Crushing and screening contractor, Casmar Mining, has deployed a pair of its large Sandvik mobiles to help Chilwavhusiku Colliery supplement its coal volumes while building a new plant on site, writes Munesu Shoko.
A train of Sandvik mobiles is up to the task of crushing high-grade coal destined for export markets at Chilwavhusiku Colliery, a fully black-owned mine based in Bronkhorstspruit. To supplement volumes during the commissioning of a new plant, the colliery sought the services of Casmar Mining, a well-respected name in the contract crushing and screening space. Casmar Mining has been on site since October 2018.
To execute the task at hand, Casmar Mining has deployed its Sandvik QJ341 jaw crusher and QE441 scalping screen. The Sandvik QJ341 is the largest in the Sandvik premium range of tracked jaw crushers, while the QE441 is also the largest heavy duty scalper in Sandvik’s premium range of equipment.
Run of mine (ROM) material is fed into the two-deck QE441 scalping screen. “We are pre-scalping before crushing because the ROM has a lot of fines. Only oversize material reports to the jaw crusher,” explains Deon Engelbrecht, Casmar Mining’s site manager. The first deck of the QE441 screens out -50 mm material, and the bottom deck screens out -25 mm material. The jaw crusher is set on a 50 mm closed side setting, and produces a well accepted percentage of -50 mm product.
High throughput
Engelbrecht says the two machines were specifically deployed on the project because of their high throughput capability, which allows the contractor to meet the high production requirements of the project. “The machines are running very well. We are producing between 1 500 t and 1 700 t per shift (6am to 6pm),” says Engelbrecht.
The QJ341 featuring a 1 200 x 750 / 47 x 29” jaw, is capable of delivering high outputs with sound reduction ratios. It comes fitted with many user-friendly features, such as hydraulic adjustment and a reversible jaw, as well as a PLC control system and colour screen for ease of operation. It is also fitted with a hydraulic raise and lower conveyor, making it ideal for coal, as well as recycling and quarrying applications.
Some of the key benefits of the machine include the Danfoss hydraulic control system for greater efficiency with all controls located at ground level for ease of access and maintenance. The full PLC control system and Danfoss colour screen allow visual data output of all plant operating parameters.
The QJ341’s load control system for feeder drive ensures continuous, uninterrupted crushing. The steel pipe work used extensively gives superior heat dissipation and provides a maintenance-free sealing solution. The speed wheel fitted to main conveyor stops the feeder, negating the need to dig out a heavily loaded conveyor.
The QE441 is the largest heavy duty scalper in Sandvik’s premium range of equipment. Designed for high-volume production, it has a large crusher-style chassis and is capable of handling tough material in harsh environments. “Whether it’s working before or after a primary crusher or as a stand-alone unit, the QE441 is designed to deliver high production with clean separation,” says Richard Young, Sales Engineer Crushing & Screening for Sandvik Mining and Rock Technology Southern Africa.
The QE441 offers user-friendly features on the i-Series screens, including an electrical control system which improves both operational effectiveness and machine safety. It also comes equipped with an apron feeder, reinforced hopper doors and impact bar lined overs conveyor – all as standard.
The QE441 has a total scalping area of 5,5 x 1,75 m / 5 x 1,75 m, allowing for enormous rates of production. It is also capable of being fed by large crushers or loaders, yet precise enough to produce accurate product sizes. “The machine also comes with a heavy duty crusher-type chassis designed to accommodate interchangeable side conveyors and is compatible for two-way or three-way split configurations. It also comes with a feeder load sensing facility to prevent blockages and unnecessary downtime,” says Young.
Close cooperation
Casmar Mining is one of the largest operators of Sandvik mobiles in South Africa. The mining contractor has been running Sandvik mobiles for the past 10 years. Its very first machine, a QA430 double-deck screen, was purchased in 2009. By the end of April this year, Casmar Mining’s Sandvik fleet reached 18 units.
“Our QJ341 jaw crusher range currently works on a wide range of applications – from road construction in Madikwe to coal mining in Middelburg, Witbank, Stofberg and Postmasburg in Northern Cape. Our QE441 range is currently working all over South Africa and in Botswana on different applications. We currently have on order 2 x QI441HS impactors and 1 x UJ440i jaw crusher to be deployed in coal production,” says Johann Raab, owner of Casmar Mining.
Why Sandvik? “There is an array of suppliers out there that will probably be able to supply us with the same type of equipment, but as an end user, we are after the best quality and client service. Casmar stays loyal to the mobile division because of the quality of the product and support,” says Raab.
Glenn Schoeman, Business Line Manager Crushing & Screening for Sandvik Mining and Rock Technology Southern Africa, says Sandvik has over the years worked closely with Casmar Mining to understand the mining contractor’s business model. Through an open communication channel, there is a better understanding of the challenges faced by both companies, the future requirements of Casmar Mining and how Sandvik can accommodate them.
“A business partnership should have aligned fundamentals. The strength of Sandvik’s core values keep our business relationship with Casmar Mining on a positive trajectory. Casmar Mining has full confidence in Sandvik to conduct business with their best interests at heart,” says Schoeman.
“Another advantage for Casmar Mining is that we have a pool of expertise to assist them, all the way from process application and equipment selection to product support and new technology developments to meet the needs of an ever changing crushing and screening environment,” adds Schoeman.
Tech matters
The new units recently supplied to Casmar Mining come with Sandvik’s My Fleet telematics system, while the company’s existing mobile crushing and screening units are scheduled for telematics retrofitting. “The Sandvik technology is an advantage to Casmar, ensuring high availability of units operating in the field through close monitoring by both Casmar and Sandvik,” says Schoeman.
Sandvik has long been regarded as a market leader in process automation and through the introduction of My Fleet, the OEM has added a powerful monitoring, control and data collection tool for its range of mobile crushing and screening equipment.
“With access provided via a cloud solution, the new functionality is designed to eliminate guesswork and provide the hard data needed for informed business decisions. My Fleet has been purpose developed to help Sandvik customers know exactly how equipment is being utilised,” says Young.
Collection and accurate monitoring of a wide array of parameters facilitates accurate production forecasting, ensuring that the most efficient use is obtained from equipment, thereby maximising return on investment.
Sandvik offers a two tier package, providing equipment owners with a basic (My Fleet Freemium) and more comprehensive offering (My Fleet Premium) to choose from. With both packages, customers have unlimited online access to the Sandvik portal 24/7 365 days a year.
My Fleet Freemium offers a basic package including the following parameters: fleet overview, machine utilisation and GSM location. With My Fleet Premium, customers have access to a wide array of parameters for a more in-depth analysis and monitoring of the equipment. These include all Freemium parameters, as well as alarms and fault finding; service intervals; geofencing; machine utilisation, including fuel consumption; detailed engine data including temperatures; pressure, RPM, DEF level and engine hours; and detailed plant data for key components – crusher, feeder, conveyors and clutch (where applicable).
Sandvik My Fleet Premium package is available as a retrofit kit for existing models of Sandvik equipment. Retrofit kits are available for i-Series models onwards.
Maintenance regime
Casmar Mining has a very strong maintenance philosophy, which is supported by Sandvik. “Casmar has a number of crushing and screening contracts across South Africa in varying applications, hence the importance of working closely with them to meet the requirements for each site,” says Schoeman.
“We cannot stress the importance of the Sandvik support staff, all the way from management, specialists to service personnel, in helping customers keep their machines running. Sandvik’s customer focus is a key element in keeping Casmar’s Sandvik mobile crushing and screening units running efficiently,” adds Schoeman.
Due to a strong maintenance regime, Raab doesn’t believe in replacement cycles of his equipment. “I don’t believe that there is a replacement cycle if you look after your fleet. With proper care and attention, machines can last for a long time. Casmar has its own workshop where we refurbish machines, and this contributes to an extended lifespan. However, I think, in general, replacement cycles should be anything between 8 and 10 years,” concludes Raab.
