ROC’N
NOVEMBER 2018 ISSUE
The True Cost of Researching your Rock
Computer modeling is a good way to get an idea
of how modifications to your rock plant may
impact total throughput or the ability to make new
products. But, models are not gospel and should
be considered as a first step in the due diligence
process.
The old axiom “garbage in, garbage out” is very
much alive and should serve as a constant reminder
to dig deeper to provide a more accurate model.
Most, if not all, plant flow software allows the
user to input field/test data which can make the
difference between a pat on the back or a kick in the
pants when the “idea” becomes a reality.
This realistic data option is just one of the reasons
REMco offers its customers test crushing services
at our in-house lab. REMco’s lab utilizes a real
production series 1025 REMco VSI crusher, not
a scaled down mini crusher for determining
performance.
This machine is easily convertible to any mode of
operation for a VSI crusher; autogenous (rock-on
-rock rotor and chamber), semi-autogenous (rock-
on-rock rotor and anvil chamber) and hard parts
(rock-on-steel shoe table and anvil chamber).
REMco Operators Council Newsletter
COPYRIGHT © REMco MMXVIII ALL RIGHTS RESERVED
Plant Flow Software
REMco’s Crushing Test Services
Figure 1: The REMco TestMax VSI and VFD unit. Available for testing in three different configurations based on each customer’s
desired product output. –!–A multi-unit REMco customer located in the Eastern
United States was interested in another REMco
SandMax VSI to produce specialty sand for one of
his big (250,000 tons per year) customers.
As with previously purchased equipment, this
customer requested REMco to test the rock from
this site to prove the viability of the idea. After
testing, it was indeed proven that the specialty
sand could be made and our customer purchased
and installed another REMco SandMax and started
making specialty sand.
However, after several months, market demand
shifted and the 250,000 tons per year customer
didn’t want “that sand” they wanted a completely
“new specialty” sand. Leaving our customer with
a dilemma; tell a very good customer no (never a
good idea) or figure out how to produce this new
sand in a processing circuit they just built to make
another product.
Project engineers contacted REMco for advice. They
needed to produce two new finished products; one
minus #20 mesh x #100 mesh, and a second product
that was minus #40 mesh x #200 mesh crushed
limestone.
As you might expect, this was not an easy application
and testing the material was the only reliable way to
determine how a new sand could be made.
Testing provides an opportunity to see how different
crusher configurations will perform with a specific
rock. Based on the given product specifications
and field performance from the existing SandMax,
REMco selected a semi-autogenous configuration
with a four-port enclosed rotor for this customer.
Further, since the machine would be operated in a
closed circuit when installed, REMco’s test had to
be done in a closed circuit, returning oversize to the
machine for a further reduction to provide a realistic
simulation.
Closed circuit testing allows REMco technicians to
determine the mass flow balance of the processing
circuit for sizing of the crusher as well as ancillary
components required to consistently make finished
products.
Why is Testing Important
Particle distribution across the sieves in conjunction
with particle shape makes the product pass or fail
stringent standards set by the customer. In this
instance, the semi-autogenous operation provided
the highest product yield with good particle shape.
On the operational side, the material had a low
abrasion index making the wear cost reasonable at
just $0.21 per finished ton making semi-autogenous
operation the clear choice.
Ever Changing customer Product Request
Figure 2: The graph above shows the output of the limestone in
open circuit; the feed received is indicated in blue and the output
of the run is seen in red. The graph below shows the results of the
limestone crushing test in closed circuit. –!–Based on the strength of the crushing test findings
REMco recommended converting the SandMax into
a ST/AR (Swing Top / Anvil Ring) machine by replacing
the autogenous component with an anvil ring kit
which included the anvil ring with anvils, rotor guard
ring, bearing cartridge shroud and hardened rotor,
for a fraction of the cost of replacing an already new
machine.
By doing the testing, our customer was able to
go to his customer with confidence (along with
finished product samples) and say YES, I can make
that material and I’ll be ready to do it in about four
weeks.
That kind of confidence does not come from a
computer program alone, it is science, art, hard
work, and a supplier partner that works with you to
achieve your goals.
If you would like to learn more about how to get
your rock tested, there are two ways that this
can be done. First, you can visit REMco’s website
www.remcovsi.com and click on the Crushing Test
Services tab. You will be directed to an online form
that will ask several basic questions about your
rock. These type of questions will help the testing
department formulate a game plan to meet your
desired objectives.
Second, if you have more specific questions about
testing, you can contact your local sales representative
who can walk you through the process:
How to get Testing done at REMco
Figure 3: On the left is a rendering of the SandMax autogenous crushing chamber, while on the right is a rendering of a STAR
semi-autogenous crushing chamber with hardened rotor.
Technical Service Manager | Jim Trinkle
jtrinkle@remcovsi.com |Cell: (925) 409-0003
National Sales Manager | Terrence Costa
tcosta@remcovsi.com |Cell: (925) 409-0356
Central Regional Manager | Mike Howell
mhowell@remcovsi.com |Cell: (501) 366-6430
Eastern Regional Manager | Dana Stephens
dstephens@remcovsi.com |Cell: (859) 512-5532
Great Lakes Sales Representative | Marty Waldorf
mwaldorf@remcovsi.com |Cell: (608) 504-6017
N. California Sales Representative | Daniel Ramirez
dramirez@remcovsi.com |Cell: (925) 409-0326
S. California Sales Representative | Dan Jaques
djaques@remcovsi.com |Cell: (951) 821-5532
Toll Free (800) 782-2411
crush@remcovsi.com
The rock never wins, you do! –!–Rock Engineered Machinery Co. Inc.
263 S. Vasco Road • Livermore, CA 94551 • USATel (925) 447-0805 • Fax (925) 447-7038
Website: www.remcovsi.com/special.html
A WORLDWIDE PRODUCT OF REMco – AN AMERICAN COMPANY
REMco would like to extend its appreciation for your continued support this year. Receive $150 gift card for REMco rotor wear part orders of
$4,500 or more placed during 11/01/18 – 11/21/18. Plus, everyday, enjoy our free *freight program for rotor wear part orders over $8,000.
Contact your REMco Team member and place your order today! Call Toll Free (800) 782-2411 with
promocode #giftcard
giving
thanks
Dealer participation required on all orders placed through a REMco authorized distributor, and applicable to end users only.
* Ask REMco’s parts department for details about the free freight program.
For Your Parts
Business
Rock Engineered Machinery Co. Inc.
263 S. Vasco Road • Livermore, CA 94551 • USATel (925) 447-0805 • Fax (925) 447-7038
Website: www.remcovsi.com
WORLDWIDE PRODUCTS OF REMco – AN AMERICAN COMPANY
Backed by 5 year manufacturer warranty!
REMco SandMax, RockMax, and ST/AR VSI
crushers are recognized around the world for
their production of fi ne aggregate and sand to
meet customer expectations for specifi cation,
fi nished TPH, and operating cost. Guaranteed!
• C33 Concrete Sand
• Specialty Sand Products
• Cubical particle shape
• High fracture face count
• Increased fi nished product durability
• Balanced plant production
Size reduction and separation equipment
designed for years of reliable service in
aggressive aggregate environments. Primary
jaw crushers, secondary and tertiary cone
crushers, vibrating feeders and screens,
REMco’s PROline can solve your processing and
budget challenges at the same time.
• Fixed installation
• Optional modular skid mount
• Optional portable mount
GO PRO AND GET IT DONE
Just Crushin’ it
since 1983 –!–Rock Engineered Machinery Co. Inc.
263 S. Vasco Road • Livermore, CA 94551 • USATel (925) 447-0805 • Fax (925) 447-7038
Website: www.remcovsi.com/special.html
A WORLDWIDE PRODUCT OF REMco – AN AMERICAN COMPANY
REMco would like to extend its appreciation for your continued support this year. Receive $150 gift card for REMco rotor wear part orders of
$4,500 or more placed during 11/01/18 – 11/21/18. Plus, everyday, enjoy our free *freight program for rotor wear part orders over $8,000.
Contact your REMco Team member and place your order today! Call Toll Free (800) 782-2411 with
promocode #giftcard
giving
thanks
Dealer participation required on all orders placed through a REMco authorized distributor, and applicable to end users only.
* Ask REMco’s parts department for details about the free freight program.
For Your Parts
Business –!–Tech Talk
It is recommended that all REMco VSI crushers be
visually inspected on a daily basis. It takes only a few
minutes and can be very beneficial in preventing
operating problems and unnecessary downtime
due to preventable failures.
While most operators are quick to inspect their
rotor parts for wear they often ignore other areas
of the crusher that require inspection and attention
from time to time. For the purpose of this Tech Tip,
we will discuss three often overlooked but critical
components of a REMco crusher that should be
inspected regularly.
Figure 1 shows customer A is an example of an
operator that ran their machine for 18 months
without inspecting the feed tube. They contacted
REMco when a maintenance attendee noticed a
hole in the floor of their feed hopper. It was after
they were instructed to inspect the bottom of the
hopper lid that they notice that the feed tube was
completely gone allowing the material to reach
the hopper lid causing the wear issue. Some of the
reasons for feed tube breakage:
Service and Maintenance tips for REM crusher operators co
More to Crusher Inspections than just the Rotor
• Feed tube will fail when it becomes thin due to
normal wear and not being replaced
• Oversized feed too large for the crusher
The Feed Tube
• Low feed rate of large rocks
• Improperly positioned feed tube inserted
too deep into the rotor
• Not centered feed tube coming in contact
with the rotor body
• Excess build up between feed tube and
feed eye of the rotor from the dirty or
sticky feed
During normal operation, the feed tube wears
vertically. This vertical wear must be checked to
prevent the feed tube from wearing to the point
that rock feed can travel over the top of the rotor.
If this occurs, wear of the top of the rotor will be
excessive, and damage to the chamber, lid, and
rotor will occur.
Feed tube breakage is an indication of feed or
operating conditions which need to be modified
to ensure proper crusher performance. If this
condition exists, contact REMco for guidance.
The Bearing Cartridge
Figure 1: Customer A noticed a hole in the top of their
hopper lid (left), and discovered the feed tube completely
worn through, and a hole on the bottom of the hopper
lid (top).
Customer B contacted REMco
after noticing an abnormal
vibration of their crusher on a
particular day. The customer
contacted REMco’s Technical
Service Manager, Mr. Jim Trinkle
for advice. After talking to Jim,
the customer investigated a
series of probable causes to
discover the top seal plate of
their bearing cartridge was worn
away allowing the material to
penetrate the bearing cartridge
wearing the seal and bearings,
which caused excessive vibration
of the VSI unit.
Figure 2 shows that the rotor
skirt that protects the top seal
plate when the crusher is in
operation had completely worn –!–Service and Maintenance tips for REM crusher operators
out which allowed material to attack the top seal
plate. See ROC’N Tech tip from our June 2017 issue
regarding worn rotor skirts. Without the rotor skirt
to protect the bearing cartridge top seal plate, the
material can damage and penetrate the top seal
plate of the bearing cartridge.
Figure 2: Customer B has worn through the rotor skirt causing
material to enter into the bearing cartridge.
The Chamber Liner
when the crusher is fed material at full load amps
continuously. With the crusher properly fed it can
last the thousands of hours with no replacements
required. Nevertheless, routine inspection is ideal
and helps when determining the difference between
typical wear versus unusual wear.
Figure 3: Customer C who ran his REMco unit empty that
resulted in exposure and erosion of the rock shelf.
Figure 3 shows customer C who ran his REMco
unit empty for an extended period. The air in the
chamber created a sweeping motion that exposed
the chamber structure. When normal feed was
reintroduced to the crusher, rock was allowed to
build up in the chamber, and excessive erosion
on the gusset protectors occurred. This same
circumstance also occurs when a VSI is operated
in an extremely low feed condition called “dribble
feed” where the load to the crusher is so low proper
chamber build up cannot be achieved.
With any routine inspection, make sure that the
chamber liner lid seals the crushing chamber.
Inspect the outer edges, bolts and gusset protectors.
If any wear is visible, it might be an indication that it
needs to be replaced. The chamber lid is suspended
by bolts from the hopper lid and is meant to protect
the hopper lid.
With routine inspection, small wear issues can
be addressed before big problems occur costing
money and downtime. For any questions or issues
that may be present in your REMco VSI, contact our
Technical Service Manager for guidance.
Additional helpful information about how to
keep your REMco VSI in top performance shape
is available in Tech Talk section of every issue of
ROC’N, REMco’s newsletter designed exclusively for
REMco operators.
Not only should the rotor wear parts be inspected,
but the rotor overall should be examined after or
before every shift. The damage seen in Figure 2 does
not happen overnight. Inspection of the bottom of
the rotor is just as important as the top and the
middle.
When inspecting the top and bottom of the rotor,
look for excessive streaming/racing behind tips,
wall plates, and bolts. Streaming/racing will be
shown by excessive wear on the face of the tip or
the wall plates. If the material is streaming/racing
on top of the rotor, it is usually an indicator that your
feed tube is wearing above rotor feed eye or not
positioned deep enough into the rotor. If racing is on
the bottom of the rotor, that is a normal indicator of
material build-up on the tunnel belt section. If this
situation is present in your current crusher, contact
REMco for guidance.
All REMco crushers are field convertible to meet any
of three basic model requirements, autogenous,
semi-autogenous, and hard-parts. These crushing
chambers are the protective armor of the crusher
body and available for coarse, medium and fine
applications.
In an autogenous application, the crushing chamber
normally does not experience any significant wear –!–This newsletter is produced for REMco users and its intent is to make your life easier! We want to hear what has been
happening with the REMco crusher in your plant . Send us your questions, comments and job stories today!
Rock Engineered Machinery Co. Inc.
263 S. Vasco Road, Livermore, CA 94551
Tel (925) 447-0805 • Fax (925) 447-7038 • www.remcovsi.com
General Manager | Kevin Cadwalader kcadwalader@remcovsi.com
Marketing Manager | Chalin Luizinho cluizinho@remcovsi.com Technical Service Manager | Jim Trinkle jtrinkle@remcovsi.com
National Sales Manager | Terrence Costa tcosta@remcovsi.com Central Regional Manager | Mike Howell mhowell@remcovsi.com Eastern Regional Manager | Dana Stephens dstephens@remcovsi.com
Chief Financial Officer | Rich Lustig rlustig@remcovsi.com
COPYRIGHT © REMco MMXVIII ALL RIGHTS RESERVED
Upcoming Events
Join us on January 22 – 25, 2019 as REMco
will be exhibiting at World of Concrete
2019 in fabulous Las Vegas, Nevada.
Visit our booth #N229 located in the
North Hall to see REMco’s newest VSI unit.
This no-nonsense crusher is built for the
tough aggregate job that lesser machines
can’t do without breaking the budget.
REMco VSI crushers manufacture all types
of sands; concrete sand with the right
F.M., asphalt sand with the right grading,
durability and volume, blast sands, and
much, much more.
Hope to see you there and don’t forget to
enter to win our daily prize.
