plant. However, given the need to press ahead with the very ambitious national road infrastructure programme, the Indian Government has moved to address liquidity issues. One new major initiative has been a moratorium on the repayment of loans taken out by contractors and plant and machinery owners. This has driven new business, but new plant trading is yet to rise above 2018-19 levels.

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Jaswinder Singh Bakshi, senior vicepresident-head of Commercial Finance - Construction Equipment & Commercial Vehicle Finance at Tata Capital Financial Services, said: “There has been spurt in cases of financial foreclosures by some major contractors, subcontractors with large equipment fleets. On a positive note, there has also been some traction on offtake of finance as well since June 2020. This is following the first quarter, under Covid lockdown.” Singh Bakshi, who is also the convenor of the finance panel at the Indian Construction Equipment Manufacturers Association (ICEMA), added: “With some improvements in cashflow, there have been enquiries for excavators, compactors, crushing and screening equipment between 150-300 tonnes per hour, and rigid dump trucks.” The National Highways Authority of India (NHAI) aims to develop 65,000kms of the government-funded Bharatmala (national road and highways) project. The DPR (detailed project report) for 40,000kms

is in process, while the tendering process for 4,500 kms is underway. There are plans to award 20,000kms of projects during fiscal year 2020-21, with 12,000-13,000kms of Bharatmala projects due to be completed in that period. Buoyed by Bharatmala works, some major commercial quarry plant owners are expanding their operations and investing in new plant. Speaking to Aggregates Business International, Saurabh Agarwal, director, LSC Infratech, one of India’s biggest commercial quarry firms, said: “We are in the process of setting up a new and completely integrated aggregates and silica sand plant at Karauli in Rajasthan, north India. The 200 tonne per hour plant being set up at substantial capital investment will be one of India’s most state-of-the-art crushing and screening and manufactured sand plants.” Currently at the commissioning stage, the new cutting-edge LSC Infratech plant features a two-stage jaw and cone plant from major Indian crushing and screening AGGREGATES BUSINESS INTERNATIONAL September/October 2020

MARKET REPORT

ABOVE: A major new plant from Propel Industries RIGHT: A Terex WJ 1175 jaw crusher at LSC Infratech’s Bharatpur site BELOW: A truck having its sand payload weighed at an Indian minerals processing facility prior to setting off on a customer delivery and manufactured sand machinery maker Propel, based in southern India. The separator for the plant is being supplied by Australian firm Mineral Technology, while the washing solution has been engineered by allmineral, part of the Germany-based Hazemag group. Aggregates from the new unit will be sold to major road contractors working in north India, while silica sand will be sold by LSC Infratech to major glass manufacturers like Asahi Glass and Saint Gobain. One of north India’s biggest upcoming road projects is the 296km four-lane accesscontrolled Bundelkhand Expressway project. The mega-expressway, which has recently been awarded by the Uttar Pradesh State Government, is divided into six packages. It will expand Uttar Pradesh’s expressway network by 1,192kms. Agarwal said: “While major Indian road contractors like G.R. Infra, Sadbhav Engineering, and DS Infrastructure, who are involved in big ticket, recently-awarded projects, continue as major customers for our aggregates, we are now also seeing aggregates demand from rural infrastructure projects centred on rural housing and roads. The Indian government’s recent ‘Swach Bharat Abhiyan’ (Clean India Drive) to improve cleanliness through the construction of drainage and sanitation systems is also creating demand for crushed aggregates and manufactured sand.” LSC Infratech sells its products to traders, they in turn sell to small contractors involved in rural infrastructure projects. LSC Infratech has crushing and screening and manufactured silica sand plants spread across Uttarakhand, north India, and in Bharatpur, Rajasthan. To improve productivity in its other plants, it has acquired five LiuGong, three Tata Hitachi wheeled loaders, and two 20-tonne LiuGong excavators. It has also acquired Ashok Leyland rigid dump trucks, made in India. “We have been receiving some very

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

positive enquiries for 20-tonne class excavators from large-scale commercial quarry owners such as AME and Alliance Mining to handle crushed aggregates from their new mineral processing units. Besides, we have also received enquiries of excavators from major road contractors like G.R Infra, Apco, PMC and KCC,” said Manoj Kotru, director, Alpha Teknisk - Volvo Construction Equipment dealer for north India. Gaurav Rughwani, director - Chandra Tech Services, LiuGong India dealer for Maharashtra, western India, covering the Vidarbha region, said: “Renewed activity in road construction led by some improvement in cashflow has been driving demand for excavators among commercial quarry firms with 150-200 tonnes per hour capacity stationary and mobile plants. There is close to a 25% improvement in demand for excavators from major Vidarbha crushing clusters that supply aggregates to road contractors. Demand is also good from

crushing clusters in Chhindwara and Seoni, in the states of Madhya Pradesh in central India.” Piyush Kumar, a Kobelco excavator dealer based in in north-east India, said: “Multiple road projects have created stable demand for excavators from quarry owners from the seven states in north-eastern India. However, poor liquidity is major issue when it comes to getting finance for new machines.” Ongoing highway widening projects, from single lane to twin- or three-lane highways, in various states are also driving Indian aggregates demand. Among recently tendered, large-scale NHAI and state government road projects is the INR 816.16 crore east India-based Bihar State government-backed 8.86km elevated road along the eastern side of the Patna Gaya Railway Line from Mithapur to Ramgovindsingh Mahuli Halt in Patna. The NHAI will be soon be calling for bids for the widening to four lanes of the Pararia to Mohania section of NH319 in Bihar state. The

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MARKET REPORT

ABOVE: Rail track renewal in east India RIGHT: Puzzolana conveyors carrying various sizes of crushed aggregates at Mondal Stone Quarry’s crushing site in the Pachami crushing cluster, 250kms north of Kolkata BELOW: Wheeled loaders and backhoe loaders in action at a big crushing site in Pachami crushing zone in West Bengal project has an estimated cost of INR 818.72 crores. Set to cost around INR 2668 crore, Rail Vikas Nigam (RVN), India’s state-owned railway construction firm, will soon start constructing tunnels, bridges, yards and supporting formation works for a new 125km broad gauge link between Rishikesh and Karnaprayag in Uttarakhand state. RVN also plans to develop high-speed rail corridors linking the four metropolitan cities (Chennai, Delhi, Mumbai and Kolkata). The company also proposes to develop dedicated coal freight corridors for high axle load freight trains. This will be increase demand for aggregates to pack beneath railway sleepers. A major track laying and renewal programme is also underway. Despite the many eye-catching infrastructure project possibilities, purchase officials from major construction companies who have mainly bid for road projects, such as GR Infra and Sadbhav Engineering, state that major new orders for aggregates to deliver such projects will depend on how soon the proposed works get their funding in place. There is also uncertainty on how long sub-contractors and plant and machinery owners have to benefit from the current finance moratorium offered by banks and other financial institutions. Some financial institutions have laid down strict clauses stipulating that parties will be only eligible for fresh loans once they have repaid their existing loans. There also remains some apprehension over how much emphasis recently elected state governments will place on infrastructure investment, while other state assembly elections are still to take place. Tripat Pal Singh, director of Chhattisgarh Minerals, one of the major commercial quarry owner in the central India state of Chhattisgarh, said: “The newly elected government in the state has put on hold some of the vital local infrastructure projects

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awarded by the previous government. Besides, the new government has put some restrictions in commercial quarrying and overburden removal. Due to the new regulations, even the NHAI projects being delivered in the state have been facing a slowdown.” Chhattisgarh Minerals owns one Propel 250 tonnes per hour plant, with jaw and cone crusher combination. It also owns one Indian-made Proman 200 tonnes per hour cone crusher. Despite a slowdown in demand of aggregates, the company is working actively to replace its two 8x2 Man and two Asia Motor Works (AMW) rigid dump trucks with a new high-capacity 12x4 advanced Tata rigid dump truck. German firm Man has stopped production at its Pithampur plant in central India. AMW has followed suit. Production of and demand for aggregates has also reduced in the major eastern India states of West Bengal and Bihar. With state assembly elections in both states scheduled to take place in the next few months, India’s

Election Commission will soon bar ruling state governments from announcing new infrastructure projects. With elections around the corner, it is unlikely that operating licences will be renewed or retendering opportunities available to commercial quarries operating in major clusters like Gaya, Nawada, Sheikhpura, and Sasaram in Bihar. However, production of and demand for aggregates from Rajmahal, Sahibganj and Taljhari areas in the mineral-rich state of Jharkhand, adjoining Bihar, in eastern India have been firm. One of the major demands is for railway ballast for new railway track laying and track renewals in West Bengal and Bihar. Sandvik has recently commissioned one 300 tonnes per hour jaw-cone crusher combination plant in Rajmahal. Production of and demand for aggregates originating from the major crushing cluster of Panchami in West Bengal has also fallen during the COVID-19 pandemic. Some key local commercial quarry owners including Kohinoor Stone Products, Orbona Mining and KBC Mining have stopped operations of their plants. Dibyendu Khamaru, senior commercial and plant operations manager for KBC Mining, said: “Premium Pachami aggregate output has also been affected by a recent shortage of rigid dump truck operators. There has also been the major ongoing issue of poor access roads connecting the Pachami cluster to main roads. Moreover, West Bengal government regulations on the overloading of trucks have become tougher with higher penalties for breaches. Finally, there is slow demand in real estate construction in West Bengal, previously a major customer for aggregates.” KBC Mining owns one 200 tonnes per hour jaw-cone crusher Sandvik plant which produces up to 45,000 tonnes of aggregates per month. KBC Mining owns eight 8x2 Tata, two newly purchased 8x2 Bharat Benz and two 8x2 Mahindra rigid dump trucks. AB AGGREGATES BUSINESS INTERNATIONAL September/October 2020

QUARRY PROFILE

SOMEVAM EXCELS IN GLASS SAND PRODUCTION THANKS TO CDE

A North African premium sand product supplier has successfully ventured into a new industry thanks to the purchase of a bespoke CDE wet processing solution. Guy Woodford reports

OMEVAM, a subsidiary of the Sebri group, has operated sand quarries in Oueslatia, Tunisia, serving the national construction market since 2001. Following testing of material, the company saw the opportunity to diversify into the glass industry in North Africa and Europe and produce a range of supplementary products, including industrial sand and silica flour. The company also wanted to produce a 30-150micron fraction that would make its offer unique in the region.

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

SOMEVAM sought an effective wet processing solution that would eliminate contaminants and offer variable cut points to increase the quality and commercial value of the end products. Each day, SOMEVAM extracts 3,000 tonnes of sand. To handle such quantities efficiently while also adhering to stringent quality standards requires the most advanced, durable and sustainable processing equipment. Together, the Tunisian company and CDE have developed a tailor-made wet processing solution to support SOMEVAM to achieve its commercial growth aspirations.

The design process, underpinned by CDE’s co-creation approach, allowed CDE engineers to work directly with the SOMEVAM team to develop a modular wet processing installation perfectly suited to the feed material (including a silica content of 99%) and the company’s production targets. Habib Sebri, CEO of SOMEVAM, explains: “Before we got into glass sand, we operated the Oueslatia site for the production of building materials. However, it was clear that the material onsite presented an interesting commercial opportunity in the field of silica for flat glass applications such as windows, mirrors and flat glazing.”

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QUARRY PROFILE

ABOVE: CDE’s tailor-made wet processing plant for SOMEVAM has helped the company diversify into the glass sand industry BELOW: In collaboration with SOMEVAM, the CDE team designed a bespoke installation capable of simultaneously producing ﬁve products of different particle sizes without the risk of mixing so as not to compromise their quality and consistency

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Sebri says it was essential to invest in the right sand treatment equipment to guarantee the success of the project. “After exhaustive research of the various options at our disposal, we chose a modular wet processing solution from CDE. The expertise of the company’s engineers and sales team, its investment in innovation and new technologies, and the quality of the materials used during the manufacturing process were the key determining factors in our decision.” To guarantee precise control of sand cut points, SOMEVAM opted for a complete turnkey CDE solution. The CDE plant can treat up to 200 tonnes per hour of sand, producing 100 tonnes per hour of silica glass sand for the glass industry. It can also make a range of secondary products including fine silica sand for silica flour production, foundry sand, concrete sand and road base. The installation features a combination of CDE equipment operating in perfect synergy; an M4500 primary wash plant to classify materials, five high-frequency Infinity Screens, four attrition cells, spiral separators, CDE’s Counter Flow Classification Unit (CFCU), a nano-cyclone, magnet, four EvoWash sand washing units and an AquaCycle water management solution. Combined, the system processes fine and coarse materials and eliminates contaminants to produce high-specification glass sand. Since its launch in 2014, CDE’s M4500 has quickly become popular and is installed in plants around the world. This high-tech plant is compact, powerful, easy to use and economical. CDE’s cyclone technology uses centrifugal force for classifying materials rather than gravity, which retains every grain of viable sand in the system. The design of the cyclone also makes it possible to establish a number of variable parameters to obtain unrivalled cut-point precision. Attrition, spirals and magnetic separation processes are used to remove contaminants from the product and maximise the silica content. Bassem Idriss, project manager for the Europe and MENA region at CDE, explains: “The M4500 demonstrates the effectiveness of CDE’s cyclone technology and the flexibility of our process and engineering teams, who have designed the process to produce very high-quality glass sand to meet SOMEVAM’s requirements. “The hydrocyclones were built according to the specific needs of the client, based on analysis of the feed material carried out by CDE during the pre-project phase. “The process water, loaded with undesirable fines, is removed at the level of the overflow of the cyclones while the treated sand enters the dewatering and stockpiling phase. With cutting points of incomparable precision, the products are treated according to the required standards and without risk of mixing.” AGGREGATES BUSINESS INTERNATIONAL September/October 2020

QUARRY PROFILE

To produce a very clean sand product requires a very good supply of clean water. The new installation incorporates CDE’s cutting-edge water management system, the AquaCycle thickener with a capacity of 1500m³ per hour. Waste water from the plant is processed by the AquaCycle thickener which recovers up to 90% of the process water to be recirculated back into the washing plant, minimising the size and maintenance requirements of the settling ponds, which is particularly advantageous where the site is situated in Tunisia. Idriss continues: “In Tunisia, a hot and dry country, it is important to consider the difficulties of accessing fresh water. It is essential not to waste a drop of water. CDE’s AquaCycle allows SOMEVAM to recycle process water in a closed circuit for immediate reuse in the system. “The waste water, after passing through the deaeration chamber and after having been in contact with the flocculant injection, passes to the centre of the AquaCycle so that the flocculation process operates and acts on the sedimentation of the fines. The integrated flocculation unit allows precise dosing of premixed flocculant for effective decantation. A single motor drives the AquaCycle rake arms for optimal sludge treatment before disposal.” The CDE installation for SOMEVAM transforms the feed material into five highspecification products with exceptional commercial value. It produces glass sand (150-650 microns) and related products, including oversized (3mm) ready to be used in water filtration systems, coarse sand (650 microns-3mm) ready to be ground to make flour silica, ultrafine (30-150 microns) for ceramics or other industries, and ironrich sand that can be used in sports fields. With a typical moisture content of 12%, the materials are market-ready straight from the belts.

CDE’s AquaCycle allows SOMEVAM to recycle process water in a closed circuit for immediate reuse in the system

Sebri comments: “Our CDE solution has made a huge impact on the glass sand industry in Tunisia and in the North African market. It represents the most advanced technology available on the North African market and has enabled us to become ultracompetitive in an industry with extremely high-quality standards. “Our glass sand is sold for the production of white glass, and the other fractions are sold for various industrial applications. Our quick return on investment was thanks to the power and efficiency of our CDE solution. “We have succeeded in expanding our offer and positioning ourselves in new markets, which has strengthened SOMEVAM’s reputation with its customers for quality and consistency of service.” CDE equipment is designed and manufactured to adapt to the circumstances of each unique site to maximise the quality

Some of SOMEVAM’s glass sand product

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

and quantity of the materials produced. In the case of SOMEVAM’s siliceous site, the requirement was an exact solution to support the business to expand its operations adhering to stringent quality standards in the glass sand market. In collaboration with the client, the CDE team designed a tailor-made installation capable of simultaneously producing five products of different particle sizes without the risk of mixing so as not to compromise their quality and consistency. CDE engineers work with the company’s sustainability ethos in mind; to achieve a goal of zero waste and maximising water efficiency. CDE offers a range of advanced technology products with modular design features that can facilitate future upgrades to the existing system. Every CDE project benefits from its customer-for-life model. It ensures transparent and effective communication from the beginning of the project until commissioning and unrivalled after-sales support. Sebri concludes: “We are very satisfied with the value for money our CDE equipment has provided. We particularly appreciate the service we received. At the start of the project we visited CDE’s facilities in Northern Ireland and felt assured by the quality of the materials used and the expertise of its engineers, both in the design and in the manufacturing of our installation. “CDE offers a complete service, from design to after-sales, managed at all stages of the project through a single point of contact and based on over 25 years of international experience and wet processing expertise. This was hugely important to us given the level of investment and the longevity of our operations. “Mr. Idriss, our CDE project manager in Tunisia, as well as CDE’s engineers onsite, were present and attentive to all stages of the project, ensuring a smooth process. I can say without hesitation that CDE has revolutionised our operations.” AB

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CRUSHING AND SCREENING

Falkland Islands quarry upgrades to meet thriving demand The new crushing and screening train in action at Pony’s Pass, East Falkland

The only operational quarry in the Falkland Islands has invested in new mobile crushing and screening equipment to meet the South Atlantic Ocean archipelago’s increasing demand for aggregates. Liam McLoughlin reports

ony’s Pass Quarry in the Falkland Islands has invested in three new crushers, an impactor and two triple deck screens. Despite its isolated position on East Falkland, the quarry is a booming site which annually produces 160,000 tonnes of quartzitic sandstone using a state-of-the-art mobile crushing and screening train. Sandvik Mobiles has advised the quarry on a train of equipment to best complement the uptime required for an operation of this scale. The chosen crushers and screens have been deployed since the start of 2020 and comprise a UJ440i jaw crusher, two UH440i cone crushers, a QI442HS impactor and two QA451 triple deck doublescreens. Pony’s Pass currently provides perfectly sized aggregates for road construction and infrastructure development projects as well as supplying an on-site asphalt plant. Future developments are likely to see the current 160,000 tonnes annual production increase to over 300,000 tonnes per year. Due to the isolated geographic position, over 300 miles from the mainland of Latin America, and the extreme weather conditions that are frequent, this meant that the solution chosen had to tackle all potential challenges. As the only Falkland Islands quarry, almost every project on the island requires aggregates from Pony’s Pass, meaning

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service and aftermarket support is also a vital component to keep operations running smoothly. The new equipment has performed with output levels always meeting expectations, according to Pony’s Pass quarry manager Marc Short, who added: “We currently use our mobile crushers to produce three small end materials: these being 10/20mm, 5/10mm and 0/5mm crusher dust. However, we have the ability to produce type 1 (all in 0/32mm) and secondary crusher run (all in 0/75mm). These machines are tracked up to the blast site (currently located in the

bottom of the quarry) where they are fed with as-blasted material.” The feed material is crushed quarzitic sandstone, with a maximum feed size of 700mm. The abrasive nature of the rock and the need for machines that can deliver maximised uptime meant that it was essential for the quarry to have a durable and productive primary jaw crusher before the material is passed through to the secondary crushing stage. The heavy duty UJ440i jaw crusher provides jaw settings that can be adjusted

The new trommel drum cleaner from MDS

AGGREGATES BUSINESS September/October 2020

CRUSHING AND SCREENING

hydraulically with a choice of jaw plates to suit the needs of the operation. This means that the crusher can work at optimum levels for longer periods, with all impact zones having a rubber lining to reduce wear and noise. In addition, the 62.5 tonne crusher has a 1,200 x 830mm jaw opening enabling it to deal with Pony’s Pass’ 700mm feed. The UJ440i can crush at a throughput of 250mtph. Following on from the UJ440i jaw crusher, the rock is then fed into the UH440i cone crushers and the doublescreens for precision sizing. Sandvik claims that its QA451 is the world’s first triple deck doublescreen, whilst the 50 tonne UH440i cone crushers are specifically aimed at large-scale aggregates producers’ requirements. The result is the production of fractions the quarry’s customers require. “0/5mm, 5/10mm and 10/20mm is used for concrete and asphalt production,” said Short. “Type 1, secondary and crusher dust is used for road construction. Some of the larger products are also used to build up sites with fill etc.” He added that one of the main reasons for choosing Sandvik was the fact that the quarry already has the same type of cone crushers on the site which is beneficial for compatibility. “We also already use two Sandvik drill rigs on site which adds to this,” said Short. “A lot of research was carried out prior to committing to Sandvik, they proved to be a good return in investment. The procurement of a mobile crushing train was a huge commitment and investment which took a lot of research. In the end, these particular machines best suited our requirements.” In addition to the above, the highway’s section acquired a QI442HS impactor to provide primary and secondary crushing and screening in one unit. The features include a new rotor position and locking device, innovative hammer-locking wedges for quicker removal and fitting, as well as a new wedge removal tool to provide safer installation and removal. This means that it is also able to deliver a wide range of high reduction ratios, superb product shape and outstanding uptime which are essential to the requirements of the island’s authority. UK trommel screen and accessories manufacturer MDS says its new drum cleaner

AGGREGATES BUSINESS September/October 2020

is a “game changer” for the trommel market. The trommel drum cleaner features a cog wheel-style configuration that meshes with the drum openings and punches out the holes to keep them clean. The cleaner is designed to replace the traditional method of trying to brush trommels clean. MDS says the drum cleaner is at its happiest when punching out the soils and clays that traditionally blind over scalpers in both quarries and recycling yards. Luke Jones, quarry manager for Whitelock Developments, near Skipton, North Yorkshire, England, said: “Without the [MDS] drum cleaner we wouldn’t have been able to screen our wet and sticky recycled products. It gives us a competitive advantage in the market when others can’t produce clean aggregate material.” All the current MDS trommel range can be fitted with the drum cleaner. This includes the tracked range (M412, M413, M515 two or three split, and M518R) and the static range (M615, M620, M720, M820 and M925). MDS says its business has continued to grow despite the global pandemic, and the company has made a 15,000 square feet extension adjacent to its current factory. The new unit will provide increased production capability for the existing range in addition to extra capacity for new product introductions such as the M518R and other trommels that are planned for launch in 2021. The company says business growth and an increasing worldwide demand for

ABOVE: Bauhof Deutschlandsberg has deployed a Rockster R1000S impact crusher BELOW: MDS is expanding production capacity for its trommel range

its products has meant the new facility is a necessity to maintain its existing lead times. Jason Purllant, MDS UK and EU sales manager, commented: “We needed to maintain our target of 6-8 weeks lead time on all products whilst introducing new products into the range.” MDS CEO Liam Murray added: “We are really excited about the continuing growth of our business globally with new dealers being appointed all around the world. “We plan to have an open day towards the end of the year to celebrate the opening but also give future and current customers the chance to see first-hand what we do at MDS.” Austria-based Bauhof Deutschlandsberg is a major player in the country’s provision of high-quality recycled building materials. As part of its recycling activities the company has deployed a Rockster R1000S closed-circuit impact crusher with a screening system & air blower since the beginning of 2020. In addition to a trommel screen, excavators, loaders and road rollers, Bauhof has also previously used a rented crushing plant which processed around 40,000 tonnes of debris, asphalt and concrete per year. At the end of 2019, the company decided to replace this rented plant with a new closedcircuit impact crusher R1000S from Rockster. The company says the crusher has three major assets in terms of guaranteeing high quality of the end-product in one workflow: a screening system for a precisely defined size of end-product; a magnetic separator for removing iron and other metals, and an air blower for separating non-aggregates such as polystyrene, wood, plastic, paper and similar. “To be honest, we were surprised at how well the Rockster Air Blower works, especially when it comes to recycling debris, it brings a huge increase in efficiency,” says Pistolnig. Since being deployed in January, the R1000S has already produced 16,000 tonnes of concrete 0/80, 8,000 tonnes of asphalt 0/18, 600 tonnes of wall ballast 0/16 and 500 tonnes of construction debris 0/20. “We are extremely satisfied with the quality of the end-product,” Pistolnig adds. “The mixture of coarser and fine grain is just right for further use in the concrete mixing plant or on construction sites.” Rockster’s hydrostatic crusher drive is particularly responsible for the sizes of the final product to be precisely adjusted to the desired quality. Bauhof’s processing capacity is 80,000 tonnes per year - which corresponds to a saved landfill volume of 55,000m³ - and it has a recycling rate of 98%. Its principle expertise

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AMMANN ARS SOIL COMPACTORS PRODUCTIVE. SUSTAINABLE. COST-EFFECTIVE. Ammann ARS Soil Compactors utilise advanced technology that meets the latest emissions standards, reduces fuel usage and gives operators valuable data that eliminates unnecessary passes. That’s just the beginning of the advantages these machines offer. • Multiple vibration frequencies and centrifugal forces enable productivity on a wide range of materials and compaction thicknesses.

• The new ECOdrop initiative and new technologies improve efficiency and reduce fuel consumption and the amount of required ﬂuids.

For additional product information and services please visit : www.ammann.com MMP-2511-01-EN | © Ammann Group

• The compactors are extremely manoeuvrable and stable thanks to the no-rear-axle structure.

CRUSHING AND SCREENING

is in building demolition, container services and the recycling of all types of construction debris. Pistolnig commented: “The management of construction waste is of growing interest for both the construction industry and waste management. Residual building materials that do not end up in a landfill but are returned to the economic cycle as highquality RC [recycled] building materials are an ecological necessity.” Lars Bräunling, director of product technology at wire screen manufacturer MAJOR, says that self-cleaning screen media offers a number of benefits, including the elimination of pegging and blinding for aggregate and mining operations. However, certain design characteristics, such as limited opening sizes, leave producers with little option on where to employ self-cleaning screen media in their operation. Because of this, self-cleaning screen media is often thought of only as a bottom deck solution. Bräunling adds that, recognising the opportunity to take the principles of selfcleaning screens a step further, engineers looked for ways to increase durability and provide application-specific customisation for a productivity-boosting solution producers could use on any deck. The result was a new category of screen — high-performance screen media. In terms of what makes high-performance media different, Bräunling says: “One of the biggest drawbacks of using traditional self-cleaning media on upper decks is that it cannot stand up to the impact and abrasive forces of larger material. High-performance screen media addresses these issues by incorporating enhanced wire and a unique structure to maximize durability and wear life.” It begins with the wire, according to Bräunling. Wire quality plays an essential role in screen performance, and he says many manufacturers choose their wire based on current market prices, resulting in fluctuating wire quality and inconsistent performance. “Some manufacturers, on the other hand, rely on high-quality wire in their screen media to ensure consistent quality and durability. It offers improved molecular structure over other techniques for optimum tensile strength, hardness and ductility, resulting in the highest quality, longest-lasting wire.” High-performance screen media’s strategically engineered wires are held together with polyurethane strips, eliminating the need for cross wires with high wear spots. This innovative design maximises open area and extends wear life as much as five times longer than wire alone — even on top decks. Taking advantage of these design benefits, Bräunling says that producers who employ high-performance screens on the top deck are able to realize the screen media’s payoffs earlier in the screening process, as well. He adds that stratification is one of the key benefits. “High-performance screen media wires vibrate independently from hook to

AGGREGATES BUSINESS September/October 2020

LEFT: An aerial view of the EvoQuip Colt 1000 scalping screen BELOW: Using high-performance screen media can extend wear life up to ﬁve times, according to manufacturer MAJOR

hook under material contact, supplementing vibrations from the screen box with additional frequency to accelerate the stratification process.,” says Bräunling. “This added frequency can be as high as 8,000 to 10,000 cycles per minute — up to 13 times higher than the standard screen box vibration — helping fine material to stratify and pass through the screen faster.” Optimising stratification at the very start of screening results in faster screening and optimal throughput, according to Bräunling. Greater quantities of fine material pass through the screen media’s open area earlier in the process, which increases the effective capacity of the machine and virtually eliminates carryover. Some aggregate and mining producers have shown as much as a 40% increase in overall production with highperformance screen media. UK plant hire company P&L Barton - based in Carnforth, Lancashire - has reconfigured its EvoQuip Colt 1000 scalping screen to meet the requirements of the latest project it is involved in. The application has been to produce limestone walling stone for one of its regular clients where space was limited. P&L Barton set about reconfiguring the Colt 1000 so that both conveyors discharged out the same side into segregated areas, maximising the area available and eliminating double handling. Richard Barton, plant manager at P&L Barton, commented: “The Colt 1000 is the perfect machine for us due to its flexibility. Being suited to scalping and fine screening and the ability to quickly convert from

3-way to 2-way split and to swap conveyor configurations means it’s suitable for many applications and job sites.” P&L Barton purchased the Colt 1000 in June 2019 from equipment supplier Blue Central, and since then the machine has been on hire contracts in multiple configurations to suit the required job sites. “We have been able to run the machine in 2-way split on one project then convert it so that mids and fines are discharged on the same side on a really compact site, and in standard set-up on another site,” said Barton. “With the range of media options available I don’t think there is any job she can’t do.” P&L Barton started out in 1972 when Peter Barton invested in his first digger, a JCB 3C, and set up P Barton Plant Hire. Almost 50 years later the company remains a familyrun business and has evolved and expanded working on a vast array of projects. Its clients include private households and businesses, local councils and large multi-nationals. It provides plant and services on a sub-contract or hire only basis, offering a wide range of services to the quarrying, construction, groundwork, civil engineering, recycling and haulage industries. The Colt 1000 is able to operate in both heavy-duty scalping and precision-screening applications and is designed to manage the most difficult of materials. Flexibility is enhanced with configurable conveyor options and two-way split conversion. It features an aggressive double deck screen, variable screening angle with numerous screen media options, broad fines conveyor, quick set-up time and tall discharge heights. AB

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The new Hitachi ZX490CLH-7 crawler excavator is part of the quarrying-suited, next-generation Zaxis-7 range of large excavators

Loads of appeal to quarrying customers Next-generation, quarrying-suited excavators and high-perfoming wheeled loaders are contributing to an eye-catching global loading machine market. Guy Woodford reports

itachi Construction Machinery (Europe) says it is putting owners and operators in complete control with its next generation of Zaxis-7 large excavators. The new ZX490LCH-7, ZX530LCH-7, ZX690LCH-7 and ZX890LCH-7 Stage V-compliant models have an industry-leading cab with firstclass comfort and safety features. Hitachi says their exceptional reliability, efficiency and productivity provide owners with opportunities to increase profits and reduce costs. An impressive claimed fuel saving of up to 20% in PWR mode (power mode) compared to previous models is said to be achieved by Hitachi’s industry-leading HIOS-V hydraulic system. This also enhances efficiency in the swing, boom lowering and arm bucket rollout. Productivity is further increased by the improved front speed for loading operations, and the increased engine output of the new Zaxis-7 machines contributes to a higher workload. The fuel efficiency of Zaxis-7 large excavators can also be controlled by using the new ECO gauge, clearly visible on the cab’s multifunctional eight-inch monitor. Besides reducing costs, better fuel economy has a positive impact on environmental performance. The new machines are Stage V-compliant thanks to the combination of the SCR (selective catalytic reduction) system, DOC (diesel oxidation catalyst) and CSF (catalysed soot filter).

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A new Hitachi ZX890LCH-7 crawler excavator feeding a primary crusher

The state-of-the-art, ultra-spacious cab is the perfect working environment. It is said to offer operators ultimate comfort and quality, with reduced noise and vibration levels in the cab, both vital in the quarrying and mining industries. New features include the synchronised motion of the seat and console – to reduce operator fatigue – and the adjustable console height with three positions to choose from. Easy operation comes from the ergonomic

design of the console and switches, and the hi-res anti-glare screen is also easier to view. Job-site safety is said by Hitachi to be enhanced by the exceptional view from the Zaxis-7 large excavators. Operators can control their own safety, as well as that of those around them, thanks to the Aerial Angle camera system. It provides a 270° bird’s-eye view, and users can choose from six image options to see the machine’s immediate environment. When working in challenging conditions, new LED work lights and a windscreen wiper with an increased sweeping area further improve visibility. Tested rigorously at dedicated facilities in Japan, Hitachi Zaxis-7 large machines have been built to last and maximise uptime. New engine parts enhance reliability, oil leakages are less likely, and the durability of the track frame has been improved. In addition, the undercarriage of the ZX490LCH-7 has robust new components that prevent potential damage. Hitachi says the ZX530LCH-7 has 30% greater traction force than the ZX490LCH-7 and increased steering force – particularly advantageous for manoeuvrability on sites with inclines, such as quarries. The ZX690LCR-7 and ZX890LCR-7 models are built with reinforced parts that are ideal for the digging and loading of heavy materials. Strengthened to cope with the rigours of mining and quarrying, they provide lower costs over the machine lifetime. Easy maintenance and cleaning features AGGREGATES BUSINESS September/October 2020

on all Zaxis-7 large excavators save operators and owners both time and money. The fuel filter is now integrated with the water separator, and the larger radiator improves heat dissipation and is easier to clean. To enable owners to feel in total control of their fleet and workload, Hitachi’s remotemonitoring systems, Owner’s Site and ConSite, give them access to vital data and tools. Both systems send operational data via GPRS or satellite from the excavator to Global e-Service on a daily basis. ConSite summarises the information in a monthly email, while the ConSite Pocket app shows real-time alerts for any potential issues. The quality of the engine and hydraulic oil is monitored continuously by a Hitachi innovation. Two sensors detect if the oil quality has deteriorated and data is transmitted to Global e-Service. This novel feature provides customers with peace of mind on the condition of their excavators and reduces maintenance and unscheduled downtime. “We’re proud to present the latest range of Hitachi large excavators to our European customers,” says Hitachi Construction Machinery (Europe) NV president Makoto Yamazawa. “Hitachi has continuously improved on previous generation machines to enhance the operator’s experience in the cab, to meet the needs of owners, and to provide support over the life cycle of our machines. By working in partnership with customers, we can help them to create their vision.” Doosan has launched the new DX800LC-7 Stage V-compliant 80-tonne crawler excavator, the largest excavator model ever manufactured by the company. Coinciding with the launch, Doosan has announced the sale of the first DX800LC-7 in Europe to a customer in Finland. Driven by the most powerful engine in the 80-tonne class, the DX800LC-7 also has the highest hydraulic flow for this size of machine, providing best-in-class performance, with higher productivity, lower

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fuel consumption and smoother controls. Like all Doosan excavators, much attention has been given to operator comfort and safety. The DX800LC-7 has a new, very spacious operator cab, equipped with ergonomic controls and instrumentation. Special care has been taken to ensure noise is kept to a minimum through enhanced sealing of the engine compartment and extensive use of sound-dampening materials. All components and assemblies are designed, built and tested to ensure durability. Multi-stage filters and features such as track guards and cylinder guards for the boom and arm, the auto grease system and greased and sealed track links are designed to provide superior reliability and long service life. The DX800LC-7 is easy to maintain, further reducing downtime to a minimum. The DX800LC-7 excavator is powered by the new stage V version of the well-proven Perkins 2506J diesel engine, providing a high power output of 403 kW (548 HP), more than any other machine in this class. The engine meets Stage V emission regulations by utilising exhaust gas recirculation, selective catalyst reduction, diesel oxidation catalyst and diesel particulate filter (DPF) aftertreatment technologies. The DPF automatically regenerates every 25 hours, and the excavator continues to work unaffected during this regeneration phase. The operator can check the status of the DPF via the display on the gauge panel in the cab. The high output of the engine is combined with a Virtual Bleed Off (VBO) hydraulic

Doosan has launched the new DX800LC-7 Stage V-compliant 80-tonne crawler excavator

system (D-ECOPOWER+), providing a bestin-class hydraulic flow of 1008 l/min and a high system pressure of 343 bar, together contributing to the best performance in the 80-tonne market. Doosan’s D-ECOPOWER+ technology utilises an electronic pressure-controlled pump within a closed-centre hydraulic system to optimise productivity and fuel consumption, depending on the mode selected. A closedcentre main control valve minimises pressure loss, while the electric pressure-controlled pump manages and optimises engine power more effectively. Software is utilised to electronically reproduce the full benefits of an open-centre hydraulic system with very little energy loss. The hydraulic system and engine output are fully optimised and synchronised, further reducing losses within the system. Improved feedback to the operator through the joystick results in improved machine control and less operator fatigue. The acceleration and deceleration of the excavator workgroup functions are smoother, allowing operators to perform repetitive swinging and digging motions with less jerking movements. The DX800LC-7 is primarily intended to serve customers in mining and quarrying applications, removing overburden and loading large amounts of material into articulated dump trucks or rigid frame trucks. The DX800LC-7 may also be operated on large construction and infrastructure projects, particularly where considerable amounts of material need to be excavated and stockpiled or loaded into trucks to be moved. Cements and Materials of Mali (CMM), a subsidiary of the Vicat Group, is a specialist in the production and distribution of cement in Mali. To ensure the operation of its up to 800,000 tonnes per year cement plant, the company has substantial human resources, and two Volvo L120Gz wheeled loaders. Established in 2004 in Bamako, CMM produces high-quality cement at its grinding site in Diago, 35km from Bamako. Today more than 150 people work on site. To ensure the productivity of its activities, the company recently invested in its two Volvo L120Gz wheeled loaders by signing a maintenance contract with the local Volvo dealer, the company SMT. This acquisition is part of a larger investment project. The purchase of a new crusher in September 2019 required the acquisition of machines responsible for stacking aggregates. Indeed, the loader in place during the construction of the plant was too large and was not as handy as desired. The two Volvo L120Gz wheeled loaders are more versatile and allow faster and easier filling of the crusher. So, these loaders take turns feeding the crusher practically 24 hours a day for better productivity. One of the decisive points in the purchase by CMM was said to be the speed and efficiency of onsite loader maintenance. Indeed, the role of the loaders is essential to the supply of raw material to the crusher and the continuity of cement production

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One of two new Volvo L120Gz wheeled loaders purchased by Cements and Materials of Mali (CMM)

in the factory. Therefore, these cannot be unavailable for too long to carry out routine maintenance. Didier Kabore, purchasing manager at CMM, said: “The most important point for us was the relationship with the brand, the availability and the speed of maintenance of our machines. SMT was able to meet and exceed our expectations. We now have a technician dedicated to our two Volvo wheeled loaders on our site thanks to our maintenance contract.” With hot and dry local working conditions, it was crucial to have a loader offering good value for money. Above all, it was necessary to have an after-sales service corresponding to the expectations of the CMM company. Elhadji Mamadou, director general at SECK, said: “We needed a loader that suited our needs and was of good quality. Several operators take turns in the cabin to supply the crusher. So, we had to invest in a reliable brand with a good offer of maintenance and monitoring.” After several months of running the two Volvo L120Gz wheeled loaders on the cement plant site, the CMM company is satisfied with its investment, both in the relationship it maintains with SMT and in the after-sales service and the quality of its new loaders.

Turkish construction and quarrying machine manufacturer Hidromek exhibited a wide range of its innovative models at the NordBau 2020 Fair in Neumunster, Germany. Staged 9-12 September 2020, NordBau Fair is one of Europe’s leading construction and quarrying equipment exhibitions. This year, it opened its doors for the 65th time. Last year, 836 exhibitors from 13 countries participated in the fair, which welcomed 62,600 visitors. Attending NordBau Fair for the third time, Hidromek displayed some of its new H4 Series hydraulic excavators - including the quarrying-suited HMK 310 LC. Other on-show models will include the HMK 640 WL wheeled loader. Offering high performance, Hidromek’s new H4 Series excavators stand out with their operating speed. By changing the diameter of hydraulic cylinders, tubes and bars, H4 series units have a higher working speed. Hidromek says the model range’s power boost and their maximum hydraulic system pressure are improved. These improvements are said to have led to produce faster, more productive and more efficient machines. Customerearning potential is more now than ever with H4 Series, says Hidromek, as the units process more material with less fuel.

Hidromek’s HMK 310 LC crawler excavator loading a truck in a quarry. The model was among those exhibited by the Turkish manufacturer at NordBau 2020

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H4 Series excavators have an electronic system that can ascertain the condition of the machine and co-ordinate its integration with other equipment. H4 model cabins are designed and built to offer maximum safety and durability under ROPS & FOPS standards. The red handles and warning labels on the new series excavators are said to be made to increase the operator’s safety. A popular machine in quarry and mining operations, concrete plants and industrial applications, Hidromek’s HMK 640 WL heavy-duty wheeled loader has a 26.3tonne operating weight and a 4.2m³ bucket capacity. It also features a 239kW Mercedes engine which, along with 1600Nm of torque, offers users high loading capacity at low fuel consumption, as well as short cycle time. The HMK 640 WL is said to supply high breakout force and excellent control capability. The machine also offers durability and efficiency for many years with its axles and components used explicitly for highdemanding working conditions. With its ergonomic operator cabin with ROPS / FOPS certificates, comfort and increased security are priorities. The HMK 640 WL is also said to offer easy serviceability with its 35° tilting cabin feature. The model has won international design awards such as the Red Dot Best of the Best Award. Hidromek aims to strengthen its place in the global industry by expanding its dealer network and product range while also increasing production. Combining its 42 years of production experience in the sector with its design and R&D power, Hidromek has more than 45,000 machines operating in more than 100 countries on six continents. Hidromek has nine dealers in Germany. Through Hidromek West in Spain, Hidromek manages its dealers and sales and after-sales in Europe. Hidromek also performs these activities with Hidromek Rus in Russia, Hidromek Construction Equipment Thailand (HCE) in Thailand and Hidromek Japan in Japan. Hidromek says it attaches great importance to aftersales services; in this sense, it offers spare parts and service to its customers with its authorised dealers in more than 80 countries and more than 100 overseas service points. AB AGGREGATES BUSINESS September/October 2020

HAULING

Hardy hauling A new Doosan articulated haul truck is proving a reliable workhorse for a Bavarian clay and loam pit operator. Guy Woodford reports

lay and loam pits are tough workplaces for machines, where the access roads are often poor and can only be travelled by vehicles that have excellent rough terrain capabilities and enormous power. This is especially the case at the clay and loam pit run by Creaton in LangenreichenButtenwiesen in Bavaria, southern Germany. To overcome these tough conditions and ensure the efficient and safe transport of materials at all times, Creaton relies on articulated dump trucks (ADTs) from Doosan. The latest addition to the Creaton fleet is a new Doosan DA45-7 ADT, powered by the new Scania Stage V DC13 13-litre diesel engine, purchased from Süddeutsche Baumaschinen and its distribution partner, Nestel Baumaschinen. Although the routes in and out of the Langenreichen-Buttenwiesen clay pit are not too long, at around 500 metres in length, the terrain is extremely challenging, especially in wet conditions. Soft ground and ascents and descents with gradients of up to 25 per cent are all par for the course. One thing above all counts in these conditions, and that is rough terrain capability. And Doosan ADTs, such as the new Doosan DA45-7 model, are said by the manufacturer to offer this like no other machines on the market. Like all Doosan ADTs, the new DA45-7 features an articulation hinge positioned behind the turning ring to provide equal weight distribution to the front axle even during maximum steer articulation. This, combined with a free-swinging rear tandem bogie, ensures equal distribution of weight to each wheel and guarantees permanent six-wheel contact and drive for equal power distribution and excellent performance particularly on difficult terrains such as soft ground, uneven surfaces, very steep slopes, tight turns or a combination of all of these problematic conditions. Combined with its high engine power of 368kW, the DA45-7 efficiently manages to transport its 41-tonne payload of material up the steep inclines to the intermediate storage area at the pit, even in wet and extremely slippery conditions. Quarry manager Roland Kanefzky said: “The DA45-7 has the best off-road capability of all the brands we tested. The previous generation of this model, the DA40-5, has been in service with us for five years and has been very impressive.” The Creaton quarry’s DA45-7 driver, Christoph Schimpp, added: “Thanks to the high engine power and the eight-speed transmission, the DA45-7 offers great power, even when fully loaded. The new self-

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TOP: The new Doosan DA45-7 at work at Creaton’s clay and loam pit in Langenreichen-Buttenwiesen, Bavaria ABOVE: From left to right: Roland Kanefzky, Creaton group manager; Hans-Jörg Nestel, Nestel Baumaschinen; and Christoph Schimpp adjusting front axle has also significantly improved driving comfort compared to the DA40-5.” Creaton has equipped the DA45-7 with some special features for use in clay and loam pits. For example, the wide Michelin 875/65 R29 XADN tyres with their low ground pressure further enhance comfort for the driver in the ADT. The Grammer adjustable, suspended operator seat, an improved layout for the display which is easier to use even for tired eyes and the

GRIFA Softstep step up all increase the driver’s comfort so they can work with the highest possible efficiency over long periods. The DA45-7 at Creaton is also equipped with an optional hauler heating system that allows the body of the machine to be heated by using exhaust gases, which is the most economical method compared to other energy sources for this heating option. From March to November the ADTs work reliably for around 1,000 hours a year in the clay and loam pit at Creaton, a member of the Etex Group. The previous DA40-5 is said to have scored lots of points in this area with its exceptionally low downtime. “The ADTs from Doosan have proved to be extremely robust, and if there is an issue, we can always rely on the very fast, good quality service provided by Süddeutsche Bau and Nestel Baumaschinen and on a fast supply of spare parts,” Kanefzky emphasised. Süddeutsche Baumaschinen, founded in 1991, with its distribution partner, Nestel Baumaschinen, based in Krauchenwies, has been a Doosan dealer since 2002. From its headquarters in Neu-Ulm, the company has around 120 employees and offers its customers a comprehensive range of services for the sale, rental and servicing of construction machinery. Also, there is an engineering shop and services available in the field of processing technology. The company has 12 customer service vehicles at its six branches. AB

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EXPERTS SAY YOU CAN ONLY FOCUS ON ONE THING AT A TIME. We chose articulated dump trucks

DRILL RIGS, TOP HAMMERS & BREAKERS

Epiroc’s PowerROC D55 is said to provide both high performance and low total cost of ownership for drilling 90–165 mm holes

Highly productive drill rigs, top hammers and breakers Premium drill rigs, top hammers and breakers are proving in demand on quarry and surface mine sites globally, with new supporting products also coming on to the market. Guy Woodford reports

piroc’s PowerROC D55 DTH (downthe-hole) surface drill rig is said to be unlocking the next level of productivity and efficiency at a limestone mine in Nanjing, China. Following a new standard of green operations in the mining and construction industry in China, many small mine owners and contractors have quickly disappeared from the market along with fleets of outdated equipment. Nanjing Anjite Mining Engineering Co., Ltd. (commonly referred to as Anjite) is a surface drilling contractor established back in 1972 which has steadily expanded its business from Nanjing to other regions of China. Anjite was awarded the highest qualification for Green Mining and Master Blasting Company in Jiangsu province, successfully cooperating with the public security bureau for ammunition destruction, and it is now a key player in China’s blasting industry. The Baota Hill Mine site is located northwest of Nanjing city, just 40km away from downtown. Although the limestone mine is situated close to residential areas, no air pollution affects local residents. When entering the worksite, it looks more like a lush garden than a mine, with green trees and plants on both sides of the open-pit ramp. Finished exploitation benches are

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located a distance away and are flat and green, which contrasts typical perceptions of open-pit mining or quarrying. Anjite’s capabilities in mining and handling blasting tasks rely on the use of a drill rig fleet from Epiroc, acquired from 2008 onward. This includes the FlexiROC T35, FlexiROC D50 and PowerROC D45. The limestone quarry has a production capacity of up to 14 million tons per year. The high productivity and good working environment, with minimised dust, has been achieved thanks to the introduction of two PowerROC D55 drill rigs, products that were designed

and manufactured in Nanjing. The PowerROC D55 units work in favourable conditions at an altitude of 250m in a normal temperature, limestone mine. The drill rigs are said to have demonstrated outstanding performance and reliability with low fuel consumption of 35 litres per hour, as well as an availability of up to 98% per year. Drilling 140mm holes in rock conditions of 60-80MPa, the PowerROC D55 achieves a maximum penetration rate of 40 metres per hour to ensure the high annual productivity. The rigs work on +-20m high benches using a drilling pattern of 4x6m.

An operator changing a ﬁlter on a PowerROC D55 DTH surface drill rig at Baota Hill Mine

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DRILL RIGS, TOP HAMMERS & BREAKERS

Baota Hill Mine in Nanjing

The PowerROC D55, a down-the-hole (DTH) surface drill rig, provides both high performance and low total cost of ownership for drilling 90–165mm holes, as Wei wen Xu, business line manager at Epiroc’s product company in Nanjing, points out. “The straightforward design of PowerROC D55 is easy to operate and maintain which is very appreciated by customers. Other reliable components of proven Epiroc technology enable high availability, ensuring the high productivity that customers need to expand their business. The RHS and the down-thehole drilling method help to drill straight holes with very good quality,” Wei wen Xu adds. This assessment is echoed by Sheng Wang, general manager at Anjite: “We trust the performance of Epiroc-branded machines as Epiroc is a leading company in the mining and construction industry. The strong cooperation between us began with our previous general manager, and we continue to order drill rigs due to their reputation for excellent reliability ever since.” “Thanks to the dust collection system, Epiroc products have helped us achieve the Green Mine Star and other awards of distinction from the government,” Wang continues. “We are the only company in Jiangsu Province that promotes the electric digital detonator in domestic China, which together with Epiroc equipment has contributed to our Green Mine distinction. We hope the cooperation will continue to advance our goals for sustainable productivity.” Following the successful deployment, there are now three PowerROC D55 units in

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An Indeco HP 2500 FS hydraulic hammer is being used at Lange e.K.’s quarry and sawmill in Sprockhövel to help process its tough Ruhr sandstone

daily operation at Baota Hill Mine. Another hydraulic surface drill rig, the PowerROC D45, is being used to help Anjite complete a national water conservancy project on the Qinhuai river for the state waterways which requires significant capacity and time-sensitivity. “The outstanding availability surprised us as the drill rigs can work 4,800 engine hours per year, with three shifts per day. That is why we call it the workhorse on site,” says Zhoujun Jiang, site equipment chief at Anjite. He continues: “I appreciate the ergonomic design of the cabin with FOPS and ROPS certification, which protects operators from injuries if the equipment rolls over on the bench. The drill rig is easy to operate and maintain due to its straightforward design. And the rigs can work twenty hours per day with regular maintenance twelve times a year.” Thanks to the partnership and continued use of Epiroc products, Anjite stands ready to expand its footprint across China with cutting-edge productivity and a green mine profile that sets a new benchmark for future operations. The Lange e.K. quarry and sawmill in Sprockhövel, North Rhine-Westphalia, Germany, features a rather compact Ruhr sandstone, even harder than most granites. The site’s material coupled with a need to boost production levels led Thomas Lange, owner of Lange e.K., to purchase an HP 2500 FS (fuel saving) hydraulic hammer. “We decided to switch to the HP 2500 FS and mount it on a JCB 220 XLC excavator. Our choice was guided by the fact that the HP 2500 FS was able to increase our production AGGREGATES BUSINESS September/October 2020

DRILL RIGS, TOP HAMMERS & BREAKERS

by 30%, as it then demonstrated in the quarry. “It’s already quite clear to us that the promises Indeco Deutschland made to us have been more than fulfilled,” said Lange. He added: “The excellent results we achieved soon convinced us of the Indeco hydraulic hammer’s superior technology.” “As so many users around the globe have been saying, Indeco breakers have an excellent ratio between energy input and energy output and consequently optimum efficiency,” said a spokesperson for Indeco Deutschland. All Indeco top hammers are installed with the ABF (anti-blank firing) system, Indeco’s patented technology that considerably improves the performance and durability of the breakers. In addition to a hydraulic system with improved efficiency, the HP series displays the FS (fuel saving) mark, indicating that the top hammer needs less hydraulic power to operate, resulting in a claimed significant reduction in the carrier machine’s rpm and fuel savings of up to 20%. While delivering consistently excellent performance and maximum productivity, Indeco top hammers are said by the company to require less oil per minute and lower operating pressures than similar size and weight hammers made by other manufacturers. Sandvik Rock Tools is launching a new product for the brand’s bench drilling top hammer customers. The ‘Guide Adapter’ is said to enable customers to reduce hole deviation in challenging conditions by up to 50%, while also achieving considerable cost savings. Significant hole deviation of 8% or more can pose problems for many bench drilling companies that operate in challenging ground conditions such as bad and soft rock, as well as deep overburden. This often results in reduced productivity, safety risks and increased tool wear. “We are very happy to be able to offer the Guide Adapter to customers facing deviation problems in their day-to-day bench drilling operations. The Guide Adapter helps them

A Doosan HB03 hydraulic breaker, part of a new ﬁve-strong HB series

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Sandvik Rock Tools says its new Guide Adapter helps customers to increase the service life of their drill string and reduce the number of drilled holes to increase the service life of their drill string and also reduce the number of drilled holes, as well as the amount of blasting needed,” says Fredrik Björk, product manager Top Hammer Surface Tools, Rock Tools Division, Sandvik Mining and Rock Technology. Sandvik’s new Guide Adapter enables customers to achieve greater productivity, longer tool service life and improved safety. Ultimately, this can also lead to lower total operational costs. “We have conducted in-depth testing with our customers around the world and the results really do speak for themselves. By using the Sandvik Guide Adapter, our customers achieved a hole deviation between 3% to 5% - a reduction by up to 50% - and also increased the service life of their rock tools by up to 40%. This truly has an effect on both productivity and in turn, profitability”, says Björk. The Guide Adapter is now available for T51 and GT60 Top Hammer threads in different diameters. Doosan Infracore Europe has launched the new HB-series hydraulic breaker range for the European market. The new range of five HB-series breakers provides a novel concept with high performance and a simplified design, specifically optimized and fully certified for Doosan excavators with carrier weights

from 1.2 to 15 tonnes. As a result, Doosan HB breakers are said to offer the highest possible productivity, whether the operator is demolishing concrete or breaking rocks. The high quality of the breakers is backed by a claimed industry-leading two-year warranty and they are available at costeffective prices, providing customer benefits in terms of total cost of ownership. According to Doosan, all these features together are aimed at greatly exceeding customer expectations for hydraulic breakers. In common with all Doosan machines and attachments, the new Doosan breakers are covered by the outstanding Doosan dealer service network and Doosan product specialists, providing fully comprehensive ‘one-stop service’ support. The service life of the breakers is extended through the adoption of an advanced heat treatment process and quality proven materials for key components including the cylinder and piston. The energy of the piston stroke is accumulated by charged nitrogen gas and the breakers use an inward valve system with a simple structure and fewer inner parts. A urethane damper prevents vibration that might damage the carrier and improves operator comfort. The front head supports the breaker and assemblies with bushing, which buffers the shock from the tool. The low noise housing is ideal for working in urban zones, where noise levels must be controlled or where local regulation may require silenced breakers. The HB-series range offers five hydraulic breaker models - the HB03, HB04, HB06, HB08 and HB15 - for use on Doosan miniexcavators and Doosan crawler and wheeled excavators. Ideally suited for demolition work, the Doosan breaker range is also intended for general construction, rental, quarrying and mining applications. The range begins with the HB03 breaker, which is suitable for use on the Doosan DX17z 1.7-tonne and DX19 1.9-tonne mini excavators. Next in the range is the HB04 model for the DX27z 2.7-tonne and DX35z 3.5-tonne mini excavators. The third model in the range - the HB06 breaker - is designed for use on the 6-tonne Doosan DX57W-5 wheeled excavator and DX62R-3 and DX63-3 miniexcavators. The fourth model in the range is the HB08 breaker for use with the Doosan DX85-3 8-tonne mini-excavator. The top-of-the-range HB15 hydraulic breaker is designed for use with the Doosan DX140LC-5, DX140LCR-5 and DX160LC-5 crawler excavators and the Doosan DX140W-5, DX160W-5 and DX165W-5 wheeled excavators.AB

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WATER RECYCLING, MANAGEMENT & FILTRATION

Quarries and materials processors face increasing regulations governing the responsible use and management of water

Overcoming the challenges of water management Water recycling makes sense both from an environmental perspective and in terms of meeting increasing legislative requirements. Liam McLoughlin reports

nnovations in the washing sector are supporting quarry operators and materials processors alike to overcome the challenges stemming from water management; cost-based, efficiency, sustainability and regulatory. Prominent among these is the modular wet processing equipment from CDE. The Northern Ireland-based company says its solutions can contribute to the easing of water scarcity issues arising from the materials processing industry’s consumption of water resources, significantly improving water efficiency, and better wastewater management practices. It adds that developing technological solutions to tackle these mounting challenges is paramount for many materials processors seeking to boost the profitability of their operation by minimising the consumption of costly water resources. Stefan Hunger, CDE regional manager for Europe & Russia, and Daniel Webber, CDE regional manager for Australasia, report increasing regulations governing the responsible use and management of water in the industry, including those aimed at protecting marine environments and water sources from pollution and over-abstraction. Hunger says: “It’s important to acknowledge that water is renewable when its usage is regulated and managed responsibly, but it is also a finite resource. Not only does water recycling make sense from a global environmental perspective backed up by increasingly stringent legislative requirements, but it also ticks all the right

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boxes in terms of return on investment.” In Europe, there are approximately 26,000 aggregates sites, nearly 60% of which are involved in materials washing activities. Webber explains that the Australian mining industry has adapted to more regulations surrounding its water usage than most other industries. “Each stage of the mining cycle requires permits, including, among other utilities, water permits. The impact of operation is also subject to strenuous environmental assessments to evaluate the management and use of water resources and the processes that will be employed to prevent the contamination of groundwater.”

In terms of sector, agriculture remains the largest user of water in Australia, accounting for almost 70% of total water footprint. Industry, however, including mining and quarrying, is on the rise at a time when water storage levels hit a 10-year low in 2019/20. Webber continues: “Pressure on Australia’s water resources is mounting on account of population growth. With this comes greater demand within the agricultural and industrial sectors to support such growth and urbanisation. We’re finding mine and quarry operators are in effect competing against the needs of urban populations, farming, and the environment in terms of water demand which is why governments are

CDE’s AquaCycle water management solution

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WATER RECYCLING, MANAGEMENT & FILTRATION

taking greater action to regulate its use.” CDE says it is therefore increasingly crucial for materials processors to invest in an effective water management strategy that ensures a steady supply of clean water to their plants through cost-effective means. While laws governing water vary around the world, it is a resource that is essential to the extractive industries and is therefore increasingly under the water management microscope. Earlier this year, in the United States, the Environmental Protection Agency (EPA), provided further clarification to its Waters of the United States (WOTUS) rule which aligns with the Clean Water Act. Darren Eastwood, CDE business development director for North America, explains: “Confusion caused by the 2015 WOTUS rule resulted in many aggregates businesses across North America incurring high costs due to the uncertainty around when federal permits were required. Its reclarification provides a clear regulatory framework to which aggregates producers can align. Its new definition clarifies that pits and water treatment basins are not subject to additional federal regulation.” Water as a resource delivers economic value to a range of industries. Within the extractive industries, the value of materials significantly increases when washed, but wet processing in mining and quarrying operations is dependent on water availability

and processing plant efficiency. Hunger comments that customers do want to wash: “But footprint, particularly in urban settings, is prohibitive. This is why CDE has invested significant resources into the design and development of compact and modular equipment that can be commissioned in urban areas while also offering the ability for future migration of the plant to where opportunities lie.” Webber adds: “More often it’s water availability and access that prevents producers from getting into the washing business in the first place. That, and the uncertainty around typical top-up water requirements which, in the case of CDE water management solutions, are very low. The focus is on recycling and recirculating as much water as possible through the system.” Bruno Paladino, CDE regional manager for Latin America, says the combination of regulatory and environmental considerations with economic factors presents a significant challenge for operators washing sand and aggregates. “Water supply is a key determining factor when assessing the viability of a new project or when considering expanding operations at an existing site,” says Paladino. “Insufficient water supply, particularly in arid regions, will drive up operational expenditure costs significantly in an industry where energy prices already represent 20% of these costs due to the investment in water infrastructure

A LONG WAY

TOGETHER

to ensure an adequate supply of clean water is pumped into the plant.” In the Americas, customers using settling ponds to recycle water often encounter significant operational and logistical challenges. Eastwood explains: “These require constant maintenance as they accumulate sludge, silt, and other solids that must settle and separate from the water before its removal. Not only do these limit the water storage capacity of the pond, but they incur significant maintenance costs. Further still, the limitations of settling pond systems often result in the loss of valuable fines, one of the key considerations in the design of CDE water management solutions.” Paladino stresses the importance of safe water management in all regions but highlights the urgent relevance of such practices in Latin America. “Over the past few years, mines in Latin America are looking for new and sustainable ways to continue their exploration, ways that are less impactful on the environment and surrounding communities. The use of water is a key factor, as is overall footprint and energy usage. CDE’s modular plant design with water recycling system is the perfect fit to help mines meet these new challenges.” CDE says it consistently invests in research and development to enhance the capabilities of its premier water recycling and management equipment. At the forefront of its

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WATER RECYCLING, MANAGEMENT & FILTRATION

water recycling systems is the AquaCycle, a single, compact unit suited to high and low tonnages across many markets. AquaCycle is designed to accelerate return on investment by maximising production efficiency, minimising the loss of valuable fines, and reducing water and energy costs. According to Dennis Zink, global product manager at US-based water management solutions provider McLanahan, filter presses provide the best solution for the issue of settling pond elimination. He adds that several types of dewatering equipment are available to separate solids and liquid in slurries to reduce or eliminate settling ponds, but one is better for overall tailings and water management. The aggregate and mineral industries have historically used the simplest and cheapest dewatering technology to manage waste slurry tailings. These old methods include dumping directly into streams, rivers and lakes or using mining surfaces or underground quarries/pits for disposal. For a number of decades these industries have been pressured to eliminate older ways of waste dumping and look for more efficient waste management technologies. Initial improvement in tailings management technology involved creating ponds or large impoundment dams to hold the waste slurry for the life of the quarry or mine. Over the past 10 years or more, pressures to improve tailings management practices have increased further due to a number of factors. Zink states that these include stricter environmental regulations, rising operational costs, higher waste handling costs, increased water conservation requirements, catastrophic impoundment failures, the need for better risk mitigation, and physical space limitations for operational expansion. Zink adds that leaders in the aggregate and mineral industries have started evaluating and investing in more efficient, cost-effective systems to dewater tailings. The systems include: ultra-fines separation, slurry thickening and slurry dewatering equipment technologies. The UFR (ultra fines recovery) and thickener equipment technologies separate and concentrate the waste materials, while the dewatering equipment recovers additional water from the waste stream and creates nearly dry solids. The types of competing dewatering equipment used in the aggregate and mineral industries today include plate filter presses, belt filter presses and centrifuges. Centrifuge dewatering is a high-speed process that uses the force from the rapid rotation of a cylindrical bowl to separate wastewater solids from liquid. Zink says: “These dewatering devices work best with material that is more easily dewatered, has a larger particle size distribution and/or a low clay content, though they generally are not going to be as efficient as a filter press since they cannot generate the high-pressure dewatering forces of the latter.” Centrifuges operate as continuous feed units that remove solids by a scroll conveyor and discharge liquid over the weir. Centrifuge equipment has high up-front investment cost and high operating cost. It is built to tight mechanical design specification to operate efficiently at very high rotational speeds. Operating costs are high due to significant electrical power requirements, expensive replacement parts and the need to use dewatering chemicals. Belt filter presses are another type of equipment used to remove water from waste slurries to produce a non-liquid material referred to as a “cake”. In a belt filter press, the waste slurry is forced between two tensioned porous belts. As the belts pass over and under rollers of various diameters, the liquid is squeezed out of slurry while the solid cake material is retained between the belts. There are many designs of belt filtration processes, but all incorporate some basic features: polymer conditioning zone, gravity drainage zones, low-pressure squeezing zone, and high-pressure squeezing zones. Advanced designs provide a large filtration area, additional rollers, and variable belt speeds that can increase cake solids by 5%. Belt filter presses have low to medium initial capital cost, with a smaller footprint for installation. Operating costs tend to be high due to the need for a full-time operator and the use of chemical dewatering aids. Belt presses have a reputation of requiring frequent belt washing and are very sensitive to process variations.

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WATER RECYCLING, MANAGEMENT & FILTRATION

Recessed plate filter presses are used to create a dewatered cake material by separating the liquid and solid materials in waste slurries. These filter presses are among the oldest types of dewatering devices and are commonly used in aggregate and mineral processing waste slurry applications. The up-front investment for a plate filter press can be high due to the size of the equipment and required support structure. Depending on the type and amount of material being dewatered, McLanahan’s Zink states that modern filter press equipment can be very big and require a large space for installation and operation. Plate filter press operating costs are low due to the requirement of only a part-time operator, lower wear parts cost and typically no need for chemical dewatering aids. Because the slurry material is captured completely between the filter plates, very high dewatering pressures (up to 225 psi or higher) can be applied to the slurry. The high dewatering pressures produce the highest cake solids concentration possible of any mechanical dewatering equipment. Plate filter presses can also employ a second type of plate called a membrane plate. In this case, the plate has a flexible membrane surface made from polypropylene or other synthetic flexible material such as hard rubber. The membrane can be thermally fused to the concave plate core, or the synthetic membrane’s edge can be embedded into the concave plate core in a small channel machined in the plate surfaces. The same initial process is used in a membrane plate press, with a high-pressure slurry pump feeding the press to fill and dewater as much slurry as possible. After the slurry feed pump is stopped and while the filter plates are still clamped together, the membrane surfaces are expanded using compressed air or water. This inflated membrane compresses the cake material, removing additional moisture to the lowest possible levels. Zink says that no other dewatering process has shown to be more efficient at removing liquid from slurries as the plate filter press. He adds that additional benefits of plate filter presses include: the highest amount of recovered water, driest cakes, lowest operating cost, lower waste handling

cost, less water hauled, and most stable solid material generated “Because of these advantages and the high efficiency of the plate filter press, it is the best choice of equipment to eliminate settling ponds,” Zink adds. Northern Ireland-based Terex Washing Systems (TWS) has a product portfolio that includes Terex AquaClear Water Management Solutions. Barry McMenamin, TWS business line director, highlighted the benefits of the water management solutions, commenting: “A lot of our customers have a need for water management, which is a continually growing sector given the way environmental legislation is evolving in certain regions.” TWS water management portfolio includes clarifying tanks, flocculent dosing systems, filter presses and all associated equipment to provide a one-stop solution. With installations globally the company says it is leading the way in providing ‘End to End Washing Solutions’ from a single source supplier. Water management solutions vary in size and complexity, but generally comprise three stages; flocculation, sludge thickening, and de-watering of solids via a filter press. For stages one and two TWS offers a wide range of AquaClear floc dosing units paired with a choice of deep cone thickener, or low-level rake thickener. The choice of thickener is dependent on the application and the plant layout, according to TWS product manager Mark Follis.

“The deep cone thickeners offer a fantastic simple solution for sludge thickening,” says Follis, “with a small footprint, no moving parts, and the ability to use the natural pressure in the tank to achieve higher sludge concentrations over 50% solids, ideal for discharge directly to a sludge pond.” For many applications TWS says stage one and two is the complete water management solution, with the AquaClear thickener providing 80% water recovery back to the main washing process, and the thickened sludge only being discharged to settling ponds, thus significantly reducing the area required for ponds or sludge storage. An example of this was the recent TWS installation at Grahams Concrete in Queensland, Australia, where the DC140 deep cone thickener can be seen working alongside the AggreSand 165. This natural sand and gravel application operating at 100tph feed rate requires only 30-40m cubed/hr top-up water to keep the system running, while flocculant usage is optimised using the AquaClear DCU (dosing control unit) which continually monitors sludge settlement rates to ensure the correct dose of floc is provided to the plant. Adding stage three, TWS says that its AquaClear filter press maximises water recovery by creating a completely closedloop system, where sludge is dewatered under high pressure and expelled as solid filter cakes with a dry solids content of up to 85%. AB

Filter presses are the best way of settling pond elimination, according to McLanahan

Thickeners such as those from McLanahan can enable producers to recover up to 90% of their water for reuse

The TWS AquaClear ﬁlter press

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ROTARY CUTTER HEADS

The extremely short cutting units, combined with their sturdy and tough housing, make quick work of removing rock

Rotary cutter heads making a real breakthrough Rotary cutter heads are making an increasingly strong case for their deployment in quarries globally. Roger Murrow reports

raditionally, drill and blast, breakers and hydraulic hammers have undertaken the heavy work required in quarries and surface mines, providing a tough, productive and efficient solution. Sometimes, however, their use may be precluded due to noise, dust emissions, the location of urban dwellings or a requirement for greater accuracy. In response, many quarries have utilised hydraulic rotary cutting technology. These are commonly referred to as ‘drum cutters’, ‘cutter heads’, ‘rock grinders’ or ‘rock wheels’. These are a flexible, cost-effective and adaptable solution for rock excavation, trenching and mine/quarry wall scaling, being suitable for any application requiring materials to be cut or ground. A rotary cutter head is a hydraulic attachment on which drums equipped with numerous picks spin around at rapid speed to cut rock, concrete or frozen ground. The picks that perform the cutting job are wearresistant, have exchangeable teeth and are generally designed for efficient operations. They may also be equipped with dustsuppression systems to improve a quarry’s or mine’s environmental credentials, as well as maximising safety (in the US this has helped quarries and aggregates plants deal with the recent silica dust regulations).

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The cutting heads have proved to be ideal for rock or concrete wall and surface profiling, trenching, frozen soil excavation, soil mixing, rock excavation in quarries, as well as utility work, demolition, and dredging (most appear able to work in water up to 30m in depth). Manufacturers of the equipment supply the cutters with a large variety of cutting heads for various applications, all being able to deliver precise and accurate work even in difficult conditions. Due to both build and operating characteristics, cutting heads can be utilised in noise- and vibration- sensitive areas, as a low-vibration profile results in no or little damage to sensitive structures, thus enabling usage without inconveniencing others in the locale. This means that they are now seen as a real alternative to hydraulic breakers by generating higher productivity in quarrying due to their design and being able to provide high levels of performance and precision, especially when working in sensitive environments.

Wide cross-section of manufacturers There is now a vast array of different cutting heads available on the market from a large cross-section of suppliers. These range from specialists in the design and manufacture of hydraulic cutting heads, whose business

is entirely focused on these solutions, to multinationals with an offering that encompasses whole ranges of equipment for quarrying, mining and construction. One such latter company is Sandvik Mining and Rock Technology, which produces a range of rock cutters with fixed teeth for excavators ranging from 2.5 to 70 tonnes. Sandvik’s RC series cutters have been designed to cut through hard rock quickly and efficiently, combine high productivity with minimal noise and vibrations, having hydraulic-powered cutting heads that can be mounted on excavators quickly and easily. They all possess efficient, geometricallyoptimised cutting heads that can be used in a number of applications, including production, scaling, tunnel rehabilitation, roadway levelling, trenching and demolition. The models range from the relatively lightweight Sandvik MA520 for lighter carrier vehicles to the heavy-duty MA720. They are designed for quick change coupling between the carrier vehicle and attachment, which makes the cutting heads productive tools for any quarrying, mining or construction application. Thanks to very low maintenance requirements and minimal operating costs, they are also a highly cost-effective solution. Another global behemoth, Epiroc, has also spotted the attributes of the cutter heads, and AGGREGATES BUSINESS September/October 2020

ROTARY CUTTER HEADS

in order to provide a full offering acquired German company Erkat whose product line features rigid and wear-resistant gear housings to ensure a smooth cutting action, while providing maximum cutting power to penetrate the rock. The cutters have proved to be particularly adept at removing precise layers of rock or frozen ground and are fitted with a central fixing system enabling the cutter to rotate 360° without having to be disconnected from the excavator. With low vibration and quiet operation, Erkat’s cutters can also work in sensitive areas. The attachments have also been designed to help save on material costs as they don’t need to remove all of the materials, but rather just the damaged or worn surface. In some applications, the spoils from the material being cut by the cutter can be used as backfill or elsewhere on the jobsite. A company best known for its underground equipment is US-based Antraquip, which manufactures an extensive line of hydraulic rock wheel cutters for a range of applications. Its cutters are suitable for material with uniaxial compressive strength (UCS) ranging from 500 to 25,000 pound-force per square inch (PSI) and come with such features as high torque hydraulic motors, robust, customisable cutting drums with durable spur gears and housing. Drawing on its experience of dealing with various rock types, Antraquip’s offering has been designed to suit different types and locations of rocks, as well as fitting different carrier machines. Applications of Antraquip cutters include an AQ-5 model operating at a limestone quarry in Australia, where the cutter was mounted on a CAT 374 excavator. Here, the rock being cut was a combination of medium-hard shale and hard limestone with compressive strength of up to 180MPa (26,000psi). In Colorado, an AQ-4 was fitted to a PC360 excavator operating in a quarry for production mining and quarry-roadway development work. The limestone production achieved (with average compressive strength of 10,000 psi or 70 MPa) was up to 100 tonnes per hour of net cutting.

Compact but still productive As well as companies that are specifically associated with mining and large-scale mineral excavation and quarrying, some specialist attachment companies are also producing more compact, but still productive equipment. Two Italian companies, in particular, have drawn on their experience in producing hydraulic excavator and loader attachments. MB Crusher’s cutting heads have been designed to deal with particularly resistant and tough materials, such as fragmented rocks, although they can also deal with softer materials, such as asphalt. They have been designed to perform excavation with extreme precision. Aimed at the more compact sector of the quarrying industry, the cutters are designed to be fitted to three-12-tonne excavators as well as skid steers and backhoe loaders from three-eight

AGGREGATES BUSINESS September/October 2020

Sandvik’s cutters have been designed to cut through hard rock quickly and efficiently

The Erkat attachments have also been designed to help save on material costs as they don’t need to remove all of the materials, but rather just the damaged or worn surface

Drawing on its experience of dealing with various rock types, Antraquip’s offering has been designed to ﬁt various types and locations of rocks

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ROTARY CUTTER HEADS

tonnes. Amongst the many features of the cutters are minimal vibration and noise emissions, with a cutter body rotation that enables the operator to rotate the cutter directly from the cab. Simex’s TF cutter heads have been purpose-developed for trenching, profiling rock and cement walls, tunnelling, quarrying, demolition, dredging, finishing operations and underwater works. They have proved to be particularly effective where conventional excavation systems are too weak, and percussion systems have little effect. Recently, the cutters were used in sedimentary rock quarries in Malta dealing with Calcarenite, which is used both as a construction material and as an aggregate. The rock has a characteristic compressive strength which ranges from approximately 20 MPa to almost 60 MPa according to the zone. Due to the small size of Malta, many quarries are sited near urban areas or tourist attractions. This often precludes the use of drilling and blast or breakers in quarrying, which has led directly to the use of Simex cutter heads, which are capable of minimising any environmental impact but still produce cut rock to the desired sizes. The cutter head used, a TF2500, has been designed for excavators weighing 40-55t and delivers a torque of 31.7kNm and a cutting force of 83.7kN. It is also fitted with an integrated large displacement hydraulic piston motor that ensures high efficiency and high torque. Thanks to the double bearings supporting each drum on the cutter, the shaft transmits only motion and bears no load. Kinshofer is another company that has developed its own range of hydraulic cutting attachments, recently re-badged as ‘KDC’. These are driven by high torque motors, feature modular construction and robust spur gearing with a gear reduction to increase cutting force. The attachments are also suited for underwater operation of up to 25m deep, thanks to the heavy-duty sealing system. The optional 360° rotation function allows exact positioning in corners, on quarry walls and other vertical surfaces for more accurate contouring. The optimised arrangement of picks ensures a high loosening performance and low wear. Three drum versions are available including an excavating version for cutting soft to medium-hard rock, a profiling version for shaping and levelling soft to

Kemroc DMW cutters are able to cut down to 1m and come with a choice of wheels with different tooling conﬁgurations medium-hard rock and a demolition version for cutting medium-hard to hard rocks and concrete.

Specialist manufacturers As well as those manufacturers who produce wide arrays of associated equipment, or are hydraulic attachment specialists, two companies stand out as specialists in the field of producing hydraulic cutting heads. The design of German company Kemroc’s cutting attachments is based on many years of experience in the industry. It aims to provide maximum cutting performance with minimum wear costs, with a selection of picks and boxes and a pick pattern for enhanced rock cutting. Kemroc has given particular attention to the design and working of the ‘picks’ on the cutting heads. When working with round picks each tool penetrates into the rock along parallel paths and breaks material out from

the space between the paths. Therefore, the cutting rate depends to a large degree on the uniaxial compressive strength of the rock being cut. Other significant factors affecting production rates include the hydraulic pressure and flow that the excavator is able to supply to the attachment, as well as the stability and weight of the excavator. The company’s DMW range has been purpose-designed for cutting hard rock with a uniaxial compressive strength of 120MPa for excavators from 14 to 60 tonnes. It is able to cut down to 1m and comes with a choice of wheels with different tooling configurations and a range of widths up to 400mm being available. The EK range of cutters is designed for use on excavators from two to 50 tonnes, being ideal for cutting stone with a uniaxial compressive strength up to 100MPa. They are efficient, vibration-free attachments for the excavation of deep, narrow trenches delivering an optimal trench profile. They

MB Crusher’s cutting heads have been designed to deal with particularly resistant and tough materials, such as fragmented rocks.

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ROTARY CUTTER HEADS

are also suited to the quarrying of medium to hard minerals with compressive strength from 15 to 60MPa where drill and blast are not possible. The effectiveness of the EK range is illustrated by the way in which a German company has made radical changes to the extraction and mineral processing methods at one of its gypsum quarries by using an EK 140 mounted on a 45-tonne excavator. The chain cutter replaced a hydraulic breaker as the primary extraction tool which reduced costs at the crushing plant. Changing the extraction method resulted in considerable savings in both plant and labour costs as extracting gypsum using a hydraulic breaker mounted on an excavator was proving to be generally a slow and difficult procedure for both man and machine. When compared to the breaker, the chain cutter worked with less vibration resulting in lower maintenance requirements for the excavator. Furthermore, when a breaker was used, the material produced lay on the ground in large blocks that had to be further broken down by the breaker before the gypsum could be sent to the processing plant for crushing. Using the chain cutter made the extraction process more efficient by eliminating many of these processes, as the chain cutter enabled the excavator operator to start the production process by placing the chain cutter at the top of the wall of gypsum, then cutting its way down to the bottom. The material produced by the chain cutter also has a much smaller grain size and doesn’t require any extra work before being transported to the processing plant, thereby lowering crushing costs.

Anglo-German partnership A rare industry development has been the pioneering ‘rock wheel’ cutting attachments, designed by a UK company but now being manufactured and marketed by a German company. Sheffield-based Webster Technologies traces its beginnings to the

AGGREGATES BUSINESS September/October 2020

early 1960s, designing, manufacturing and distributing mining equipment, being one of the first companies to use hydraulics for cutting. The Webster roadheader quickly became well known in the industry and is still used in quarrying and mining applications today. Building upon its reputation as an industry pioneer, in 2013 Webster Technologies licensed the manufacture, global sales and distribution of its Rockwheel cutter to German company Rokla GmBH. This collaboration has combined creative technical design, quality manufacturing and sales and service focus. The combined rock wheel cutting technology maximises precision as well as being said to be two to three times faster than the usual speeds achieved with breakers. The extremely short cutting units, combined with their sturdy and tough housing, make quick work of removing rock. Moreover, they leave projections clearly visible and immediately workable, unlike ripper teeth which break up large pieces of rock and make work difficult for excavator operators. When the removed

The Rockwheel D30 model with the two excavating drums is equipped with 60 wear-proof special picks for use in highly abrasive sand and gravel material is internally processed as aggregate, the Rockwheels kill two birds with one stone, as excavated material will already be one to three cm in size. Illustrating the benefits of the Rockwheel is a particular Germany quarry which has highly abrasive rock, specifically sand and gravel. For many years scarifiers had been used for quarrying the rock (classed as a seven conglomerate,) resulting in high levels of wear and tear. The extreme impact required also placed a huge stress on the excavator being used. Having only three major components (housing, motor and cutting heads equipped with picks) meant that these difficulties were overcome by the Rockwheel D30 model, supplied with two excavating drums equipped with 60 wearproof special picks for use in highly abrasive sand and gravel conglomerate. All the Rockwheel cutting units possess solid drive shaft bearings and are designed for long service life. Their sealing system also enables them to operate underwater without the need for any conversion. As a rule, maintenance times are short, as all components can be easily replaced. Furthermore, when compared to the use of a breaker, the cutter produces a smaller, more consistent grain size, resulting in savings in crushing costs and material handling. The German quarry owners have been so impressed with the cutters that they are now using them at their gypsum quarries when drill and blast are not suitable for the extraction of the mineral. AB

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BLASTING & ALTERNATIVES

BlastLogic is said by Maptek to deliver productivity and efficiency gains beyond the drill and blast space

A premium Maptek approach to blast execution & analysis A long-time leading global name in premium site analysis software for quarrying and mining professionals, Maptek remains on a ﬁrm growth path. Guy Woodford conducted a Q&A with Mark Roberts, Maptek group product manager for mine operations, to learn more about the Australian-headquartered company’s work on drill and blast optimisation How does Maptek see the current global surface mining sector for its product range around blast execution and analysis? Most surface operations have piecemeal solutions to drill and blast - one system tracking drilling, another blast hole loading, another post-blast analysis, as well as ad hoc attempts to audit and analyse historical information - all in a disparate collection of paper sheets, survey data and file formats. Measurement While Drilling (MWD) systems are great, electronic firing systems are great, intentions are great, but the information cannot be cross-correlated in a timely way to be of ultimate benefit to the operation. Maptek BlastLogic is termed a quality management system or a design and reconciliation system, and regardless of those descriptions at the end of the day, the solution provides a unified platform (one-stop-shop) for improving drill and blast. Customers describe the value delivered through BlastLogic as providing transparency and accountability on their blast designs and how well these are executed. The combination of blast design, integration and reconciliation tools through a paperless system with near-live

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synchronisation is how Maptek differentiates its solution from siloed reporting mechanisms. Reporting tools collect the data during the shift or a production cycle, bring it together and report it. By then, the shift is over, and it’s too late to apply the analysis to make informed decisions mid-shift when it can actually make a difference. Importantly, BlastLogic delivers productivity and efficiency gains beyond the drill and blast space. Linking the performance of the blast to geology, the production plan and downstream processes add agility to

Mark Roberts, Maptek group product manager for mine operations

planning and production. For example, integrating dig rates or vibration results means all stakeholders overseeing the safety, production and cost drivers of the mine or quarry can apply information around ‘how well that blast performed’ to the knowledge of the impact on the overall operation. Correlating all of the blast-related data in one place and getting objective validation and analysis around that data, with results transparent to all teams in surface operations, facilitates greater coordination among functional groups. The learnings gained from analysing that data are fundamental to blast performance. The founding premise of an all-inone design and reconciliation package is in substantiating how well you are executing your design. Think of it as a way of measuring confidence. If you measure something, you can benchmark it because you now have a baseline that guides the metric for improvement. Closing the feedback loop between planned outcomes and what actually happened from blast design to reconciliation provides the certainty that businesses look for. Don’t get me wrong, trial and error still exist. No-one wants to tell their manager or shareholders that they couldn’t show where AGGREGATES BUSINESS September/October 2020

BLASTING & ALTERNATIVES

improvements were made because they weren’t tracking performance. Analysis of the blast outcomes over time provides decision guidance on how to improve - either improve blast designs or look to the execution phase to identify where gains can be made.

What impact has COVID-19 had on market demand? Early on with COVID-19 when customers relocated their staff away from sites or corporate head offices, it became even more important to transition to digital tracking and reconciliation systems. The single source of blast data could easily be available to everyone, regardless of where they worked. Maptek Account enables web browser access to all Maptek software entitlements, even for customers who may work offline. In this way, blast engineers and field crews can still record, model and analyse their blast data to support the operational production cycle.

Where do you see growth coming from in your product offer to open-pit mining customers? Tighter integration between drill and blast and other operational processes is a key consideration in the Maptek development strategy. Surface operations need a continuous feedback loop of collecting, validating and reconciling data to better manage their planning and production cycles, and allocate resources efficiently. Field and management teams at quarries and open-pit mines are supported by the digital data flow to respond appropriately to the need for changes in real time, knowing that their decisions are founded on current information and actual conditions. The drive for optimisation solutions, by which we mean a balance between value and practicality, is behind an ambitious new Maptek project to automate the currently

When stock levels can be updated dynamically in the ﬁeld using Maptek’s BlastLogic Tablet, possibly confusing paper-based record-keeping is unnecessary, and manual calculation errors reduced

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BlastLogic digital explosives management

intensive engineering design process. We’re using our scalable cloud platform, the Maptek Compute Framework, to build a new blast optimisation tool. BlastMCF applies an evolutionary algorithm to handle multiobjective, many-constraint, population-based modelling. The approach has been proven in our scheduling and domain modelling solutions to generate realistic results faster than with traditional methods. The outcome is a dramatically improved workflow for blast engineers. Instead of focusing their time coming up with one design (that may prove to be sub-optimal), they will pivot to trading off the multiple designs that are automatically prepared. Typically these are more than 90% ready to be executed, and the chosen design can still be updated manually in BlastLogic if minor tweaks are required.

compliance. When stock levels can be updated dynamically in the field using the BlastLogic Tablet, potentially confusing paper-based record-keeping is eliminated, and manual calculation errors are minimised to account for all explosives used on a particular blast, or not used and returned to the magazine. Tablet data is synchronised with the BlastLogic desktop application and central server, and reports can be created and printed for regulatory sign-offs. Live dashboards give a real-time view of inventory and allow flagging and investigation of stock discrepancies. Digital record-keeping is secure, provides greater clarity and aligns with the industry trend for paperless operations. The BlastLogic digital workflow is helping customers reduce downtime and reap the benefits of a datadriven, decision-making approach.

What success have you had in the marketplace with your latest product solutions centred on blast execution and analysis? Can you give a couple of customer examples?

Is Maptek planning to introduce any new products for surface mining sector customers in the next 12-18 months? If so, when are they likely to be made available? And crucially, how will they add to/differ from what is already on the market?

Specialists tasked with continuous improvement and innovation are typically keen to look at their mining or quarry operation holistically. Proper explosives handling and tracking is crucial to safety and efficiency, and going digital is key to ensuring operational

BlastMCF mentioned above is one of the key areas where automation can deliver benefits to surface operations such as open-pit mines and large quarries. Maptek will soon introduce the ability to record as-drilled data on our tablet applications. This will benefit many operations that cannot access drill navigation technology on all their drills. For example, contractor equipment which may not have drill navigation installed, or sensors may not be functioning correctly and awaiting repair. With BlastLogic, drill operators will be able to use the BlastLogic Tablet instead of paper plod sheets. As-drilled data like drill operator name, drill ID, drill time, depth and custom drill properties that are supported in BlastLogic will be recorded, making it immediately available to be consumed in the design-validate-reconcile feedback loop for blasting. The recording of accurate digital data has shown to significantly improve overall performance by enabling this measurement to be used earlier in the drilling and blasting process, so re-drills and backfilling are accurately performed in time for charging. AB

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BLASTING & ALTERNATIVES

Going wireless in surface mining Orica has achieved great commercial success with its groundbreaking wireless WebGen solution for the drilling and blasting process in surface and underground mining. Guy Woodford reports

n early 2017, Orica launched WebGen, the world’s first fully wireless initiating system as the critical first stage in fully automating the drill and blast process in surface and underground mining. One of the most exciting blasting technologies to be developed since the introduction of electronic blasting systems in the early 2000s, WebGen has already been fired in over 1,000 blasts in both surface and underground mines around the world. The system allows for groups of in-hole primes to be wirelessly initiated by a firing command that communicates through hundreds of metres of rock, air, and water. This is said by Orica to eliminate the need for down wires and surface connecting wires, enabling new mining methods and blasting techniques that are safe and reliable. Using low-frequency magnetic signals to communicate with each WebGen primer before a blast, WebGen is also the only commercial explosives product with a safety integrity level (SIL) 3 rating.

WebGen is said to unlock endless possibilities including safe drive over WebGen loaded blast holes, increasing vertical advance

AGGREGATES BUSINESS September/October 2020

WebGen has demonstrated the benefits of its fully wireless blasting technology in many underground mines and has enabled the development of seven innovative mining techniques such as the temporary rib pillar (TRP) method and the sub-level cave (SLC) mining method. The success of WebGen in underground mining is said by Orica to have led to increased adoption of the technology in surface mining. With its fully wireless capability WebGen presents an opportunity to overcome one of the industry’s most persistent limitations: a physical or wired connection to each primer in a blast. Wired systems have a large physical presence and are susceptible to damage at every point along the connecting line. The potential for misfires due to downline damage has commonly led to the application of redundant initiation systems and can impede the loading of adjacent blast patterns due to flyrock damage. These contributing factors, says Orica, increase

ABOVE: WebGen includes an i-kon III plug-in detonator, a Pentex W booster and a DRX - a digital receiver comprising a multidirectional antenna and a battery, which serves as the in-hole power source blasting costs, reduce mine efficiency and limit blast productivity. Wired systems also require precautionary measures in priming, loading, stemming and tie-in activities to protect wired connections, adding burden to manpower needs and timing. Being fully wireless, the application of WebGen in surface mining is said to simplify bench operations with no tie-in process and reduced on-bench resources, inventory, and misfires that occur due to line damage or cut-offs, slumping or operator error. Stemming costs are also reduced, and back-up inventory is eliminated with wireless systems. Orica says WebGen also improves employee safety in surface mining operations by reducing the time spent on the bench in extreme heat and dusty conditions and by reducing physical movement. This reduction is significant when charging significant blasts or when facing extreme conditions around the world. The absence of downlines also removes the interaction between heavy vehicles and initiating systems while reducing people’s exposure to on-bench hazards. The tie-in process is eliminated, and spotters are not required to protect downlines, nor are they exposed to the dust and dangers from typical stemming operations. With increased flexibility in pit planning and blasted inventory, Orica says that mine operations enabled by WebGen can also prime and load larger single blasts as well as eliminate firing window variability. AB

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HYDRAULIC HAMMERS – AFRICA

Caterpillar’s GC value hammer line-up based on gas ﬁre technology is designed to work with 12 to 40 tonne carriers

Advancements in hydraulic hammer technology Relentless technological advancements in hydraulic hammers in recent years have ensured proper operation, enhanced breaking efficiency, minimised operating costs and the time associated with completing tasks, thus helping fleet owners achieve long-term productivity and cost efficiency. By Munesu Shoko

o remain competitive in today’s challenging economic environment, quarry owners are looking beyond the basics. They are looking at how their equipment can squeeze more margins and volumes, and a strong attachment focus is gaining momentum. Quarry owners understand that a key factor in succeeding with any fleet of equipment, especially excavators, is getting the most out of the machines. Attachments are key to equipment versatility and utilisation. Using various tools and attachments can turn excavators from one-dimensional pieces of equipment into multipurpose and adaptable machines. For many years, attachments have been designed to enhance equipment fleets. While that likely won’t change, advancing technology in hydraulic hammers – probably the most popular type of machine attachment – means today’s equipment operators can benefit from innovations that are taking accuracy and breaking efficiency to a whole new level. One of the most recent technological advancements in hydraulic hammers is the blank-firing protection feature. Blank firing occurs when the operator activates the hammer without the tool engaged with the material to be broken. In such an event, the energy of the piston striking the tool has

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The non-silenced GC hammer is built to handle highproductivity applications

nowhere to go but back into the hammer and the carrier machine. The effect of blank firing is increased wear on both hammer and machine. Thus, blank-firing protection is designed to minimise wear and tear that the hammer faces. By employing blank-firing protection, the hammer can be protected from direct metal-to-metal contact, thus guarding against premature deterioration. Reducing the stress transmitted back to the carrier machine also has the additional benefit of providing a substantially more comfortable environment for the operator. “Blank-firing protection is key to ensuring the piston will not cycle after the tool penetrates the material,” explains Gilles Ronnet, demolition product application specialist, EAME (Europe, Africa, Middle East) region at Caterpillar. This, he says, reduces internal stresses and protects the assets, both the hammer and the carrier. “This feature lowers owning and operating costs and is operator friendly.” Ronnet says Caterpillar is developing different combined technologies for both machines and hammers. Caterpillar has integrated a hammer auto-stop function in the Next Generation machines, which alerts the operator of blank firing after 15 seconds, and automatically stops the hammer after 30 seconds if the operator doesn’t stop AGGREGATES BUSINESS INTERNATIONAL September/October 2020

HYDRAULIC HAMMERS – AFRICA

Caterpillar offers several hammer line-ups with product deliverables satisfying different customer requirements with different technologies

hammering, as per good practice. The new safety feature protects both the hammer and the machine and reduces drastically customers’ maintenance costs. “The auto shut-off feature instantly stops the piston when breaking through material. It prevents blank firing, which is a top cause of hammer wear. Internal stresses are reduced, providing more productive hours of work. The hammer is protected, regardless of operator skill level,” he says. Another technological advancement of note is the energy-recovery valve, which is designed to increase the striking power of the hammer by transferring recoil energy to the tool’s next blow. “Energy recovery is using the

A Cat hammer deployed to break rock in a quarrying application

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

bounce energy of the piston to help it cycle down in combination with the pressure of the accumulator,” says Ronnet. Speed control is yet another technological advancement that has come to the fore in recent years. This feature offers increased productivity and minimises backflow of harmful energy to the excavator. According to Ronnet, speed control adapts the speed and consequently the power of the hammer to the material being broken, resulting in optimum productivity. “This feature – with two manual turns on the side of the power cell – doubles the piston speed without reducing the power. The slower speed allows the hammer to hit at full

power. This allows for maximum production and matches the hammer speed and power to the application,” says Ronnet. Caterpillar offers several hammer lineups with product deliverables satisfying different customer requirements with different technologies. The E performance hammer line-up based on oil-fired technology matches carriers in the 11 to 52-tonne weight category. The silenced hammer line is recommended for high-time utilisation and high productivity. Caterpillar’s E Series is a good example of forward momentum in hydraulic hammer development. The range comes with a number of features that set the bar high in the hydraulic hammer field. For example, the tri-suspension system comprises the suspension jacket, the lower and upper buffers. Suspension aligns the power cell and gives manageable, smooth performance. The lower and upper buffers, at both ends of the power cell, absorb reflective forces, isolating them from the machine. The result is quiet, reliable operation and reduced operator fatigue. The suspension jacket, which dampens vibration and sound, allows the hammer to be used in urban and other noise-sensitive areas. With the seal carrier, gas is retained in the power chamber by a series of five seals. These are engineered using technology developed for Cat engines, and provide maximum gas retention between scheduled service intervals. When service is needed, the seal carrier is easily removed. A pressure control valve (PCV) maintains maximum hydraulic pressure to ensure the hammer delivers all blows at full power. PCVs can be easily checked and adjusted from outside the hammer in about 30 minutes. A check valve isolates harmful pulsation spikes from the carrier hydraulic circuit. The plug & perform feature is designed for convenient installation on Cat machines. There is no adjustment necessary for hydraulic pressures or flows. The hammer

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HYDRAULIC HAMMERS – AFRICA

handles full auxiliary flow and pressure, automatically adjusting to match the Cat tool carrier. Hammer over-speeding and shortened service are prevented. The GC value hammer line based on gas-fired technology is ideal for 12 to 40-tonne carrier weights. The non-silenced hammer is built to handle high-productivity applications and is designed to fit customers’ budget requirements. Tharen Peterson, product application specialist, attachments for machines under 10 tonnes at Caterpillar, says the silenced H hammer line-up based on gas fire technology matches carriers from one to 10 tonnes, as well as skid-steer loaders, compact track loaders and backhoe loaders. The B series is also a gas-fired hammer that matches carriers from less than one to 10 tonnes, as well as skid-steer loaders, compact track loaders and backhoe loaders. The hammer range comes either silenced or non-silenced, and is offered with fewer features and just as much capability with budget requirements in mind. In addition, Caterpillar is launching the PL161 asset tracker and locator. Every Cat hydraulic work tool (for machines above 10 tonnes) – as at first phase of deployment starting in May this year – will be shipped from the factory with this device that allows operators to keep track of tools and record working hours accurately to schedule the necessary preventative maintenance. The PL161 locator is said to be the most advanced OEM-integrated technology solution for attachment tracking. With the ability to track location and utilisation, users can know where their attachments are across all worksites, reduce the number of lost attachments and plan for attachment maintenance and replacement. “The PL161 attachment locator can be used on attachments and non-powered assets as an affordable option for last known location tracking, and it integrates easily into users’ operation for full fleet management of machines and attachments from one dashboard on a smartphone or a tablet,” Ronnet explains.

“Maintenance is key for an optimum hammer life and for reducing maintenance costs” Tharen Peterson, Caterpillar

“A work tool recognition system has been added to the Next Generation machines, allowing an automatic hydraulic setting adjustment. All these features are now available on Next Generation Cat machines and work tools and are part of the Cat fleet management system,” explains Ronnet. As with some of the features on the Cat B and H hammers, Peterson says Caterpillar

ABOVE: Blank-ﬁring protection ensures the piston will not cycle after the tool penetrates the material BELOW: Caterpillar is launching its PL161 asset tracker and locator

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is constantly looking at the portfolio and determining what functionality is offered throughout the line. What makes sense on the larger hammer and machine offering, he says, may not yet be a customer requirement on the 10-tonne and under class. “As such, the auto-stop function is not part of the less than 10-tonne offering at this point. Similarly, on the compact construction equipment side, the PL161 will not be installed on the 10-tonne and under attachments as this has not become a requirement in this size of attachments, yet. Across the line, we intend to bring value to our customers. Again, what works on the larger machines and attachments may not yet be a requirement for the compact construction segment. We have that flexibility to offer what different customer groups require,” explains Peterson. Like any other piece of equipment, regular maintenance of hydraulic hammers is of utmost importance to minimise wear and tear, increase efficiency, productivity and lifespan. Thus, hammers should be inspected on a regular basis to identify any wear and tear signs. All the indicators showing wear and tear on the console of the hammer, for example, must be checked periodically. This can lead to identification of the damage at an early stage before they become big and costly issues. “Maintenance is key for an optimum hammer life and for reducing maintenance costs,” says Ronnet, adding that the right machine, hammer choice and commissioning are also key parameters of importance. “All the hydraulic parameters – right flow at right pressure, back pressure check and relief valve setting – have to be set properly,” he says. Training is also key for optimum productivity and reduced maintenance costs. “This is part of Caterpillar’s standard delivery process, we deliver both iron and expertise,” concludes Ronnet. AB AGGREGATES BUSINESS INTERNATIONAL September/October 2020

CHINA’S BRI IN THE MIDDLE EAST

A new harbour is emerging on the Persian Gulf in front of Dubai’s skyline

Projects delayed as Arab world struggles to cope with COVID-19 COVID-19 continues to play havoc with China’s ongoing multi-billion Belt & Road Initiative (BRI) projects in the Middle East. V L Srinivasan reports

hen hundreds of Chinese workers returned home from the region to celebrate the Lunar New Year in January 2020, they had little or no inkling that the coronavirus would shatter their plans of returning to their respective workplaces in the Arab world where they were involved in several infrastructure projects. As the pandemic assumed alarming proportions in the region, several countries imposed a travel ban and enforced lockdowns to avoid spreading the virus. Still, coronavirus took a heavy toll on human life and most of the projects were either cancelled or put on hold till the situation returned to normalcy. However, some of the countries have started opening up and precautions are in place to contain the virus. In the last few years, China has been making its presence felt among the Arab countries by building close economic and strategic ties with key markets and countries in the region. According to China Customs Statistics (export-import), China-Middle Eastern

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

countries’ trade volume increased to US$294.4 billion by 2019, up from US$227 billion in 2018, as both sides have cemented their cooperation in the fields of energy, trade, project contracting, and investment. These countries are strategically important as they lie at the heart of China’s BRI. Many countries have set up bilateral investment funds with China to finance BRI-related projects. For instance, the UAE has established a $10 billion joint strategic investment fund between Abu Dhabi investment group, Mubadala, the China Development Bank and the Chinese State Administration of Foreign Exchange, according to leading data and analytics company GlobalData. As of mid-2019, China had signed agreements with 21 MENA (Middle East, North Africa) countries, including 18 Arab League nations, on a joint BRI project. At a meeting of the China-Arab States Cooperation Forum (CASCF) in Beijing in 2018, China pledged $23 billion in loans and development aid to the region. The meeting identified the UAE’s Khalifa Port, Oman’s Duqm, Saudi Arabia’s Jizan, and Egypt’s Port Said and

Ain Sokhna as key projects that China will develop in association with the BRI in the Middle East. Chinese contractors are also involved in major infrastructure construction contracts in Qatar, including the $25 billion expansion plans for Hamad International Airport (HIA), which will deliver an expanded capacity of 53 million passengers by 2022 (compared with 34.5 million handled in 2018). The scope of China’s interest in the Gulf region has increased in recent years from a limited focus on hydrocarbon trade to a multitude of investments in energy, industry, finance, transport, communications and other technology. A report by the China Global Investment Tracker said that Beijing’s investments in the region stood at $93.3 billion in 2019. Most are in the energy sector ($52.8 billion), real estate ($18.4 billion), transport ($18.6 billion), and utilities ($5.9 billion). This is crucial for the region as most MENA countries are under pressure to diversify their economies and have been embarking on ambitious infrastructure and construction projects, GlobalData said.

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CHINA’S BRI IN THE MIDDLE EAST

Projects impacted Speaking to media in June, China’s Foreign Affairs Ministry International Economic Affairs director, General Wang Xiaolong, confirmed that about 20% of projects under BRI were seriously affected by the pandemic while about 40% were adversely affected and a further 30%-40% were “somewhat affected”, as quoted in the Hong Kong-based South China Morning Post. According to Wang, restrictions on travel and the flow of goods across borders, as well as local measures to combat COVID-19, were the main reasons for the impacts on projects. “As the situation improves, we have confidence that the projects will come back and the execution of them will speed up,” he added. Reports also said that Egypt has postponed construction of a coal-fired power plant, Bangladesh has cancelled plans for a coal plant, Pakistan has asked Beijing for easier repayment terms on $30 billion-power projects and Tanzania is planning to cancel a port project. Growing influence Despite these hiccups, China’s influence in the region continues to grow even as COVID19 disrupts supply chains. An example of its role in the region came on 26 April when Saudi Arabia’s National Unified Procurement Company (NUPCO) signed an agreement worth $265 million with China’s Beijing Genome Institute to expand COVID-19 testing capacity in the Kingdom. As per the agreement, Beijing will provide 9 million COVID-19 test kits, 500 experts, specialists and technicians to ramp up testing in Saudi Arabia. Six large test laboratories will also be established including an inflatable mobile laboratory with a production capacity of 10,000 tests daily. In the field of energy, Saudi Aramco awarded contracts for the four main packages that are part of its estimated Aramco’s $2 billion Aramco’s South Ghawar unconventional shale gas field development project. The largest deal signed in April this year in the region was a $2.86 billion contract signed between China State Shipbuilding Corporation (CSSC), the world’s largest shipbuilder, and Qatar Petroleum (QP) for the construction of LNG (liquified natural gas) tankers. The tankers will be built by Hudong-Zhonghua Shipbuilding at its unit in Shanghai. This contract is the first part of a huge order that could include more than 60 LNG carriers in total as QP has announced its plans to increase its LNG production capacity from the present 77 million tonnes per year to 126 million tonnes per year in the coming few years. GlobalData’s Economist Yasmine Ghozzi said China’s overseas investment and construction saw a considerable shift in 2019 that could be explained by a drain of foreign exchange used to finance construction and investment since its BRI launch in 2013. It will continue to search for growth drivers

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“In terms of infrastructure building and trade investment, the BRI will continue to focus on megaproject building, and the MENA region has an active pipeline for its 2030 vision.” Yasmine Ghozzi Economist, GlobalData

“Most countries in the Middle East have placed entry restrictions on Chinese citizens or individuals travelling from China. The longer that Chinese workers are unable to return to projects overseas, the longer the BRI projects will languish incomplete, and some may be abandoned altogether.” Dr. Mordechai Chaziza senior lecturer, Ashkelon Academic College, Israel

globally and the Middle East presents vast opportunities to explore areas of cooperation in different industries to help the region accelerate its own development and industrialisation. “In terms of infrastructure building and trade investment, the BRI will continue to focus on mega-project building, and the MENA region has an active pipeline for its 2030 vision,” she noted. Even the nuclear power industry looks promising for the Chinese as Saudi Arabia, the UAE, and Egypt have plans to develop nuclear power industries. Although Russia has been the dominant player in the region when it comes to nuclear power investment, there is room for China to also play a crucial role. A second area is aerospace satellite cooperation. As part of the “digital Silk Road”, satellites are a priority for China in the Middle East. China has already set its goal to install its BeiDou Navigation Satellite System in more Arab countries, where it will launch eight satellites over the skies of Arab countries for application in communication, navigation and meteorological remotesensing services. Telecommunication companies in Bahrain, Egypt, Kuwait, Saudi Arabia and the UAE have all partnered with Huawei to build 5G networks, Yasmine Ghozzi said. Temporary setback Liebherr Group, which is one of the largest manufacturers of the construction machinery in the world, has been associated with several projects in the Middle East for many years. But like other companies, Liebherr too has been impacted due to the COVID-19 pandemic. Liebherr (China) General Manager Patrick Schulz said that due to the outbreak of the pandemic, several projects have been delayed due to lockdowns and major challenges for the medical system in the respective countries. “This, however, is considered only a temporary setback as there were no projects cancelled up to now. At the moment, we assume that COVID-19 may cause delays of approximately two to three months. Of course, that’s a current prognosis possibly changing as the pandemic is not over yet,” he said. On returning to normalcy, he said: “Further situation mainly depends on the pandemic’s development in the Middle Eastern countries and the regulations the governments are forced to enact. Generally, it seems as if the Middle Eastern region puts high emphasis on tracking and testing instead of requesting complete lockdowns. That’s why we expect projects to be continued soon.” Making inroads in Israel In Israel, China has become the dominant force in the local construction industry and in November 2016 five Chinese construction giants won the government tenders to build residential housing in the country and to AGGREGATES BUSINESS INTERNATIONAL September/October 2020

CHINA’S BRI IN THE MIDDLE EAST

manage these projects as the company responsible for all of its the engineering and performance aspects. In January 2017, Israel and China signed an agreement to bring 20,000 Chinese professional construction workers to Israel in the coming year. By March 2020, 3,500 Chinese workers had arrived and another 700 were commissioned by contractors and were expected to arrive soon. But 1800 workers remain in China. Dr. Mordechai Chaziza, who is working as senior lecturer in the department of Politics and Governance and the division of Multi-disciplinary Studies in Social Science, Ashkelon Academic College in Israel, said that Beijing has repatriated citizens working in Iran due to the spread of the virus, a measure it could apply to any BRI host country in the Middle East severely afflicted with the spread of the coronavirus, and one which will bring other BRI projects to a halt. “Most countries in the Middle East have placed entry restrictions on Chinese citizens or individuals travelling from China. The longer that Chinese workers are unable to return to projects overseas, the longer the BRI projects will languish incomplete, and some may be abandoned altogether,” he noted. The coronavirus has also hampered China’s manufacturing supply chains, and BRI projects are predominantly reliant on Chinese, rather than local materials and supplies.

Keller is using a HS 8130 with vibro-ﬂot for the soil compaction work

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

“This, however, is considered only a temporary setback as there were no projects cancelled up to now. At the moment, we assume that COVID-19 may cause delays of approximately two to three months. Of course, that’s a current prognosis possibly changing as the pandemic is not over yet.” Patrick Schulz General Manager Liebherr (China)

Currently, almost half of China’s oil imports are sourced from the Middle East, principally from the Persian Gulf. The pandemic has compromised the global supply chains that keep BRI projects moving forward, limiting the goods flowing out of China to the point that China ran a trade deficit during the first two months of this year. China’s shuttered factories not only need workers to be released from quarantines to resume normal output, but also need restored supplies of raw materials, adequate stores of protective gear for workers, and active truckers and shipping ports to deliver their goods abroad, he said. “The coronavirus has also disrupted the global shipping industry and slowed to the point that more tonnage of container ships was idled around the world in February than during the worst points of the 2008 financial crisis,” he averred. On how soon these projects will be back in action, he said that it was still too early to predict and depended on many factors that are not necessarily controlled by the Chinese or local countries. The restrictive travel bans, port closures, cancelled flights, and blocked roads have prevented Chinese workers from returning to BRI worksites abroad, while the shutdown of Chinese factories that supply machinery and raw materials for BRI projects has hindered projects from moving forward. These and other disruptions are causing delays, missed deadlines and have increased infrastructure costs that local economies will find difficult to absorb. “Nevertheless, COVID19 will not be fatal to the implementation of BRI projects, but the disease’s fast and lethal spread will cause Middle East governments to rethink the risks attached to ever more integration and economic dependence on PRC’s (People’s Republic of China’s) infrastructure,” he added. AB

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High-performance screen media

Aggregates asce ascent

An assessment of its bottom-line-boosting potential p19

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PONSI BLY

F OO T P R

I N T E D & PO S

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QUARRY PROFILE Cyprus’s biggest quarrying group’s renewed ﬂeet advantage p47

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DUCE OU

INTERVIEW Bheki Mthembu: PPC’s next steps in uncertain South African cement sector p10

DRILL RIGS, TOP HAMMERS & BREAKERS A high-quality drill rig for major China limestone mine p28

PONSI BLY

RES

CRUSHING & SCREENING An elevated view of scalping screen excellence p23

INTERVIEW Arnaud Colson: Fighting to secure a rock for all ages p9

I N T E D & PO S

‘Grands projets’ boost for French aggregates demand p19

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WATER RECYCLING, MANAGEMENT & FILTRATION Innovation in washing plant technology leads to big commercial gains p31

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EQUIPMENT UPDATE Caterpillar has celebrated the unrivalled success of the elevated sprocket design in the medium dozer class by producing three commemorative 175,000 units

More water through Tsurumi pumps Tsurumi’s new HS3.75SL (manual) and HSZ3.75SL (automatic) submersible, trash pump models can pump roughly twice as much water as the company’s high-head HS3.75S pump. This means customers will be able to save time and money in dewatering applications. “Our new HS3.75SL and HSZ3.75SL models are ideal for applications where customers need to dewater faster so they can get onto the job site quicker, such as construction and utility jobs, and in disaster remediation, when time is crucial,” said Glenn Wieczorek, managing director of Tsurumi America. “These trash pumps handle debris, sand and solids that come in ﬂooding water with minimum wear and clogging, which makes them great support in such events.”

Caterpillar celebrates 175,000 medium high-drive dozers In 1985, Caterpillar expanded its revolutionary elevated sprocket undercarriage concept to its medium track-type tractor (MTTT) line with the launch of the H-Series models. Still unique to this day for the 100 to 250kW dozer class, the high-drive design conformed to the ground better, improving durability, service serviceability and performance compa compared to low-drive and oval track d designs. The Cat D4H, D5H, D6H and D7H d dozer models were the first to feat feature the high-drive design, and in 1987, the D8L model was added to the family. In addition to brin bringing many of the same large d dozer advantages to the mediu medium line, the elevated drive sprock sprocket allowed movement of the fro front and rear track idlers. This he helped to fine-tune machine

balance and ground pressure for specific applications more easily than oval track machines. For the first time, variable pitch angle tilt (VPAT) blades were made available to high-drive dozers with the D4H and D5H models for finishing jobs faster by grading at higher speeds. Thirty-five years later, Caterpillar has celebrated the unrivalled success of the elevated sprocket design in the medium dozer class by producing three commemorative 175,000 units in May 2020. Wes Holm, chief engineer, Caterpillar medium tractor products, said: “With our nextgeneration medium dozer line, which includes the new D5, D6 and D7 models, we continue to push envelopes through adaptation of technology to drive productivity and efficiency to

another level.” With travel and gathering restrictions resulting from the ongoing coronavirus pandemic, Caterpillar cancelled in-person celebrations to mark the historic 175,000-unit milestone for its medium dozers. However, three customers took possession of the commemorative units, which feature special decals on the fenders denoting the 175,000-unit milestone. Built in East Peoria, Illinois, USA, the first two commemorative units were Cat D6 XE electricdrive dozers, featuring a sleek dark grey and black paint scheme. The third unit, a D6 dozer with 4-speed, fully automatic transmission, is finished in traditional Cat yellow with special black tracks and blade.

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Su Superior Industries’ new Telestacker conveyors Te Tsurumi’s new HS3.75SL submersible, trash pump model The new pumps offer a maximum ﬂow rate of 140GPM and a total dynamic head of up to 40ft, with a motor input of just 0.75kW. Compact and lightweight, they are easy to transport and operator friendly. Low maintenance is another strength, as the pumps’ wear parts are made from highly durable materials. The shaft incorporates Tsurumi’s original agitator to prevent airlock, as occasionally seen in vortex pumps and semi-vortex pumps, and to stir slurry efficiently. The difference between the two models is that the HSZ3.75SL contains a simple ﬂoat switch-equipped automatic sensor to prevent dryrunning operation and to reduce power consumption. www.tsurumipump.com

Superio Industries, a U.S.-based Superior manufacturer and global supplier manufa of bulk material processing and handling solutions, is introducing a new standard set of TeleStacker conveyor models with onboard power. These self-contained, radial, telescoping conveyors are equipped with a 96kW Cat 4.4 Tier 4 Final engine. The most popular applications for the new models will be remote quarrying

and mining sites, where access to permanent electrical power transmission is not practical. Today, self-contained TeleStacker conveyors are designed in 914mm-belt widths and fully extended operating lengths of 34m, 40m and 46m. Superior says its engineering team will collaborate with bulk handlers requiring custom widths and lengths. Other standard features

include XTP swing axles, hydraulic drives for the primary and stinger conveyors, Superior brand idlers and pulleys, plus an onboard counterweight. Additionally, the manufacturer offers dozens of options to match the TeleStacker conveyor to its environment. Since Superior Industries produced the ﬁrst highly mobile, road-portable TeleStacker conveyor in 1997, the company has continually taken telescoping radial-stacking technology to next-level effectiveness. In countless applications worldwide, TeleStacker conveyors deliver cost-efficient material-handling solutions that boost stockpile volumes and loading capacities, while preventing material segregation and additional material handling, plus eliminating costly loader and haul truck use.

www.superior-ind.com

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

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EQUIPMENT UPDATE

Haver & Boecker introduces Pulse Vibration Analysis Service Haver & Boecker Niagara has launched its Pulse Vibration Analysis Service. The company’s new service programme uses the revolutionary Pulse vibration analysis technology to evaluate vibrating screen performance and provide recommendations to increase uptime and efficiency. Haver & Boecker Niagara (H&B Niagara) says the service will help customers achieve production targets, minimise unscheduled downtime and demonstrate sustainable improvements through online asset management in partnership with H&B Niagara’s vibrating screen service expertise. Wilm Schulz, H&B Niagara’s parts and service manager, said: “Our Pulse Vibration Analysis Service offers more than just technology. We want to help our customers by serving as an extension of their maintenance teams, bringing the knowledge of an OEM to help support their operation.” Pulse Vibration Analysis Service uses the company’s industry-leading Pulse Vibration Analysis software to examine the health of a vibrating screen

McCloskey’s new standout feeder stacker

Haver & Boecker Niagara has launched a new Pulse Vibration Analysis Service to ensure optimum screening performance and equipment reliability. Pulse detects irregularities that could translate into diminished performance, decreased efficiency, increased operating costs and imminent breakdown. This gives producers advanced notice so that their operation can plan preventative maintenance programmes to avoid premature wear, downtime and additional expense. The service programme includes a complete vibrating screen inspection by an H&B Niagara-certified service

technician. Following the inspection, customers receive a Pulse Diagnostic Report, which provides an analysis of their vibrating screen and detailed recommendations to prevent downtime. All Pulse Diagnostic Reports are stored in an online asset management system, giving customers access to a complete record of their vibrating screens’ service and performance histories. This information allows customers to maximise uptime and productivity, and as a result, increase profitability.

www.haverniagara.ca

McCloskey International has unveiled its newly designed SF50 compact feeder stacker. The SF50 facilitates the handling and stockpiling of materials including, but not limited to, aggregates, sand and gravel, coal, construction and demolition waste, topsoil and compost. The model’s 10ft hopper transfers material onto a 50ft conveyor. The SF50 allows operators to stockpile/transfer material and eliminates double handling of materials. The easy to load and transport SF50 ﬁts a 40ft cube container for reduced costs. The up to 500 tonnes per hour capacity, 55kW engine-powered SF50 features a hydraulic folding heading section for transport-minimising setup time, a hydraulically adjustable discharge height of up to 6.5m, 3.5m tracks for claimed superior manoeuvrability and stability, fuelefficient hydraulics, user-friendly hydraulic controls, and hopper extensions to increase capacity. Overall, the SF50 adds a versatile and mobile solution to McCloskey’s range of feeder stackers. www.mccloskeyinternational.com

McCloskey’s new quarrying application-suited, newly designed SF50 compact feeder stacker

Metso Outotec releases new Conveyor Solutions Handbook

Metso Outotec has launched a new edition of its Conveyor Solutions Handbook

www.AggBusiness.com

Metso Outotec is releasing the second edition of its Conveyor Solutions Handbook, designed as a definitive guide for conveyor professionals in the aggregate and mining industries. Conveyor systems are a crucial factor in mining, aggregate and industrial operations, underpinning efficiency and – ultimately – profitability. “We are really excited about the new updated Conveyor Solutions Handbook. Our goal is to help customers find the right solution for their conveying needs,” states Raul Camargo, director of Conveyor Solutions at Metso Outotec. “Metso Outotec has a full ‘ABC’ range of conveying products – meaning we offer a complete range of conveyor accessories, belts and components to help our mining

and aggregates customers keep their conveying systems running properly.” The Conveyor Solutions Handbook is a comprehensive 248-page guide covering all the typical challenges involved in properly maintaining a conveyor system. Solutions within the handbook address issues such as carryback, belt mistracking, spillage around the conveyor, excessive dust and waste reduction. The handbook covers belts, idlers, roller options, tensioners, cleaners, sealing systems, protective devices as well as impact cradles and loading solutions. Multiple selection guides are also found throughout the book to help users match their application with the right solution.

www.mogroup.com

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

EVENTS | FOR A FULL LIST OF EVENTS VISIT WWW.AGGBUSINESS.COM/DIARY

2020 NOVEMBER 24-27 bauma China Shanghai, China Organiser: Messe München Tel: +49 89 949-20252 info@bauma-china.com https://www.bauma-china.com

2021 FEBRUARY 23-26 bauma Conexpo India Gurugram/ New Delhi, India Organiser: AEM and Messe München Tel: +49 89 949-20251 info@bcindia.com https://www.bcindia.com/en

MARCH 03-07 SaMoTer Verona, Italy Organiser: Veronaﬁere S.p.A. Tel: +39 045 8298561 customercare@samoter.com http://www.samoter.it

APRIL

JULY

14-17 steinexpo 2021 Homberg/Nieder-Oﬂeiden, Germany Organiser: GEOPLAN GMBH Tel: +49 7229 606 30 info@geoplangmbh.de https://www.steinexpo.eu

07-10 EIG 2021 Exeter, UK Organiser: EIG Conferences marcus.dorey@hanson.biz https://www.eigconferences.com/ future-conference-2020

SEPTEMBER

MEET THE TEAM 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.

19-24 INTERMAT Paris, France Organiser: Comexposium laura.sanchez@comexposium.com https://paris-en. intermatconstruction.com

15-18 Construction Indonesia Jakarta, Indonesia Organiser: PT. Pamerindo Indonesia Tel: +49 3999905 0 contact@merebo.com https://ci.merebo.com

JUNE 2021 22-24 Hillhead 2020 Hillhead Quarry, Buxton, Derbyshire, England

MAY

OCTOBER

25-28 bauma CTT Russia Moscow, Russia Organiser: Messe München Rus Tel: +49 (0)89 949 20251 info@bauma-ctt.ru https://bauma-ctt.ru

13-16 bauma CONEXPO AFRICA Johannesburg, South Africa Organiser: AEM and Messe München GmbH Tel: +49 89 949 21480 johannes.manger@messemuenchen.de https://www.bcafrica.com

JULY 2021 07-10 EIG 2021 Exeter, UK

JUNE 22-24 Hillhead Hillhead Quarry, Buxton, Derbyshire, England Organiser: The QMJ Group Tel: +44 (0)115 945 4377 Email: Harvey.sugden@qmj.co.uk https://www.hillhead.com

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

NEW FOR 2020

www.aggbusiness.com NEW state-of-the-art website

HOUSE AD.indd 2

ADVERTISERS INDEX

VOL.8 ISSUE NO.5 SEPTEMBER/OCTOBER 2020

19/02/2020 12:15:59

Advertisers in AGGREGATES BUSINESS can now be contacted via their websites - for instant links to all the websites listed below, by category, go to: www.AggBusiness.com COMPANY

PAGE NO

WEBSITE

COMPANY

PAGE NO

WEBSITE

Allu

www.allu.net

LiuGong

www.liugong.com

Ammann

p21

www.ammann.com

Metso

OBC

www.mogroup.com

Beumer

p33

www.beumer.com

Sumitomo

IFC

www.sumitomokenki.com

BKT

p32

www.bkt-tires.com

Terex Trucks

p27

www.molsongroup.co.uk

CAT

www.cat.com

AGGREGATES BUSINESS INTERNATIONAL September/October 2020

www.AggBusiness.com

TO THE LATEST SHOW VIDEOS

ConstructionTV.TV is dedicated to broadcasting first-class coverage of the world’s leading construction events and the latest industry trends. Combining short, high quality programmes with the latest in digital delivery, ConstructionTV.TV is optimised for mobile devices and can be accessed anywhere, anytime. Individually themed channels provide specific industry information to construction professionals needing to stay ahead in their field of expertise. With expert opinion from only the most experienced editors, ConstructionTV.TV delivers the most reliable and relevant information to the construction industry.

www.constructiontv.tv Contact: Roger Adshead | radshead@ropl.com | +44 7768 178163

Looking for a long-term partner? Look no further. Aggregates production is demanding on your crushers and screens. Ť performance is not easy. Metso Outotec has designed wear and spare parts that are built to last even under heavy duty applications. We have also upped our game with some of the highest crusher parts inventory levels in the business, for parts that are available when you need them most. With an Equipment Protection Services (EPS) plan, you also gain extended warranties, inspections and remote monitoring with Metso Metrics Services for maximum performance. Today and into the future.

Partner for positive change. mogroup.com

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