Thanks to its flexibility and expertise as a one-stop service provider, especially in drilling, blasting and processing, Recycling GmbH Lahnau landed a major order near Wuppertal at the end of 2012. The challenge was to produce a high-quality mineral blend from a limestone deposit containing substantial impurities.
This objective could only be met with an additional pre-screening solution. The pre-screening facility in the existing crushing technology would not have been sufficient to remove the clay and mud from the limestone to be crushed. Because of the size of the feed particles and the up to 60 % clay content, the question was raised whether a mobile screen capable of sustainably meeting such a challenge was even available on the market. This screen was to separate a material < 60 mm with a high proportion of cohesive constituents, so that from the clean coarse product a high-quality mineral blend could be produced in the next step, that is crushing. To meet this challenge, Recycling GmbH Lahnau opted to buy the just under 50 t heavy-duty mobile screen WARRIOR 2400 from C. Christophel GmbH.
The POWERSCREEN screen box of the WARRIOR 2400, engineered with the high-quality “hock bolt” method typical for the POWERSCREEN, ensures the required screening efficiency. Three shafts with adjustable stroke and speed effect the necessary acceleration. The screen box is aligned depending on the screen feed. The 1830 mm x 6100 mm screen box with an up to 16 mm stroke separates even the most difficult materials of varying consistency at a rate up to 800 t/h. After C. Christophel GmbH had previously successfully concluded a test with “heavy-duty finger screens” in the upper deck over several months, a special upper deck was delivered for the WARRIOR 2400, which can handle the required feed size and remove a high content of impurities.
Other requirements were to automate the stockpiling and repiling of the finished mineral blend, homogenize the quality, avoid impurities and consequently reduce costs. For these tasks, Christophel supplied the chain-mounted TC 421R stockpiling belt from Telestack with its fully automatic stockpiling program. The 21-m-long conveyor with 1000-mm-wide belt can stockpile the crushed material with a loading rate up to 400 t/h to just under 10 m without any problems. Thanks to the wheel drive, which can be operated with remote control or works automatically, stockpiles of around 9000 m³ are possible. The energy consumption and environment protection were crucial factors, the Telestack belt was ordered and delivered with dual-power drive. The primary crusher has ample power reserves so the TC 421R can be co-driven with electricity without any additional combustion engine.
Recycling GmbH Lahnau is now operating with two more Telestack belts and two smaller sisters of the WARRIOR 2400, namely two WARRIOR 2100s. The operating weight of these machines is less than 40 t. Otherwise, the WARRIOR 2100 screens are also equipped with three-shaft technology and all other features of the WARRIOR 2400 models. With these somewhat smaller screens, Recycling GmbH Lahnau can supply its own sites and respond fast and flexibly to customer requests. These machines are now used in prescreening chippings and aggregate, gravel extraction as well as in soil remediation and construction waste processing.