To design a crusher capable of handling twin seam mining in addition to running at full capacity and increasing productivity, required integrated knowledge and experience, the company said.

Longwall Associates CEO, Tony Campbell said, “During 2001, we will be introducing several new products, the Rock Master Super Crusher, is the first of those products. While we are extremely proud of each new product we have added, we are very proud of our Rock Master Super Crusher.”

The design team at Longwall Associates, which included all departments, worked extremely closely with the mine personnel to develop the crusher.

“This particular mine is extremely skilled and successful at designing their own equipment and have done so in the past. In light of this, we are honored that they chose to work with our team in the design and manufacture of the Rock Master Super Crusher,” said engineering manager for Longwall Associates, Kevin Howden.

The specifications of the crusher incorporate many user-friendly features, which are crucial for a unit of this size. In determining applicable tolerance points for user-friendly features, the team relied on simplicity.

Kevin Howden explained: “Often times, designers over-engineer a piece of equipment. When this happens the equipment becomes so difficult to operate that it loses any anticipated benefits. It’s better to start with clarity and engineer from a fundamental standpoint. The result is a fully integrated system designed to provide all anticipated benefits without difficulty of operation.”

The first crucial element required for the design was incorporating quick assembly and dis-assembly features, which the heavy duty frame integrates. Longwall Associates said these features allow the crusher to be easily transported from OEM manufacturer to mine site. These features reduce installation time of the crusher and will play a large role in panel moves and rebuild requirements. Other user-friendly features include:

- An inspection door, which allows for easy hammer inspection.

- A wide mouth inlet which eliminates surge blockages.

- Smooth material flow feature, which is designed to reduce noise levels.

- And an innovative dust suppression system on the inlet and outlet of the Crusher.

In addition to user friendly features, the crusher has the following innovative benefits:

- Twin sheave wheels to maximize twin seam mining material content.

- Kinetic energy of over 1.5 million foot pounds.

- Throughput capacity of 5,000 TPH.

- Product range, 9” up to 12” setting available.

- Crushing capacity to 50,000 psi.

- Tip speed in excess of feet per second.

- The diameter over the hammers is 48 inches.

- A spherical roller bearing with a dynamic rating of 4,000,000 N.

- The system is rated for a 500 hp drive.

- Replaceable hammers with the option of adjustable settings.

Combining all facets of the Crusher has assisted the mine in increasing their productivity, resulting in record production days. Based on the performance of the ‘Rock Master Super Crusher’, the mine ordered an additional machine.

“Not all mines require such rugged and durable equipment, simply based on their geological content. However, for the mines that do require an extremely tough machine to maximize their output, we are delighted that we can offer a successful solution,” said senior design engineer for Longwall Associates, Don Kestner, who was an integral part of the design team.