The VGH1000 is well-suited for standalone operation in scalping and screening of coal, aggregate, sand, construction and demolition (C&D) waste, mine ore, blasted rock and river gravel.

Vibrating Grizzly Hopper

The VGH1000 Vibrating Grizzly Hopper has maximum feed size capacities up to 300mm designed to suit Pilot Crushtec’s complete range of crushing, screening and washing equipment. It is mounted on a heavy duty skid frame supplied complete and ready to run ensuring rapid installation.

Heavy grizzly bars scalp fines from the feed and heavy duty coil springs absorb tremendous impact loads and isolate vibration from the support structure for high performance feeding.

The VGH1000 vibrating grizzly hopper features a 30kW electric drive through a variable speed reduction gearbox, 1000mm wide variable speed belt feeder and rubber lagged drive drum. The VGH1000 Vibrating Grizzly Hopper is tried and tested and built to withstand the toughest jobs in all types of applications.

Class 500/4ply 5 mm top and 1.6 mm bottom cover belting
30kW electric drive
Variable speed vibrating grizzly feeder
Rubber lagged drive drum
Easy access maintenance and inspection doors
Easy access grease points
Heavy duty, welded support structure
Low maintenance
Short set-up time

The CDE air classification technology has been proven over 70 years and 3000 worldwide installations to be the most efficient and effective air classification technology available to the world market.

Sirocco Air Classifiers

Specifically for the processing of -6mm material this materials-handling system allows for the accurate removal of fines which is key for the production of high quality sand products. The CDE Sirocco air classifier allows for tighter particle size control than other air classification technologies which ensures the removal of unwanted fines that will compromise the final quality of your sand product.

Sirocco air classifiers allow for external adjustments to be made which ensures variations in feed material can be accommodated and optimum production is maintained. This is not possible with other air classification systems.

The Sirocco air classifier system can be used to process a wide range of materials including: Granite, Limestone, Gabbro, Trap Rock, Sand and Gravel. The CDE Sirocco air classifier range comes in the following models: Sirocco W50, Sirocco W100, Sirocco W200, Sirocco W300, Sirocco W500 and Sirocco W800.

Modular Isenmann non-bolted Polyurethane
Screen media
Stainless steel sump float
Rubber lined feedbox
Splash cover on screen
Polyutherane pump protection mats
Sigma hose
Galvanised walkways (1 side) and access stairs
Pre-wire, isolator and emergency stop
Control panel

By dewatering, water is allowed to drain from the bottom while screw carries away the material and classifying controls the retention of desirable product. With adjustable overflow weirs, the sand screws enable operators to control the depth of the head and velocity of overflow waste water.

Built with large, three stage gearboxes and outboard lower bearing assemblies, the units are designed for long operating life and maintenance ease. The TSW4432 is fabricated with a heavy duty tub, ensuring a long operating life. It features an extreme duty gearbox, designed for maximum torque and slow speed operations.

With oversize gears, these critical components of the sand screws provide an added safety factor for operators. The TSW4432 Fine Material Washer has throughput capacities of up to 318 tonnes per hour and a feed size of -10mm. The maximum screw speed is 17rpm.

The TSW4432 Fine Material Washer performs three important functions for the aggregate producer. Firstly, it removes excess water from the washed sand, so that the washed product can be transported by conveyor to the finished stockpile. Secondly, it classifies the sand particles that range between 100 mesh to 200 mesh in size. Lastly, it washes the deleterious material away from the sand.

Feed material enters the feed box and is distributed into the washer’s settling pool. Internal and external baffles control the feed velocity and limit water current speeds and turbulence, enabling the washers to retain fines. Lighter products, such as silt, excessively fine material and other deleterious materials do not settle and are carried away with the water over the long, adjustable side and end weirs.

The settled material is augured up the washers by the spiral flights. Additional cleaning takes place by the abrading action of the material fractions. Excess water is drained back to the pooling area as the material is conveyed up and out the upper end of the trough.

2 X 18.5kW electric motor
12.24” Driven sheave and bushing mounted on machine
Built with large, three stage gearboxes and outboard lower bearing assemblies
Fabricated with heavy duty tubs
Extreme duty gearbox with 100% to 16% reduction capability
Oversize bearings and gears
Heavy duty, replaceable shoes
Rising column of water
Internal and external baffles to control feed velocity and limit water current speeds and turbulence
Heavy walled auger shafts
Rising current system
Cast or urethane wear shoes
Adjustable weirs
Easy maintenance
Easy to transport

Compound crusher

Compound Crusher

Compound crusher is mainly adapted to medium-sized raw materials and clinkers, at the same time can also be used for fine-crush dolomite, coke precious stones, lead-zinc, serpentine, blast furnace slag, coal gangue, phosphate rock materials with medium hardness, especially suitable for hard limestone, dolomite, granite, basalt artificially build sand or highway pavement stone processing.

Compound crusher has big breaking ratio, discharging size is adjustable, don’t suffer from the wear of plate hammer and the plate, it is not easy to plug when crushered high moisture, large mud containing materials.

Using elastic and regulatory stucture, the material which can not brken ,they will be automatically discharged, it can’t make the damage to equipment; the bearing is horizontal and with long life, it can break high temperature materials (such as cement clinker); unique rotor structure, when break materials, the rotor body is virtually non-wear; the behind Cavitiy set-up screwrod or hydraulic open structure, do not need main equipment you can easily replace the easywearing parts.

Compound crusher working principle:

Materials fall into the high-speed rotation impeller from the above of machine, under the action of high-speed centrifugal force, have high-speed impact with another umbrella form materials which flow around the impeller, after they attack each other, then discharged from the bottom, it forms close-circuit and with many times circulation,it can achieve the required product size by screening equipment controlling.

Compound crusher Features:

1. Simple structure, low operation cost. Using the principle of stone strike stone, smaller wear.
2. Broken rate is high, energy conservation
3. With fine, coarse grinding function
4. Little affected by material moisture content, humidity can reach 8%.
5. Working noise is less than 75 db, less dust pollution.
6. Suitable for breaking medium hard, especially hard materials.
7. Products are cubic, packing density is big, a very small iron pollution
8. Little wearing of the impeller, easy maintenance.

I. Vertical Compound Crusher Usage and Application

The machine is fine crushing equipment that crushes materials in middle hardness, such as rocks and mines with pressure strength less than 210MPa and humidity less than 5%. E.g. limestone, dolomite, cement clinker, iron ore, molybdenum ore, aluminum, cobble, rock phosphorite, copper ore, burned magnesite, serpentine, calces, gypsum, lump coal, zeolite, sandstone and so on. It is widely used in the industry of mining, metallurgy, building materials, fireproof materials, cement, coal, glass, chemical industry, electricity power and so on.

II. Vertical Compound Crusher Working Principle

The motor drives the rotor that fixed on the main bearing to run quickly toward certain direction when the machine works. The materials are fallen into the throw-up disc and impacted by the high speed strips of the throw-up disc, and then strikes with the impact board under the effect of Centrifugal Force.

Because the impact board is bevel and the gravitation, the materials are threw to the taper crushing room and impacted by the high-rotating up hammerhead. After gaining sufficient energy, the materials are thrown to the impact board again and action repeats. The materials strike with each other in the crushing room and then are down to the column-shape rotor room.

Then crushed, pressed, and ground and action repeats. In this way, the materials go through up, middle, and down rotor crushing rooms and crushed, pressed, and ground by the hammers and the impact boards, and finally the materials are gradually crushed into needed sizes and come out.

III. Vertical Compound Crusher Features

The machine has special structure in the part of throw-up disc, which can improve the usage of abrasive material and reduce the cost. The wearing parts are made of anti-abrasion material (metal alloy in high hardness and toughness), so it can endure for long time. It has the advantage of high crushing ratio, large output, high efficiency, and low consumption.

It is of easy operation, good performance, low noise, little vibration and good airproofing, so it is a high efficient and high level fine crushing equipment.

Box Crusher

The compressive strength of not more than 200 Mpa of limestone, rock, gypsum, coal and other materials, broken, broken stones is a must have device. Automatic assembly line, the provincial people saving, energy efficient side is a combo box crusher crusher, you can set the traditional two broken as a broken, is an ideal limestone gravel processing equipment.

Heavy breakers, square box crusher main advantages:

Box Crusher

1. Square box crusher feed opening large, high crushing chamber to meet the material hardness, block degree, the product powder less.
2. Heavy material hanging crusher, crushing power consumption.
3. New heavy Hammer crusher, impact large.
4. Heavy-duty breaker hammer shaft installed adjustable, hammer and long life.
5. Grid size adjustable, granularity control, particle shape well.
6. Heavy-duty crusher chassis can be turned over to maintenance easier.
7. Square shank bolt, impact resistance, abrasion resistance.
8. Compact heavy-duty crusher, the machine rigidity.
9. Heavy-duty crusher spell structure, handling, easy installation.
10. Heavy hammer crusher, impact crusher square box, counter, hit (a stone at stone) broken-function, high efficiency, mechanical abrasion is small, comprehensive benefit is remarkable. Nissan tons or more, is currently the most advanced and most suitable stone equipment, by users.

Box crusher Application

Box crusher as a main secondary crusher, is used to crusher materials 450—1200mm millimeters long, into power 80mm particle size of the ore. It can deal with various materials lower the average hardiness, especially suitable for crushing of materials of mining, building, chemical industry and metallurgy.

Box Crusher Main Features & Benefits:

1. Large feed lump size, high reduction ratio and regularly output size
2. Its high rate of finished products can fully meet the requirement of usage; the grainy product could reach 85%.
3. High capacity and stable performance
4. Rough, medium and fine crushing function could in place within only one step makes the process flow simplified
5. Lower matched power, low energy consumption, simply maintenance and less wearing parts

Box Crusher Working Principle:

When materials get into the area where the board hammer plays apart, under the impact function of board hammer at a high speed, the crushed ones are thrown to the impact device above the rotor continuously. And then they are rebounded from the impact liner to the area where the board hammer plays apart, impacted again.

Materials from large ones to small ones get into the impact cavity for being crushed repeatedly. The process is going on until the materials are crushed to required size and discharged from down of the machine.

“It is very encouraging for us to see that a company like Zimplats is buying equipment which we are interpreting as a sign that not only the Zimbabwe economy seems to be picking up, but also that the platinum mining industry is showing signs of recovery,” says Wayne Warren, Pilot Crushtec’s Africa sales manager.

Zimplats, which is 87% owned by South African based Impala Group of Companies, bought the machines for its Metallurgical Plant at Selous Metallurgical Complex in the country’s platinum rich Hartley Geological Complex.

Warren explains that the machines, which include a Pilot Modular GFH560 grizzly feed hopper, a Pilot Modular/TRIO MJ1252 jaw Crusher, a Pilot Modular MFH25 feeder hopper and two Pilot Modular MC600 conveyors of different lengths, will be used to recycle reverts.

“The machines will be used to crush down solidified slag reverts and return the material to the furnace again,” he explains.

Up until now, the mine used a crusher to break down the solidified slag but this particular crusher was also used for various other applications.

The mine feeds the slag into the Pilot Modular GFH560 grizzly feed hopper with a front end loader.

Material then travels to the Pilot Modular MJ1252 jaw crusher via a 13 metre long Pilot Modular MC600 conveyor. The Jaw crusher then crushes the material down, and it then travels to the Pilot Modular MFH25 feeder hopper via a 16 metre long Pilot Modular MC600 conveyor.

The Pilot Modular GFH560 grizzly feed hopper prevents oversize material reaching the crusher.

The Pilot Modular/TRIO MJ1252 jaw crusher has a closed side setting of between 25mm and 90mm and weighs approximately 10 tons. It forms part of Pilot Crushtec’s highly successful modular plant system which includes crushing, screening, washing and stockpiling equipment.

According to Pilot Crushtec sales manager – Africa, Wayne Warren, the current situation in the Zambian construction industry is akin to what was happening in South Africa in the period preceding the 2010 FIFA World Cup.

“Zambia is growing its infrastructure at an ever increasing rate, expanding road and rail networks and constructing power stations, all of which is geared to exploiting its mineral wealth. The production of aggregate is critical, and Ndola Lime alone has firm orders for more than 50,000 tonnes of aggregate, which will keep its new plant busy for the next two months.”

Zambian Construction Industry

The plant comprises a Pilot Modular/TRIO MJ2436 jaw Crusher, a Pilot Modular/TRIO MC90 cone crusher, Pilot Modular DD4815 and DD3615 double deck screens, a Pilot Modular MC800 20 metre conveyor, three Pilot Modular MC800 16 metre conveyors, four Pilot Modular MC600 16 metre conveyors and a Pilot Modular/TRIO CRP36 permanent overband magnet.

The correct choice of equipment is a critical decision in any new undertaking, and Ndola Lime Projects Engineer Rodrick Chalwe explains that the company went to considerable lengths before making its final decision.

“We did a lot of research to find out what is on the market and what equipment would meet our specifications. We also learned a lot from companies who are in the business of producing aggregate. The semi-mobile Pilot Modular plant met our specifications and a number of visits to the Pilot Crushtec factory outside Johannesburg left us happy that we were dealing with the right supplier.”

The 13-piece Pilot Modular plant arrived at the end of May, and was assembled by Pilot Crushtec’s on-site installation arm, InstalLink. It was up and running by early June.

“From the moment they arrived on site it was obvious the team knew what they were doing. They double checked everything and the whole process went smoothly,” says Rodrick, describing the experience as ‘super’.

Warren makes the point that the Pilot Modular system delivers the customer a plant that is easy to understand and operate as it is built using standard components that can be adapted to suit individual customer requirements. Ndola Lime’s experience of the plant in only its first month of operation proves that this is no idle boast.

“We purchased the plant on the understanding that it would deliver a guaranteed production of 100 tonnes per hour (tph). However with constant feeding we can achieve up to 150tph,” says Rodrick.

From Ndola Lime’s perspective, the acquisition of a Pilot Modular plant has not only gained it entry into the market, but provided it the leverage to supply customers with aggregate produced to any product size or specification on demand. Product ranges from the mobile crusher are as follows: 0 – 7 mm, 7 – 14 mm, 14 – 19 mm and 19 – 30 mm.

The future looks bright as an increasing number of contractors are seeking bulk supplies of aggregate to feed their projects. Ndola Lime has a considerable bulk of material with which it can meet these requirements and can step up production still further with the easy option of adding a larger crusher to its Pilot Modular plant.

Based in Newcastle in northern KwaZulu-Natal, the company specialises in the beneficiation of coal products, by devolatising anthracite in rotating kilns, for sale to customers in the steel and manganese industries, as a replacement to coke.

According to Pilot Crushtec regional sales manager Nicolan Govender, the customer’s original enquiry was for a Crusher to complement its existing screen.

Coal Calcining Plant

“When we entered into discussions with Quantum, we realised that a modular plant would provide a turnkey solution. The flexibility it offers by being able to accommodate a wide range of sizes and specifications with minimal changeover time would be ideally suited to Quantum’s needs.”

The new plant includes a Pilot Modular GFH560 grizzly feeder, a DD2412 double deck screen, a BR0605 impact crusher, a 13 metre MC600 conveyor and three MC600 10 metre conveyors.

Installed and commissioned in July, it is already achieving significant results, processing up to 40 tonnes per hour of anthracite products, nearly doubling the output previously achieved using only a scalping screen.

Quantum director Pieter Cronje comments that the plant has been a revelation as the company can now offer a far wider range of sizes to meet the requirements of both existing and new customers.

“We now have the freedom to do what we like for our customers. The modular design gives us the convenience we need as to change sizes is just a matter of moving the conveyors and adjusting the crusher. Pilot Crushtec has helped us get as close as possible to meeting our customer’s requirements,” he says.

The freezing weather provided a stern test for Pilot Crushtec’s InstalLink personnel who installed and commissioned the turnkey plant in near arctic conditions.
“Neither rain nor snow prevented us from getting the job right first time and on schedule,” says Govender. He adds that Pilot Crushtec is rapidly extending its footprint in KwaZulu-Natal, with a significant upsurge in demand for its crushing, screening and washing products.

Pilot Modular Conveyor

They are light and highly mobile and can be moved around a site with ease. They enable efficient transfer of a wide variety of materials such as coal, aggregate, sand, construction and demolition (C&D) waste, mine ore, crushed rock and river gravel.

The MC450 has a robust construction and an adaptable, modular design built to deliver many years of service. Its standard features include feed boot, tail guard, self tensioning belt scraper, tail drum plough scraper, adjustable troughing idlers, a rear pedestal and front V-legs support. The MC450 is inclined and is 10m in length. A 3kW petrol engine and hydraulic drive allow variable belt speed up to 2m/s.

All conveyors are available ex-stock and are supplied ready to assemble and are easily transported. The MC450 conveyor is tried and tested and designed to integrate with the Pilot Modular range ensuring rapid installation of an entire transfer and stockpiling system.

• 450mm wide conveyor belt
• 10m length
• Feed boot with rubber skirting
• Tail drum guarding
• Tail drum plough scraper
• Angle adjustable troughing idlers
• Self tensioning belt scraper on drive drum
• Rubber lagged drive drum
• Electric motor drive
• Emergency trip lines
• Spare parts are readily available from our PartsLink division

“Although not the biggest crusher in our range, this is the biggest machine we carry in stock and is the first one of its size sold by Pilot Crushtec in South Africa” says Graham Kleinhans, sales director at Pilot Crushtec.

Kleinhans explained that the jaw crusher, which can handle raw feed material of up to 650 mm in size, is the primary crusher for a plant at the mine and will feed minus 200 mm sized coal into a secondary roller crusher.

Crusher Woking Plant

Palesa Mine engineer Theo Ferreira explained that the reason for the decision to purchase the larger Jaw crusher was to handle the oversized feed material.

“Coal is blasted and a certain percentage of the material is in the size range of 700 mm or more and our plant could not break this oversize material. Our roller crushers can only take material with a maximum feed size of 350 mm so we needed to break it down,” he said.

The throughput of the Pilot Modular/TRIO MJ3254 has also impressed HCI Khusela Coal.

“Our throughput requirement was 600 tons per hour,” explains Ferreira, “but we have found that this machine easily exceeds that and actually goes up to 650 tons per hour, depending on the coal received from the mine. When the blast is finer, the throughput increases.”

Spares availability worried Ferreira when he first heard that this was the first Pilot Modular/TRIO MJ3254 in the country but Pilot Crushtec assured him that in line with its spares stocking policy, all machines introduced in the country are only launched when strategic emergency as well as wear parts required are stocked at its Jet Park factory.

“We looked at other jaw crushers and the prices were all similar, but our biggest issue was availability because we didn’t have that much of a lead time. The Pilot Crushtec machine was immediately available and it was the right size so the choice was simple,” Ferreira explained.

The only modification the Pilot Modular/TRIO MJ3254 needed was to adapt it for the mine’s 525 volt electricity supply but he said this did not affect mine production because a 525V motor was supplied by Pilot Crushtec in less than two weeks.

Installation of the jaw crusher went smoothly because of the Pilot Modular’s simple assembly processes and the only task needed was the construction of a retaining wall behind the primary crusher.

“We commissioned the crusher on June 28, 2010 and I can say that we have had no problems with the crusher itself since then. However, I expect Pilot Crushtec to regularly visit the mine to inspect the crusher to ensure that it operates at optimum performance all the time,” Ferreira said.

To conclude, Kleinhans explained that the sale of some 20 odd jaw crushers over the past 4 years into coal crushing has definitely proved that Pilot Modular jaw crushers offer economical solutions to primary coal crushing requirements.

The Pilot Modular/TRIO MJ3254 jaw crusher sold ready to install, is mounted on a heavy duty skid frame and is equipped with a vibrating grizzly feeder to ensure optimum feed at all times by removing undersized material. It has a hydraulically adjustable jaw crusher which enables it to process large quantities of material.