IMPLEMENTING a Weir Minerals’ full process-focused solution has enabled South African sand and aggregate supplier CNC Crushers to raise throughput at its Roadstone Shaft 5 crushing plant by 45% while cutting back on maintenance and simultaneously increasing production.

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A Warman WBH 100 slurry pump from Weir Minerals.

CNC Crushers owner Carl Crous said, “Partnering with Weir Minerals Africa increased my production output significantly and my uptime increased overnight.”

Weir Minerals general manager for Trio and Enduron equipment JD Singleton said the customer was experiencing high wear on the installed conventional cyclone, as well as on the older technology pump, having to replace liners every 120 hours of operation.

“Our brief was to increase solids to the cyclone underflow and increase wear life on the cyclone feed pump,” he said. “The continuous breakdowns experienced with the older-technology crushing equipment, and excessive oil usage was also causing high downtime for the plant. CNC Crushers needed a solution that would utilise the existing footprint and infrastructure.”

As a solution, Weir Minerals installed a new technology Warman WBH 100 slurry pump and a Cavex 400CVX10 hydrocyclone. It also replaced the existing cone crushers with Trio TC51S and TC36SH cone crushers to increase up-time and reduce maintenance costs.

“After 1900 operating hours, the slurry pump was still running without needing any replacement parts, a vast improvement on the previous mean time between liner replacements of 120 hours,” he said.

Carl Crous said this meant the company could take pumps off the critical maintenance list. “Pump problems are something of the past.”

The hydrocyclones proved more efficient than conventional hydrocyclones, highlighting the benefits of the Cavex laminar spiral inlet geometry. “The Cavex hydrocyclone increased the mass pull to the underflow, which resulted in increased production and reduced slimes to the tailings dam,” he said. “Using new technology equipment pays.”

The cone crushers increased plant availability as well as production, while meeting the criteria of matching the customer’s existing footprint. These crushers also incorporate multiple hydraulic cylinder clamping and adjustment, which enabled them to reduce closed-side setting adjustment time from 90 minutes to just five. In addition, their larger socket assembly was able to give full support under extreme and light load conditions, providing a longer service life.

After the cone crushers were installed, a spares and service agreement was put in place to maintain maximum plant availability.

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