The most profitable solutions come when we combine the customer’s unique operating experience from the plant, with our knowledge from both operation and construction of facilities.
During the construction of the new coarse crushing plant at Lia, we took both parts with us into the development of the new plant. We dared to call a spade a spade and challenged on both sides of the table.
The result of the open dialogue was solutions that gave higher production capacity and safer working conditions in all parts of the plant.
See what the press is writing (norwegian)
Challenge
Thomas Thorgård looked up from a steaming cup of morning coffee. On the other side of the frosted window, snow shoveling by transporters awaited. The day before, the same task took an hour in tens of degrees Celsius.
He was not looking forward to the maintenance work at height. In such conditions it was often slippery and the fine material from the crushed stone stuck around parts. In addition, it hindered production. In every crushing step.
An ordinary stormy day at the Franzefoss crushed stone division Lia plant, 9 kilometers outside Trondheim. When they contacted us to build a new facility, the challenge was clear; maximum production capacity throughout the entire line and top HSE in all weather conditions.
First, we excavated the area, to get the correct fall in the plant.
Then we created automatic feeding to ensure that crushers continuously have stone. Seamless flow in all crushing stages is essential for high production.
Solution
To protect employees, we chose carriers with full equipment, which minimizes maintenance in severe weather conditions. With a roof structure, operators don’t have to shovel snow, plows and scrapers prevent them from having to shovel loose material, and the tracker prevents belt misalignment.
In sum, the transporter will be as maintenance-free as possible, and when maintenance first needs to be carried out, the transporters have wide walkways for easy access.
The next measure was to build in the coarse crusher and the entire intermediate crusher. With walls of insulated sandwich structure, operators do not have to blow frost fumes while fiddling with a frozen wrench. Exposing someone to work in stone dust was not appropriate, so we installed a modern dust suppression system.
Justerbar sikt
Etterspørselen varierer på 22-120 mm, det løste vi med egen mater som slås av/på for den fraksjonen.
Automatisk mating
Automatiske matere fra bufferlager gir nøyaktig mengde stein til mellomverket.
Valg av komponenter
Kunden valgte selv Sandvik knusere, Skako matere og Wima sikter.
Minst mulig kjøring
God logistikk til og fra bruddet gir minst mulig kjøring og kontinuerlig pålasting til grovknuser.
Bedre HMS
Takoverbygg hindrer snø og arbeid i høyden, brede gangbaner gir god tilkomst ved vedlikehold.
Specific HSE measures
- Roof structures on conveyors prevent employees from having to shovel snow at height
- Nordic Transportør specially developed for Nordic conditions, as extra weight in snow
- Better working environment in the cold when crushers are built in with insulated walls
- Increased access with wide walkways everywhere you work at height
Overall, well-being increases, and “quick solutions” that can quickly arise under demanding working conditions are avoided.
Increased production
In addition to top HSE, the superstructure shields crushed mass from precipitation in large parts of the production. As they are already considering building in a new fine crushing plant, flow through the entire line is essential. If the material sticks and stops in the sieve of the coarse crusher, it spills over the flow in the entire line.
Although the plant has several automatic feeders and sensors for consistent production, tailor-made dampers for optional fractions and the flow principle is laid down in all stages, it does little if the weather puts a stop to it. That is why all the necessary equipment is built in with a roof.
All factors must be taken into account in order to achieve optimal production.
We wanted to try a Norwegian supplier this time. They understood the project from the start and have a lot of knowledge about the whole of a crushed stone work. It has exceeded all expectations.
Pål Richard Thomas, technical manager at Franzefoss Pukk
During the development of the new facility, we looked at needs today, but also those that will come.
As the fine crusher is from the 70s, we made the intermediate crusher scalable, with space for the next construction stage in the same building. When Franzefoss Pukk wants to upgrade the fine crusher, everything is ready.
Optimum flow in all facilities
Good flow throughout the entire facility is one of the things we put the most work into. To get an optimal process, crushers and conveyors must stop at the right time, avoid overfeeding, and remove fractions evenly. In this way, Franzefoss has predictable operation throughout the year.