Full Turnkey Plant Latest Jewel in Family Crown

Presented by Qme Engineering Pty Ltd

QME – Quarry & Mining Engineering – is involved in the fabrication and installation of full turnkey plant and equipment in mines and quarries throughout Australia. The company, which has been headquartered in Bendigo since its inception in 1980, is aided on all its projects by support services and contractors. It counts Terex Jaques, Sumitomo and Indeco among its network partners.

Ian Rowan, the managing director of QME, told Quarry that GEM Group first approached him in 2019 about establishing a new crushing and screening plant at Moree Quarries. After being briefed by Sutherland about the key requirements of the new plant, Rowan and the QME team recommended a new plant on a hectare-sized footprint that would incorporate Terex Jaques equipment.

The new Moree Quarries circuit, which has been operating since May 2021, consists of a Terex Simplicity 5124 vibrating pan feeder, a Jaques ST48 jaw crusher, a Cedarapids TSV6203 medium scalper vibrating screen, two Cedarapids MVP450X cone crushers, a Canica 100 rock-on-rock (ROR) vertical shaft impact (VSI) crusher, and three triple-deck Cedarapids TSV8203 vibrating screens.

A Supervisory Control and Data Acquisition (SCADA) operating system manages the plant processes via a programmable logic controller (PLC); the PLC reports data to and communicates with the SCADA system. The plant operation and status is communicated to the plant operator via a 660mm touchscreen Human-Machine Interface (HMI) monitor (SCADA or Panelview system) in a desk-mounted console.

The Canica Model 100 VSI crusher with 2 x 220kW motors (centre), and rotor and rock box configuration. Its primary aim is to shape material already reduced by the cone crushers to a cubical final product.

Fixed Circuit

All the machines were statically mounted and designed to operate in a fixed system, Rowan and John Flynn, the Australian and New Zealand Business Manager for Terex Jaques stated there was

“All crushers have some configuration options,” Flynn told Quarry. “There has been no unique customisation but the machines are configured to best operate as a complete system per Moree Quarries’ requirements.”

Flynn said the 1295mm x 13m long Simplicity 5124 features a full length pan suitable for accepting a large primary feed. It is equipped with an oscillating twin-shaft drive arrangement that moves material efficiently and effectively.

As part of the new Moree Quarries circuit, the Simplicity 5124 feeds material to the Jaques ST48 single toggle jaw crusher which is renowned for its large gape feed opening (1067mm x 1219mm) and hydraulic closed side setting (CSS) adjustment. The primary feed from the ST48 is then transferred to the double-deck Cedarapids TSV6203 which, Flynn said, “is installed at a five-degree angle to best handle coarse jaw crusher product and resisting pegging in the large scalping apertures of the top deck”. The variable slope capability of these screens allows installation from a zero- to 10-degree angle to best suit the application. The TSV6203 is the latest generation El-Jay horizontal screen which can handle a broad range of applications.

The Cedarapids MVP450X cone crushers are the next links in Moree Quarries’ crushing and screening chain. They each feature a roller bearing design, a 10mm to 51mm CSS setting, a 300kW motor and a hydropneumatic tramp iron relief system. They can process sand and gravel, shot rock and recycled materials, with a throughput of up to 500 tph. 

The secondary feed from the MVP450X is then passed to the 220kW Canica 100 VSI crusher, which has a maximum feed size of 125mm and a throughput of 400 tph. “The configuration of the Canica VSI can be set up with primary aim to crush, shape product or a combination of both,” Flynn said. “The Canica Model 100 ROR at GEM Moree has a rotor and rock box configuration. Its primary aim is to shape material already reduced by the cone crushers to a cubical final product.”

Feed from the Canica VSI is passed to the three Cedarapids TSV8203 triple-deck horizontal screens. Flynn said the TSV8203 is built for durability and its patented lubrication system, coupled with high tolerance machined components, enables efficiency and a long bearing life in the final screening duties at Moree Quarries. “A high G-force operation ensures that required specifications can be met through highly efficient screening.”

The Cedarapids MVP450X are the next links in the Moree quarries crushing and screening chain.
They each feature a roller bearing design, a 10mm to 51mm CSS setting, a 300 KW motor and a hydropneumatic tramp iron relief system. They can process sand and gravel, shot rock and recycled materials, with a throughput of up to 500 tph.

The secondary feed from the MVP450X is then passed to the 220KW Canica 100 VSI crusher, which
has a maximum feed size of 125mm and a throughput of 400 tph. The configuration of the Conica VSOI can be set up with primary aim is to crush, shape product or a combination of both. The Canica Model 100 ROR at Moree has a rotor and rock box configuration; its primary aim is to shape material already reduced by the cone crushers to a cubical final product.

Feed from the Canica VSI is passed to the three Cedarapids TSV8203 triple-deck horizontal screens. Flynn said the TSV8203 is built for durability and its patented lubrication system, coupled with high tolerance machined components, enables efficiency and a long bearing life in the final screening duties at Moree Quarries. “A high G-force operation ensures that required specifications can be met through highly efficient screening.”

An aerial view of the new Moree Quarries circuit, which was a collaboration between GEM Group Holdings, QME and Terex Jaques.

Sutherland said he and the GEM Group are pleased with the new plant’s early results and praised QME and Terex Jaques for their work. “From the first initial catch-up in January 2019 through to commissioning, QME has been fantastic,” he said. 

“Day or night, Ian and Sue from QME have been available and had our best interests at the forefront. QME have handled the whole turnkey operation at a high level. The commissioning and handover between QME and Terex Jaques was smooth and I recommend both companies to anyone who is in the market for an upgrade to an existing plant or for a full turnkey plant.”