New Semi-Mobile HAZEMAG Crushing Plant at LEHIGH’s New Windsor Quarry
In September 2015, Lehigh Cement Company (HeidelbergCement Group) ordered a big semi-mobile limestone crushing plant for their cement plant in Union Bridge / MD at HAZEMAG. The plant is going to process up to 2,500t/h limestone at a feed size of up to 2,000mm edge length. The cement plant in Union Bridge requires 3.5 – 3.8 million tons of limestone per year, which will be processed in the HAZEMAG crushing plant in Lehigh´s New Windsor quarry.
The crushed material will be transported via a 4.5 miles long overland conveyor from the new quarry to the cement plant; a journey where the crushed limestone will be conveyed across the country-side; farms, towns, highways, etc. Some 2.1 – 3.5 million tons of cement are produced from the limestone. The new developed quarry hat New Windsor has a limestone reserve of 200 million tons, which will last for some 65 years. Due to the close living area, noise level has to be kept in tight limits. This new primary crushing system will ensure that the Lehigh Cement Company continues to deliver a high-quality product, economically and without interruption.
The raw material is delivered to the primary station by large, 100 ton capacity quarry trucks and discharged by means of a HAZEMAG apron feeder HAF 25160 with integrated scraper conveyor from a 400 t feed hopper.
A critical component in the design of this plant can be found in the HAZEMAG roller screen HRS 2638; which effectively removes the minus 100 mm fines from the raw feed material. These fines can be problematic as they are made up of sticky clay, high moisture content and at times a rather high percentage of the overall feed stream.
The heart of the plant is found in the primary impact crusher; type HPI 2230. The crusher is fitted with the very latest design and operational technology; such as.
- Extra Heavy-Duty GSK-Rotor System
- HAZtronic® Automated Control System
- Retractable grinding path (HAZEMAG patent)
The gap settings, for example, can be aligned to the specific characteristics of the raw material conditions, thus ensuring the production of a consistent, high-quality product. We call it intelligent crushing! The HAZEMAG primary impact crusher HPI 2230 crushes the material down to D99 less than 125mm.
The required mobility is achieved by use of special heavy transport systems (SPMT), which can relocate the crushing plant (pontoon design) in two units within the quarry.
In total, HAZEMAG supplied more than 1,000 tons of steel and equipment. The erection time took from August 2016 to April 2017. Performance test in March 2018.
- Location: New Windsor, MD
- Facility: New Windsor Quarry
- Feed Material: Limestone with clay mixtures
- Feed Size: ROM, up to 2,000mm edge length
- Capacity of plant: 2,500t/h
- Capacity of the crusher: Nominal 1,800t/h
- Apron Feeder Type: HAF 25160
- Roller Screen Type: HRS 2638
- Primary Impact Crusher Type: HPI 2230/GP Design
- Installed Power: 2,300kW