Coal Age

NOV 2015

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housing is designed." The housing has been improved to con- trol fugitive dust. Steel, or what the professionals refer to as "noncrushables," is another area for concern on these high-capacity systems. "TerraSource uses the Nitroil system — nitrogen gas over oil — to protect its units," Schaefer said. "The nitrogen is preset for normal coal-crushing applications. If a piece of noncrushable material passes through the system, it will overcome the preset pressure. The roll will move back and allow the noncrushable material to pass without damaging the crusher. It's instantaneous. With the large 8- in. bore cylinders, the roll moves right back into the run position because it's under pressure. The repeatability is very high." As far as general maintenance, the consumables on a roll crusher are the roll teeth, which make contact with the coal. "The teeth are replaceable, and they have gone through a series of changes over the years," Schaefer said. "The original teeth were hard surfaced and then they moved to a carbide face, which increased the life." These crushers are large units and the rolls are heavy. Instead of removing the entire roll, they are segmented in such a way that maintenance crews unbolt a shell segment and bolt another one onto the roll. "Segments in the PRB are normally changed once a year," Schaefer said. "These mines are moving higher tonnages than most coal mines. This maintenance work is scheduled downtime over a weekend, where the segments are shipped in advance and the crews are mobilized with the proper tools to do the job." Looking toward the future, Schaefer sees a lot of aging sys- tems that will need to be replaced soon, not just in the U.S., but Canada, too. Those customers will likely want to incorporate more remote monitoring controls for these crushers into the mine's central control system. Sizers Offer an Effective Alternative For those that associate sizers with small capacities, David Pitchford, president, MMD Mineral Sizing for the Americas, has a reminder. If the conversation turns to overburden rather than coal, where capacities can run quite a bit higher, MMD p r i m a r y c r u s h e r s c o n t i n u e d November 2015 www.coalage.com 39 TerraSource 80- x 30-in. chisel tooth segmented roll. Local Presence – Global Competence North America, USA www.dsiunderground.com South America, Brazil www.dsiunderground.com.br EMEA, Poland www.dsischaumchemie.pl APAC (ASEAN), Australia www.dsiminingproducts.com INNOVATIVE SOLUTIONS DYWI ® JFP 95 – Dust Control System Easy to Install and Maintain 30% – 40% Reduction in Respirable Dust Proven with Numerous Installations Benefit from a Support Team On-Going Maintenance Designed to Work in Cold Water www.dsiunderground.com Contact DSI for a 30 Day Mine Site Trial! 800-332-3308

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