With a new portable plant, Alberta, Canada-based Reco Construction gained control over job scheduling and costs, and material quality and availability. The company serves the booming oil industry with services such as oilfield lease padding and rig ditching. For the last 12 years, the company had hired a subcontractor to process materials at each of its four pits. "It was always hard to coordinate our projects with a subcontractor's schedule, so we were constantly juggling jobs and inventory. We had to get our own plant, so that we could have the right materials at the right time," says Co-Owner Grant Wald. Plant General Manager Warren Hawkridge says that top priorities were increasing tons per hour by better matching production capabilities between the primary and secondary crushing circuits; achieving greater screening capacity and processing flexibility; streamlining labor-intensive maintenance; revamping material handling methods to eliminate costly double handling; and strengthening an ongoing safety focus.
Reco purchased a new Telsmith JCP 2238-38, a two-stage portable crushing plant that includes a Model H2238 Hydra-Jaw Crusher; a 38SBS Cone Crusher; a 36-inch x 12-foot vibrating grizzly feeder; and a Telsmith 5-foot x 15-foot triple-deck inclined screen. "Telsmith did a tremendous amount of engineering to place all these components, plus the conveyors, on one chassis," says Wald. "We mine a very abrasive quartzite river rock and the jaw needs to handle up to a 20-inch maximum feed size. Our products include a 3/4-inch crushed gravel for roadway base course; and an asphalt rock that is split three ways and blended back at a specified rate. The new plant gives us the complete control we need over the finished product," he says.
The H2238 handles up to 533mm (21 inches) of quarried stone feed, and offers push button hydraulic adjustment, automatic tramp iron relief and auto reset, and remote control hydraulic chamber clearing – all features that contribute to reduced downtime and greater operational safety. "We are able to keep our operators away from potentially risky situations as we can make all of our adjustments, or safely clear the chamber, right from the tower," says Wald. "Also, unlike most jaws, the H2238 is designed with both jaw plates being the same. One spare jaw plate fits either side. This means less components that you need to inventory – and that is a big plus," he adds.The plant was upgraded throughout with a series of new KPI conveyors – eight new conveyor systems comprising stationary transfer conveyors and fixed stacking conveyors, plus a 36" x 150' Super Stacker telescoping radial stacking conveyor. The placement of these conveyor systems allows the operation to stockpile material just where it is needed, avoiding double handling.
Regarding the 38SBS Cone, Wald says that its hydraulic dynamic adjust system is integral to his operation. "Unlike older cone models, you don't have to shim it to adjust it. Without a self-adjusting cone, the downtime would have killed us, especially when making asphalt rock," he says. Also, Wald points to the fact that the SBS does not utilize a nitrogen-based hydraulic system. Its single power unit utilizes a pressure-compensated variable displacement pump to provide the correct hydraulic flow and pressure at all times. Since no accumulators are used, the result is more consistent pressure and less maintenance and downtime, he explains.
But most importantly, Wald stresses that the new portable plant has allowed his operation to gain control over job costs and profitability goals. "Depending upon the job location and requirements, we can move the plant strategically to save on trucking costs," he says. "Previously we were guessing as to where we needed to build material inventory. Now as we see the next job coming, we can easily move to the nearest pit and crush there. From job to job, our customers dictate where and when we will crush. Mobility is a must," he says.