Here’s something you should know about crushing and screening productivity

More $ spent on site set up = Lower project costs & Higher productivity

If ever there was a reality that applies to mine site crushing and screening services – what seems to be the lowest cost method of doing things, invariably doesn’t work out that way.

The way to maximise site productivity in relation to output and costs of production is to take the long term view.

When it comes to crushing, screening and conveying, the site set up and equipment commissioning can make all the difference between a so-so operation and one that will give maximum efficiency.

Achieving maximum efficiency often means higher initial set-up costs, but when it comes to production, reliability and cost savings – in the long run, this method finishes up being a mile in front.

This is the Rapid Crushing and Screening Contracting Services way of doing things.

With 15 plants around Australia and 38 years of experience in providing contract crushing and screening services, we have learnt a thing or two about:

  • designing and building plant
  • delivering tonnage to meet client requirements
  • delivering at the lowest possible tonnage cost
  • delivering to the highest possible production targets and standards.

The process of being able to create plant with first rate delivery capabilities came through our engineering division, Irvine Engineering (WA) Pty Ltd that our Principal, Neil Irvine had established prior to beginning a one plant crushing and screening operation.

He began as most crushing and screening contracting services do – by purchasing off-the-shelf equipment and competing with others to win contracts.

When it was realised that better productivity could frequently be achieved by reconfiguring the equipment, (often to meet the configuration of a site) our unique engineering works came into its own.

Nowadays, when we win a contract we look seriously at client requirements and the layout of the site to select the machinery best suited and whether it needs changes to its configuration.

It means we never have to make something fit that’s not quite right for a project. It enables us to take on the more difficult projects, satisfying the most stringent specifications that often cannot be met by other crushing plant operators because they’re limited to the capabilities of their machinery and reliance on third party contractors for repair and maintenance work.

Without our engineering works this would have been more costly and difficult to achieve.

Proof of the right gear making a difference!

In 2014 we proved to a major mining company how much more efficient we can be than our competitors.

The client had a pressing need to produce a major amount of tonnage in a short period of time and had several contractors working the site.

When they realised the required production deadline was unlikely to be met, they called us in.

Our machinery, completely out – produced what was on site with the final result being that the target was achieved.

A great example of creating a unique design was at the Moly Metals Spinifex Ridge DSO Mine in the Pilbara.

Rapid commissioned a large 3 stage fixed crushing and screening circuit to process 1 million tonne pa of ore with a capacity to ramp up production if required.

This plant was uniquely designed and constructed to fit the contours of an elevated escarpment with about 12m difference between the ROM feed point to the toe of the product stockpile to achieve a stockpiling facility of around 80,000 tonnes.

The difference in output capacity between what we were able to produce and what a standard conventional system would have achieved was considerable. End result – cost savings for the client.

FMG’s Cloud Break Site

The plant we have installed at FMG’s Cloud Break mine has a unique cone screen combination that gives us a greater level of throughput.

In addition to a better level of efficiency, an aspect that particularly appeals to us is that this unique design took less time to assemble on site.

This particular contract follows on from previous work that Rapid undertook for FMG at

Christmas Creek where Rapid produced nearly 4 million tonnes of iron ore for shipment in a particularly tight time frame.

Essentially, Rapid Crushing is one of the rare companies with the know-how to build and modify plant ourselves – making it superior to the plant you can buy ‘off the shelf’.

While that doesn’t sound significant to someone simply examining quotes, it does become significant with respect to the final outcome of a project.

In fact we can prove that a more expensive quote is often a cheaper quote in the long run.

So, if you’re thinking of calling for a site contractor, why not ask us how we would tackle your project?

 

Plant to suit your project

Rapid Crushing has created a wide range of high production crushing, screening and conveying circuits ranging from mobile & modular plants crushing up to 600 tph and fixed plants able to crush 1,000 tph.

Rapid is currently operating the following fleet:

►►Seven Track Jaw / Cone & Screen Circuits

►►Six Modular Jaw / Cone & Screen Circuits

►►Two Fixed Jaw / Cone & Screen Circuits

Each has been configured to suit the specific site in which it is operating.

Rapid crushes and screens all types of mineral ores including iron ore, gold and nickel as well as construction materials such as concrete and road aggregates, specialty fill materials, rail ballast, road base, blast stemming, rip rap and armour rock so the need for a varied range of equipment is considerable.

Why not give us a try…. Be assured, we won’t disappoint you.

On site lab helps us get it right and keep it right

Failing to monitor on a daily basis, the end product of a crushing cycle can run the risk of producing crushed material that is out of specification.

Furthermore, if incorrectly sized material is mixed in with product that meets the required specifications, you may not even become aware of the problem until much later when it could cost a packet to rectify the problem.

We at Rapid Crushing and Screening Contractors don’t take chances when it comes to ensuring crushed rock falls within a client’s specified product curve.

We are always on the lookout for the possible effects of machine wear and changing rock feed on end product consistency.

Unlike some other operators, we do not have to send our samples away for analysis – a process that can take days.

Instead, where required, we have a fully equipped mobile laboratory on-suite to analyse crushed rock samples right away to give daily reports. This allows us to make immediate adjustments to crushers or screens.

Our specialist lab technicians can produce sample results that give clients the comfort of knowing that the end product is in spec.

‘Doing it right’ is our motto.

It has come from our in-depth knowledge, acquired through 38 years of operation, of how critical it is to produce crushed rock that meets the specifications for blast-hole stemming, road base, road sealing, rail ballast or concrete aggregates.

Of course, ensuring we get it right starts well before we set up a plant on site.

A great deal of expertise is often required to meet the often strict specifications set by mining and construction industries – particularly so when producing aggregate.

In order to satisfy specs relating to size and grades there are many variables to consider when setting up and running a crushing plant. These include the choice of crushing equipment to be used and the nature of the material to be crushed.

Decisions have to be made about crusher settings, fine tuning of crushers, the location of screens and the choice of the right screen-cloths for the job.

It is also necessary to analyse the material to be crushed to determine factors such as hardness and abrasiveness. Failure to properly examine the rock can result in heavy dust loads or possibly in having to send the material through the crushing circuit a second time at a major cost in terms of time and money.

Absolute confidence needed

One key thing that spells a difference: A mine operator can have absolute confidence in the job being done to spec and to schedule!

If there’s one thing a mine operator needs from a crushing and screening contractor, it is absolute confidence in the contractor’s ability to deliver the required out-put to a given schedule.

That’s one of the key differentiating factors in the Rapid Crushing story.
We have the ability to get things done according to schedule because of a key factor that very few other screening contractors have.
We have a major engineering workshop within the Rapid Crushing Group that is the foundation of our business. It is the facility that enables us to build crushing and screening plant designed specifically to suit the configuration of a mine site and to the requirements of our clients.

This is a significant difference from the large and small crushing and screening operations that import off-the-shelf equipment from overseas based manufacturers.

Building our own purpose-made equipment gives us the tools to fine tune our designs to the conditions specific to a site and to create better and better crushing solutions.

Furthermore, in the event of a breakdown (everyone has them) we have the know-how and the equipment to expedite repairs immediately. That’s a big difference from having to bring in another party to undertake the repair and possibly having to wait for a part to arrive from interstate or overseas.

That reliability of absolutely minimal lost time is one of the big differentiators between Rapid Crushing and Screening Contractors and other services.