Improved operational efficiency and reliability for Longcliffe Quarries Ltd

Longcliffe Quarries LTD supplies a wide range of specialty high-quality calcium carbonate products in both granular and powder format for a number of manufacturing sectors; thus it requires a flexible approach to production at all times.

Metso assisted Longcliffe’s management team to model various operating scenarios to satisfy the long-term objectives. After reference visits to view the new Nordberg© C150™ jaw crusher in operation at Backlane quarry and the Lokotrack® LT160™ at Swinden Quarry, Longcliffe’s project team had the confidence they needed. The order was placed with Metso to supply and install the Nordberg C160.

Commissioning and start up completed ahead of schedule

Metso appointed Roltech Engineering Ltd as their installation partner to make the necessary changes to the existing support structure and chute work required to complete a successful installation of the new crusher into the existing primary station. Roltech took on both principal designer and principal contractor roles under the CDM regulations and had a full-time site manager supervising the overall installation, as well as Metso engineers building up the crusher from the new support level.

The new crusher had to be installed into the existing space, respecting the feed and conveyor system; to gain access, the roof and existing lifting beam had to be removed. The scope of installation also included a new magna start for the slip ring motor and electrical control panel. During the planning stage, which included all the stakeholders, it was determined that the best solution was to build up the crusher “in situ”. This overcame the challenge of crane access for the size of lifts involved with sufficient reach available for the best position near the primary building.

With the effort made during the planning stage and with everybody’s co-operation, the installation proved successful – and commissioning and start up were completed three days before the deadline.

Comprehensive results achieved

According to Andy Meadows, Group Engineering Manager from Longcliffe Quarries, the results are comprehensive:

• Improved throughput

• Impressive ability to crush marginal stones the size of the crusher mouth

• Reduction in downtime and in use of the hydraulic breaker

• Reduced downtime adjusting the crusher setting by using the hydraulic setting equipment

• Improved maintenance with the auto lubrication system, the compact design of the machine and easy access to parts

“The Nordberg C160 is already impacting our business with improved production at the primary station through better utilization of the load & haul fleet asset and associated manpower. We have also noticed that even with the increased production there hasn’t been an increase in power consumption with the new Nordberg C160 compared to the old primary crusher,” he said.

Mr. Meadows is pleased to see the crusher delivering its predictions and the capex investment providing the business improvements that were outlined in the justification.

“Longcliffe Quarries Ltd takes a long-term view on the purchase of equipment, and that is why we have also agreed to a crusher extended warranty and care package with Metso”, he concluded.

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