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Jan 22, 2024

Mobile coal crushing solution with less fines, more value

I n the highly competitive world of mobile coal crushing, Pilot Crushtec’s

In the highly competitive world of mobile coal crushing, Pilot Crushtec's DoppiaTrac DR400 is a triumph of local design and engineering, with a decade of success in the field.

"We designed the DR400 from the ground up to give us the flexibility to produce a truly great crushing solution," says Jorge Abelho, director technical support at Pilot Crushtec. "It has proved itself through its combination of throughput, reliability and economy."

Indeed, it is Africa's only locally manufactured, fully mobile double-roll crusher – capable of averaging production rates from 300 to 350 tonnes per hour and reaching 400 tonnes per hour. Its ability to reduce the generation of fines is thanks to the double-roll crusher. While a horizontal shaft impact crusher creates more coal fines due to impact energy, the double-roll crusher forces material through a constant gap.

"The crusher uses just enough energy to break the material down to the size of the gap," explains Pilot Crushtec sales engineer Ben Armitage. "The DR400 generates less than 5% of 0 to 6 mm fines, compared to around 12% created by impact crushers – depending on coal hardness and crushing ratios."

The DR400 boasts a large hopper that is readily fed by loaders or excavators. To increase the average production rate, the unit can be interlocked as part of a crushing train. Connected with a Metso LT106 jaw crusher, the two units can communicate to synchronise the feed-rate. This optimises throughput by automatically adjusting the rate of material moving between the machines. The on-board hydraulic rock breaker on the Metso LT106 also allows oversize material to be quickly broken, avoiding blockages and preventing downtime.

Crushing efficiency is enhanced by feeding material into the crushing chamber at exactly the same speed that the drums are spinning. This minimises attrition and friction, even at high throughput rates.

"The safety features on the DR400 ensure that it is compliant with demanding safety protocols applied by mining companies," says Armitage. "These include full guarding around all moving parts, access points, nip points and crushing points – as well as pull cords and emergency stops to quickly isolate the unit when necessary."

He explains that the efficient Volvo engine delivers the lowest kW per tonne of any mobile double-roll crusher working in the coal sector. Depending on coal characteristics, the engine's 160 kW output can convert to a ratio of just 0.4 kW per tonne.

"The fuel consumption is also a significant factor for operators, and this crusher can run on as little as 17 litres per hour," he says. "This is achieved with a hydraulic load sensing system and an optimised crusher chamber design, which reduce the power needed to crush the coal."

The quality and simplicity of the DR400 is demonstrated by the fact that over 25 of these machines are currently in operation around South Africa – one of which exceeds 22,000 hours of operation. Pilot Crushtec supports the DR400 through its legendary service levels, massive stock holding and unrivalled after-market offerings.

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