Generator Mods Make Unit Ideal For Rock Crushing Plant

A rock crusher is a machine designed to reduce the size of large material (like rocks and stone) into smaller aggregates such as gravel, recycled concreate, crushed stone, or dust. 

Large mining operations can often use more than one crusher and conveyors. Construction projects are also heavy users of these machines and the materials they produce. Each crusher has a different input and output classification (size of rock). Some mines use rock breakers to reduce the size of large rocks into crushable sized rocks.
 
There is more than one style of crusher available. A few common styles are listed below:

• Jaw Crusher - Used for heavy mining, quarried materials, and recycling sand and gravel
• Gyratory Crushers - Used for heavy mining and quarried materials
• Cone Crushers - Used for quarried materials, sand and gravel
• Impact Crushers - Used for heavy mining, quarried materials, and recycling sand and gravel
• Small to medium operations can use crushers that are powered by Power Take Off (PTO) or engine drive. Mining and large industrial operations utilize large electrically powered crushing plants. These plants use power for:
• Feed Conveyor - Motor for conveyor that transports material to crusher bin
• Crusher - Motor that drives crusher operation
• Output Conveyor - Motor for conveyor that distributes crushed product
• Control Panels and Lighting - Lighting for site area and digital control panels if crusher is equipped with one

Large quantities of dust is a by-product of the crushing operation. Sometimes the best location for a rock crushing plant does not have electrical utility access.

Diesel generators are the most practical solution to meet the backup, prime, or continuous power needs these plants require. Operating engines in extreme dusty conditions can cause the filter to fail, which reduces life or kills the engine.

Diesel Generator Modifications

Generator Source customized a 750 kW Cummins diesel generator set for a customer to operate in the extreme conditions their portable rock crushing plant produces.

We started with a Cummins 750 kW in a sound attenuated enclosure. This is an all-in-one unit that includes a cooling system and fuel tank. The client's specifications required the ability to run efficiently, even in the worst possible environment.

The client's needs included:

• Removal of sound attenuated enclosure and accompanying framework
• Designed and constructed custom framework to accommodate installation of a pancake muffler
• Customized welding and fabrication
• Installation of a Donaldson air filter kit (the air filter is micro-filter designed for dusty operation)

These modifications allowed the client to operate their rock crushing plant in an above-average dusty environment. This is the second unit which we designed with these modifications.
Generator Source is the world's largest low-hour used generator dealer. We provide custom design and fabrication services to accommodate any power generation need.
Our skilled staff is ready to help you in selecting a generator that meets your power requirement needs. Our technical staff can perform any needed upgrades or fabrication. Contact us for more information.

Story Summary

What is a rock crushing plant?
A rock crushing plant is a facility that uses heavy machinery to break down large rocks into smaller stones, gravel, or rock dust. It typically includes equipment like crushers, screens, and conveyors.

Why might a rock crushing plant need a generator?
Many rock crushing operations are in remote areas without access to the electrical grid. Generators provide the necessary power to run the crushing equipment, conveyors, lighting, and control systems.

What types of modifications are commonly made to generators for rock crushing plants?
Common modifications include:

• Installing heavy-duty air filtration systems to handle dusty conditions
• Customizing the frame and enclosure for portability
• Adding specialized mufflers for noise reduction
• Upgrading cooling systems for high-temperature environments

Why are air filtration upgrades important?
Rock crushing produces large amounts of dust that can damage standard generator engines. Advanced filtration systems like Donaldson air filters help protect the engine in extremely dusty conditions.

What size generator is typically used for a rock crushing plant?
Generator sizes can range from 100 kW to over 1000 kW depending on the size of the crushing operation. A 750 kW generator is common for medium to large portable plants.

What are the benefits of customizing a generator for rock crushing?

• Customization allows the generator to:
• Operate reliably in harsh, dusty environments
• Be portable for mobile crushing operations
• Meet noise reduction requirements
• Provide consistent power for efficient crushing
• What should be considered when modifying a generator?
• Key considerations include:
• The specific power requirements of the crushing equipment
• Environmental conditions like dust, heat, and moisture
• Portability needs for mobile operations
• Local noise regulations
• Fuel efficiency and run time requirements

Is it better to modify an existing generator or purchase a purpose-built unit?
This depends on factors like budget, timeline, and specific needs. Modifying an existing generator can be cost-effective. A custom, purpose-built unit may offer better long-term performance but have a bigger price tag and wait.

Generator Source can modify units to work for you. Whether it's a voltage change or custom modifications like this in case, we can get it suited perfectly for you. See our currently inventory here.  

administrator | 2/12/2018 2:10:40 PM | 0 comments