Longcliffe Quarries Ltd make Jaw crusher history for Metso UK.

In the summer of 2016 at Brassington Moor Quarry in Derbyshire’s Peak district, Longcliffe Quarries Ltd invested in the installation of the first fixed Metso C160 (1600 x 1000mm) Jaw crusher in the UK. Up to this date, the biggest C Jaw running in the UK was the C160 on the tracked LT160 Loko Link system at Swinden quarry.

Longcliffe Quarries LTD supplies a wide range of speciality high quality Calcium Carbonate products in both granular and power format into several manufacturing sectors which requires a flexible approach to production always.

Over several years, the efficiency and reliability of the existing Primary Jaw Crusher had started to deteriorate which was impacting on the overall production of the site. Therefore, it was decided at the end of 2015 to investigate replacing the Primary Crusher to improve the operational efficiency and reliability. Discussions took place with several manufacturers to establish which jaw crusher would fit best Longcliffe’s requirements After extensive feasibility studies the Metso C160 became the preferred option

Metso UK assisted Longcliffe’s management team to model various operating scenarios to satisfy the long-term objectives. After reference visits to view the new C150 in operation at Backlane Quarry and LT160 at Swinden Quarry, Longcliffe’s project team had the confidence to compile their capex request complete with recommendations on crusher size. Detailed proposals were ready for the board approval in March 2016 and in early April 2016, the order was placed with Metso UK to supply and install the C160 at the end of July 2016.

Metso appointed Roltech Engineering Ltd as their installation partner to make the necessary changes to the existing support structure and chute work required to complete a successful installation of the C160 into the existing Primary Station. Roltech took on both principle designer and principle contractor’s roles under the CDM regulations and had a full-time site manager supervising the overall installation, with Metso engineers building up the crusher from the new support level.

Metso configured the crusher for the application to include:

  • Slip ring drive motor mounted on crusher with motor pulley mounted on its own Lay shaft.
  • Complete with dive guards all pre-determined, all to reduce installation time and convenience for maintenance. 
  • Super tooth jaw profile selected to reduce “slabby” crushed product. 
  • Auto lube system for all crusher bearings.
  • Hydraulic adjustable jaw plate setting to allow variable crusher set points
  • New digital display of crusher setting to help with setting changes.
  • Heavy-duty feed funnel designed to suit crusher opening.

The new crusher had to be installed into the existing space, respecting the feed and conveyor system, to gain access, the roof and existing lifting beam had to be removed. The scope of installation also included a new Magna start for the slip ring motor and Electrical control panel. During the planning stage where all stakeholders were involved, the best solution found was to build up the crusher “insitu”. This overcame the challenge of crane access for the size of lifts involved with sufficient reach available for the best position near the Primary building.
With the effort made at the planning stage and with everybody’s co-operation the installation proved successful with commissioning and start up completed 3days before the deadline.

On analysis of the investment, Mr Andy Meadows Longcliffe Quarries LTD Group Engineering Manager is pleased to report that:

The C160 has delivered all of Metso’s expected results:

  • Improved throughput 
  • Impressive ability to crush marginal stones the size of the crusher mouth.
  • Reduction in down time and use of the hydraulic breaker. 
  • Reduced downtime adjusting the crusher setting with the use of the hydraulic setting equipment
  • Improved maintenance with the auto lubrication system, the compact design of the machine and easy access to parts

The C160 is already impacting our business with improved production at the Primary station with better utilisation of the Load & Haul fleet asset and associated manpower. We have also noticed that although we have improved production the power consumption of the new C160 has not increased versus the old primary crusher.

Andy also commented that it is pleasing to see the crusher delivering its predictions and the capex investment providing the improvements to our business that was outlined in our justification.
Longcliffe Quarries Ltd take a long-term view on the purchase of equipment and is why we have also agreed to a crusher extended warranty and care package with Metso UK.

Metso would like to thank Longcliffe Quarries Ltd and especially Andy Meadows for the co-operation in the production of this article.

Metso is the world’s leading industrial company in the mining and aggregates industries and in the flow control business. Our knowledge, people and solutions help drive sustainable improvements in performance and profitability in our customers' businesses.

Metso has an uncompromising attitude towards safety. Our products range from mining and construction equipment and systems to industrial valves and controls. Our solutions are delivered and supported by decades of process knowledge and a broad scope of services backed by a global footprint of over 90 service centres, thousands of service employees, and an extensive logistics network.

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