Lehigh Cement – Union Bridge Project

Mission completed – the new semi-mobile HAZEMAG crushing plant at the New Windsor Quarry of LEHIGH´s Cement Plant in Union Bridge, Maryland/USA has successfully passed the performance test with bravura.

In September 2015, Lehigh Cement Company (HeidelbergCement Group) ordered a big semi-mobile limestone crushing plant for their cement plant in Union Bridge in Maryland/USA at HAZEMAG. The plant is going to process up to 2500 t/h limestone at a feed size of up to 2000 mm edge length. The cement plant in Union Bridge requires 3.5 to 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 7 km (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.

The plant produces some 2.1 to 3.5 million tons of cement from the limestone annually. The newly developed New Windsor quarry has a limestone reserve in excess of 200 million tons, which will last for more than 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 25 160 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. The HAZEMAG primary impact crusher HPI 2230 crushes the material down to D99 less than 125 mm. 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 1000 tons of steel and equipment. The erection time took from August 2016 to April 2017. The performance test took place in March 2018.



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