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MEI Online: Plant Operation News: Europe: February 21st 2005


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:: Sandvik Rock Processing Supplied Russia's Most Modern Crushing Plant

During 2004, flats and apartments were built in Moscow totaling 8 million m2 of floor area. Prefabricated concrete modules were vital for this gigantic construction project.

These modules came from factories in the Russian capital - factories that required large quantities of aggregate. High-quality aggregate is brought to Moscow all the way from Sortavala, located close to the Finnish border, in the Republic of Karelia, some 1000 km from Moscow.

The quarry in Sortavala is run by PIK Holding, one of the largest construction companies in Moscow. Recently, Sandvik Rock Processing supplied an automated crushing plant to the Sortavala quarry; it is believed to be the most modern crushing plant in Russia.

The raw material processed in Sortavala is a hard granite. No quality material is available within 600 km of Moscow, so it has to be brought in by train or barge from distant Karelia.

Sandvik Rock Processing's compact design has enabled the new plant to fit in well on the existing jobsite, meeting all the customer's requirements. PIK Holding replaced all the equipment in this project, with the exception of an existing railway loading system.

The plant consists of a primary crushing station with a JawmasterTM JM1211 jaw crusher with a 120x110 cm feed opening and an E64 Rammer hydraulic hammer for oversize boulders. Natural fines are separated from the feed material. The crushed material is conveyed to a Hydrocone® H6800 crusher, as a secondary stage crusher, via an intermediate stockpile. Two Hydrocone H4800 cone crushers are responsible for the final shaping of the aggregates. The design of the plant allows quality adjustments of the crushed material according to current market demands. The plant is fully computerized, so that one operator can control feeders, crushers, screens and belt conveyors.

The four screens are of the new Sandvik free-fall type; the screening decks have differing inclinations. This operating principle allows a small screen to process the same amount of material as a traditional screen twice the size.

The plant has a capacity of 430-475 metric t/h depending on operating mode. It was designed to maximize production of high quality 5-20 mm material for asphalt and concrete. But equally, the plant can be set to produce 5-10, 10-15 and 15-20 mm materials. Trains take care of transportation to PIK Holding's concrete prefab factory in Moscow, the main end-user.

The Sortavala plant forms a complete Sandvik Rock Processing delivery, and was sold through their dealer in the region - Integra Ltd. Sandvik Rock Processing designed and built the control system. Each Hydrocone crusher has an ASR-system for fully automatic regulation of the setting in accordance with hydraulic pressure and motor load. The plant is dust encapsulated and almost dust-free thanks to modern point filters on crushers and screens. The equipment was manufactured in Sweden and France.

The Sortavala plant is quality certified in accordance with ISO 9000. Representatives of the government of Karelia were present when the plant was taken into operation on July 12, 2004.

"Having run the plant for about half a year, we find it reliable and efficient", says Mr. I. Boshakov, General Director of the Sortavala Crushing & Screening Plant Ltd. "Not only does the new plant cover PIK Holding's aggregate requirements, it covers several other customers' requirements as well. Well-coordinated supplies of wear and spare parts from stock held by the local dealer in Saint-Petersburg, the service group certified by SRP, and round-the-clock readiness to assist us, facilitate successful operating results", adds Mr Boshakov in a final remark.




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