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Crushing, Screening and Recycling Solutions

For several years, our company Naessens Hydraulics specialized in equipment and solutions for applications in the Recycling Industry. Due to very strict and difficult environmental standards in Belgium and neighboring countries it was necessary to develop innovative solutions which satisfy the ever increasing waste to recycle. In collaboration with our valued customers, we have developed a creative solution for soil recycling and for the automatic sorting of construction and demolition waste. Many years of intense testing and research into effective recycling solutions, we can build a solid reputation which involves several specific applications and brings us to a prominent leader in the supply of machinery for the recycling industry. Construction and Demolition waste Sorting Plant: Construction and Demolition waste(C&D waste) is one of the largest waste streams in the Benelux countries. The sorting of this waste is an intensive and very expensive job. With the selective sorting is much manual labor involved and often yield very low and the separate groups are not sufficiently pure. Our Company has developed a unique and innovative solution to sort construction and demolition waste. The construction and demolition waste is first sorted by an excavator with grab sorting. restfraction of 0 to -300 mm is loaded into the plant where a trommelscreen seperates the fine fraction of 0 to 40 mm. Then the 40 to 300 mm fraction is fed into the Windscreener or also called a windsifter where the waste is separated into three groups,in particular stones, wood residue and ofcourse the restfraction containing plastic, paper, cardbord ect.. This process happens automatically. If necessary, the non- ferrous metals can be sorted out manually by only one operator. The installation is running a high capacity, is fully electrically driven and is very user friendly. Mobile Soil Recycling Plant: In road construction and drainage works, in many cases so that the excavated soil and underground structure is often poor and usually filled with stones and other contaminated materials. This situation is this bad understructure to be transported per transport to a landfill. The landfill is often not allowed and if so the costs are often very high. It should also be taken into account that the evacuated soil must be replaced by a sand- cement mixture to refill and stabilise the excavated canals. The system developed by Naessens Hydraulics is designed to offer the land directly to the site can handle. The system ensures that all stones and other contaminated materials are separated from the ground after it is mixed with lime or cement to be back in the soil structure and capacity to obtain. This operation will have important substantial savings on landfill expenses. The full installation is highly mobile thanks to the tracked chassis and easily transportable cement silo. The installation is very simple and fast which made it possible to start up the production within in less than one hour. The benefits and advantages of our soil recycling machines are: High an cleanProduction Simple fast operation One single-operator at the machine Production of calibrated fractions. Pure and clean fraction stones Intensive mixing Dust-free operation Rental of recycling machines: In our rental fleet we have a wide range of mobile screening machines, mobile Jaw Crushers, VSI crushers, Impactcrushers, Cone Crushers and various windzifters. All machines are available to rent in Europe for one day, one week or one month.

What is the best method of driving a mobile crusher

A topic of discussion which is guaranteed to provoke any disagreement among design engineers and confusion among crushing plant users alike, but why and what separates the mechanical and hydraulic methods? Here is some insight to this of this frequently asked question.

Usualy the mobile crusher would be v-belt driven directly from the diesel prime mover, decoupled by a mechanical clutch. Due to the immense inertia of the flywheels it would be necessary for the operator to fiddle the clutch lever in order to coax the machine to start without stalling the engine.

This worked well, and in many cases is still a good solution if a few starts a day and low throughput is all you need, however, the market is now saturated with other solutions all claiming to be the best way and it can be confusing for plant users to know what will work best for them.

Omitting torque converters and hybrid diesel-electric drive solutions, which have niche applications but are not in widespread use due to their cost, the industry gravitates around dry plate clutch and hydraulic drives.

For example the dry plate clutch! Bolt it straight onto the engine and hang a pulley on the output shaft to drive v-belts. In terms of absolute efficiency, this certainly has the lowest power loss of all methods if your only consideration is how much fuel you use.

The trade-off is pure efficiency vs. functionality.

To offer a soft-start clutch engagement, computer controlled pilot systems are now the norm for modulating or “fiddling” the engagement (as the operator used to do by hand). As every start raises the clutch plate temperature, its thermal capacity limits the permissible number of starts per hour.

Depending on the arrangement of clutch main shaft bearings, limited side-load capacity can leave the clutch and engine sensitive to over-tensioning of the drive belts and as the drive belts have to be tensioned by moving the entire engine pack correct tensioning can be difficult. Also, the direct vee-belt drive limits the available positions for the engine installation.Torsional vibration from the engine can cause “micro-slips” which raise the running temperature and can lead to premature failure.

As mobile crusher with varying feed size and quality can be prone to blockage, the crushing chamber of a direct drive machine must be cleared manually if a blockage was to occur. If an attempt to start a blocked crusher is made by clutch engagement, serious damage may occur. While some machines are able to open the setting to discharge some of the blocking material, it is still unlikely that a re-start is possible without manual intervention.

The dry plate clutch occupies the primary power take-off on the prime mover. A track-mobile crushing plant will require an additional high-torque power take-off to drive track pumps. This frequently leads to some ingenious designs to accommodate the additional requirement for PTO by way of external drive splitter boxes, crankshaft nose PTO’s and even forward belt drive and cardan joints. Original equipment accessory drives, which are fitted behind the engine, bellhousing raise the pumps high, making it difficult to properly flood feed the pump inlet port and leading to cavitation in colder weather.

While the OEM cost of a hydraulic transmission systems can exceed that of a dry plate clutch, the main system pump will supply hydraulic power to both the crusher and tracks for mobility. The main pump occupies the primary power take-off of the prime mover and no secondary high torque power take-off is required, resulting in a very compact design.

As the crusher drive is indirect, the engine and pump assembly location is not constrained by the drive train. Consequently, the engine may be mounted in the best position and orientation for effective operation and maintenance. It should also be remembered that the mobile crusher drive is only a part of the whole system. A wasteful auxiliary drive system can easily lose any efficiency advantage gained by the drive method. Hydraulic drives have been used for crusher drive for some time by several major manufacturers with a good history of success. The major benefits of a hydraulic system relate to greater flexibility in both control and operation.

hydrustatic transmission mobile crusher

What is the difference between hydraulic and hydrostatic drive? Essentially a conventional open loop hydraulic system draws oil from a oilreservoir, through a high pressure pump, and then drives the  hydraulic motor. The return flow from the motor passes directly back to the oiltank. This system allows the motor to be reversed using a directional control valve and is protected from overload by a pressure relief valve.

In the hydrostatic system, high pressure oil from the pump passes to the motor then returns to the inlet of the pump in a continuous closed loop. This means that if the load tries to run faster than the pump, the engine is used as a brake to maintain control. By these means the crusher can not only be driven by the system but can also be slowed and stopped down.

Having stopped the mobile machine in an emergency, the jaw is now left full of rock! A clutch drive machine would now have to be manually cleared; however, the hydraulic machine can reverse jaw rotation and start up, the jaws still full, without danger of damage. Blockageclearing is considered one of the most dangerous procedures when operating a jawcrusher. With hydraulic blockage clearance it becomes a routine which can be performed remotely and with reduced danger. The backwards crushing action can also be used for crushing delicate materials such as Asphalt which are susceptible to packing, as well as blockage clearance.

Exact control also manifests itself in tracking. A heavy plant can now steer by varying the speed of each track independently as well as slewing on the spot. It is not necessary to constantly shock the plant by slewing just to take a curve in the way; it can be steered by running one track faster than the otherone.

Given the degree of electronic control, to assist the operator a direct data link may be fitted to enable remote access from the manufacturer. Not only can performance data be recovered to assist in breakdown situations but, if necessary, modifications may be made to the programming to adapt the performance of the machine to the operator’s requirements.

A further advantage of the hydrostatic system is that the pumps can be controlled infinitely directly by the machines on-board computer, making it incredibly controllable.

Typically, when a mobile crushing plant is shut down, the flywheels continue to rotate for several minutes, slowly dissipating their stored energy. Having gently accelerated the flywheels to working speed, the hydrostatic drive system can now bring them smoothly to a stop in just a few seconds. An additional benefit to this degree of control is that “emergency stop” can mean just that, by bringing the entire plant safely to a stop in just a few seconds!

Todays transmission pumps are able to be controlled exactly by an on-board computerized system. In starting the crushing plant, the flywheels may be accelerated up to speed over several seconds without imposing excessive load on the engine and also doing it almost silently. The control system monitors the engine working parameters in real time and if the power draw becomes excessive the pump delivery can be reduced to enable maximum productivity without interruption.

But, what is the down side of all this? Hydraulic driven machines are often accused of inefficiency but a good designed system can offer more advantages which offset the less overall efficiency. Ok, a simple gear pump and motor combination when hot and heavily loaded can get down to 50-60% efficiency, agreed, however, a modern axial piston transmission pump/motor is much different. Individual component efficiency can be well over 90% providing the system is well designed and thermal management is effective as the system is most efficient over a small range of oil temperature.

Older open-loop transmissions were filled with over 1000 litres of oilcontent , frequently dumped and refilled. This is no longer the case, state of the art, closed loop hydrostatic drives require a much lower reservoir capacity and rather than adopt a filter and oil replacement system based on the hours it runs or months of service, condition based maintenance based on oil sampling can significantly reduce the maintenance costs.

mobile crusher control

 Conclusion

Hydraulic transmissions offer greatly improved functionality and durability with very low routine mechanical maintenancecosts and will continue to appeal, especially the new generation hydrostatic machinery which enjoy enhanced control and safety features unavailable on mechanically driven machines.

While dry plate clutch technology continues to develop with intelligent engagement systems and improved bearing capacity, the attractions of an efficient transmission system are obvious providing the complete plant has been optimized for maximum efficiency.

Contact us for more information: info@naessens-hydraulics.be

mobile washing plant for C&D

mobile washingplant

The mobile washingplant for construction and demolition material poduces 100 tonnes an hour washed sand and aggregates to reuse in the concrete production plant.

feedmaterial

The material being processed through the M2500 mobile washing plant is C&D waste material with ca 30% stone aggregats. The process includes feeding, screening and sand washing on a compact chassis. The sand washing element is achieved through the integrated Evowash sand plant and an the material is being dewatered and  stockpiled by a integrated conveyor.

washed sand

The aggregate material is delivered from the M2500 to an AggMax attrition system, which includes a  logwasher and double deck rinsing screen. In this logwasher is the aggreagats are not only scrubbed but also separated from any waste material as plastiek,textiles and any other organic waste material. This will be dewatered before dropping it in a wstebin. Once the aggregate materials have been scrubbed they are then given a final rinse on the double deck screen and classified into the required aggregate sizes. This stage also allows for any 5mm material to be recovered from the recycled aggregates and returned to the Evowash to ensure maximum sand production.

clean washed and scrubbed aggregats

As is the case with many construction and demolition waste processors the issue of limited space available on site to accommodate the new washing plant was critical for each contractor. This has been addressed on the new plant with the inclusion of the Aquacycle thickener which allows for recycling of 90% of the water reused in the washing process.

Waste water from the plant containing the minus 63 micron material is delivered to the Aquacycle thickener where the dosing of polyelectrolyte forces the sludge to settle and the recycled water to be returned to the washing plant. The sludge is subsequently pumped from the thickener and the specification of the Aquacycle system greatly reduces the volume of waste material to be handled while also reducing the use of fresh water.

Contact us for any information

VSI Crusher

VSI crushers (vertical shaft impactors) are based on the impact principle of destruction of pieces, colliding at a great speed with a still barrier. This type of destruction which crushes more friable parts of material is more rational as compared with compression destruction. Energy consumption for fine crushing of the raw material and clinker at VSI crushers is considerably lower than at traditional crushers because the greatest part of the energy expended is directed towards the material and not towards moving of a working tool.

Vertical Shaft Crusher

Compact jaw crusher

The new model GI CRUSHER VULCANO is the most modern COMPACT Jaw Crusher, equipped whit last generation management systems, it is easy to use and environment friendly.

compact jaw crusher

The HCS system check all the machine components, this means maximum performance in terms of:

• Low fuel consumption

• Low crushing chambers wear

• High production
it means: Low running cost. The structural integration between the chassis and jaw crusher guarante the maximum strength to the crushing stress.

Characteristics:
High production with the new Gasparin’ s jaw crusher design

Very aggressive swing jaw action, for a maximum crushing effect.

High jaw chamber’s efficiency HCS (Hydraulic Crushing System), it means full hydraulic management machine. The system check and adjust continuously the different machine’s components.

Output until 190 t/h Low fuel consumption, typically 12-16 l/h

Vibrating Grizzly feeder with replaceable double step bars grid.

Main belt conveyor’s discharge height: 2,70m

Easy access to the engine.

Big access under the jaw crusher, for maintenance.

Feel free to contact us for any information

mobile jaw crusher on tracks

Headquartered in Treviso, Italy, Gasparin Impiante offers a seven-model range of tracked mobile crushers, ranging in capacities from the 30 120 t/h Vulcano, which weighs in at 24.5 t, to the 45-360 t/y, 54 t Everest. Each of GI’s machines features the company’s ‘non-stop’ hydraulic safety system, which allows oversize or even tramp material to be handled effectivly.

mobile jaw crusher

Two machines on display at this year’s Bauma show: the compact Vulcano  portable jaw crusher and the company’s mid-range Olimpo mobile jaw crusher. With an impactor opening of 1,100 x 750 mm, the GI1111 can handle between 30 and 250 t/y, depending on the feed material, and is powered by a 224 kW engine. Since the machine weighs just 37t, moving it between sites is easy using a low-loader, the company notes.

The 42 t Olimpo is powered by a 205 kW engine and can produce up to 360 t/h of crushed rock. It is fitted with a pre-screening system and an independent feeder into the crusher, which has a 1,150 x 730 mm opening and a discharge setting of 35-160 mm.

In 2004, the Belgian quarry company,  Gravel Quarry, bought an Olimpo for use at its operation , some 50 km southeast of Brussels. One of the key selling points for the machine was its manoeuvrability, with the company planning to open a new area in the quarry soon. However, this part of the resource is up a steep hill, and is being designed to minimise its visual impact, This company needed a self-contained crusher that could move itself to the new location.

The Olimpo is being used as a primary crusher on quarried whinstone, producing a range of crusher-run materials that are currently loaded directly into trucks for hauling off-site. The company has found a major benefit in the speed with which the crusher can be adjusted, with the facility to change the settings in seconds hydraulically.

In addition, the crusher then maintains these settings, without any movement from the set-point.

Depending on what type of product is required, jaw crusher is producing between 500 and 1,500 t/d of material. Unlike the company’s old permanent crusher, which could take several hours to adjust, the new machine is very responsive to changing product requirements, meaning that the quarry no longer has to maintain large stocks of various products to keep its output going while the crusher is being reset.

For more information

Construction and Demolition waste recycling

Demolition Waste is mostly crushed heavy fractions, like tiles, concrete, asphalt,soil and aggregates. The rest mostly consists of wood, RFD ,rebar and metals. Construction waste that is much lighter mostly consists of waste materials, cardbord packaging, and rubble from a construction or renovation. It contains wood, paper, plastic, sand, metals, carpeting, glass, concrete, and aggregates. The compositions of these waste streams differs as the origin differs. Up to 97% of the total mass can be re-used in or as a product.

C&D waste recycling

For the C&D industry several options are available. One of the most common reusable products in C&D waste flows are the aggregates. Clean aggregates can be reused as a foundation material in road constructions, as a gravel substitute in concrete or as a trenchfill material for road maintenance.

Altough there are several kinds of separating and cleaning methods available for treathing these aggregates, the windshifters are the most effective and popular way to handle this difficult job sucessfully.

With the use of a trommelscreen we can separate the fines from the aggregates before feeding them into a windshifter. With high pressure air blowers installed under the flow aggregates  and the combination of the fast speed separation roller, the machine is able to reach high capacity and a high separation ratio to produce top quality cleaned aggregates

An aditional sorting line it is possible to get much more out of your waste flow. sorting lines can separate your waste flow and produce materials like wood, metals, plastics, RDF, soil and aggregates. To see a machine in action click here.

Horizontal Silo

The horizontal silo is used mainly to temporary sites and mobile equipment such as mixing plants, soil improvement and rehabilitation facilities to store and dose lime, cement or any other additive products.

horizontal silo

The Company Rematech, a sister company of Naessens Hydraulics, is specialized in developing and producing machines and solutions for the recycling industry.
As part of our soil remediation plants Remasilo 34 is the answer to the demand for a mobile storage solution for additional materials such as cement or lime which must be dosed as an additive in the mixing plant.

The main advantages of the horizontal Remasilo34 are:
1. Easy to move
2. Very fast startup time (operational in less than 30 minutes after arrival on site)
3. No anchoring in heavy foundation required
4. No assembly required crane
5. Perfect dose
6. Accepts a full truckload.

The silo is equipped with an extraction system consisting of one horizontal and one inclined screw-conveyor, which allows a perfect uniformity of dosage. Six vibrating motors and an efficient blower system ensure a complete empty silo in various kinds of materials and all conditions. The level indicator is equipped with a switchable alarm siren.

horizontal silo

The silo is always placed on a hard surface underground, it can be moved simply by lifting it with four mechanical jacks and carry by truck or any trailer. Also thanks to these mechanical jacks, the silo is ready for operation within a half hour after arriving on site.This not only offers a great advantage in time savings but also in significantly lower costs for organizing or renting a crane assembly.
The 34,000 liters capacity allows for a full truckload to be blown so that the purchase price of the filler material as low as possible.
Remasilo is the answer to the ever higher demands on the contractors more flexibility, efficiency and time pressure on the present sites.
The company

The Company Naessens Hydraulics is responsible for the sale and rental of the silos and is happy to serve.
For all required informatie. info @ Naessens-hydraulics.be

high quality product with VSI crusher

The Vertical Shaft Crusher or short VSI.

This mobile secondary crusher on tracks has his roots in the mining industy of South Africa. The machine performance is excellent and is continious where other type of crushers has reached there limitations.
The Vertical Shaft Crusher is the ideal machine for all applications in highly abrassive materials where a lot of wear resistance is needed.

The main component of the VSI crusher is the modular rotor.
This rotor is mounted on a vertical shaft and runs between 1000 and 1600 rpm and will speed up the feedmaterial by its centrifugal force to start the crushing proces. The to be crushed material is first centralised before it is fed into the modular rotor. The high rpm of the rotor will speedup the material higher than 90 m/s and will continually discharge its stones in a with stone filled around chamber. This is also called the “Rock on Rock crushing Process”. Thanks to this unique rolling stones crushing effect a high quality product with round shaped aggregats are produced.
These cubical formed stones are not only stronger but do have less surface than flat stones . This automatically results in less cement needed for the same strenght in applications such as concrete production.

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