Karelpriodresurs, Russia – a leader in quality
Russia currently has some of the strictest aggregates quality requirements in all of Europe, specified in detail in several nationwide standards. Using Metso’s portable crushing and screening plants, Karelpriodresurs has exceeded the quality demands, in addition to increasing the quantities it produces.
Pls feel free to ask for more information. We also appreciate your feedback in all automation related issues.
Sergey Popovich (right), responsible for Karelpriodresurs’ quarries, with Kaalamo Quarry Manager Igor Vladimirovich following the performance of Lokotrack LT125 jaw plant.
Only the best granite and gabbro deposits, processed into highly cubical end products, can meet these Russian quality standards. Therefore, Karelpriodresurs carefully studies the rock quality in the quarries to be opened. Every plant built is exploited using Metso’s modern, three-stage crushing and screening process.
The company’s target is to open one portable plant every year. With its four existing ones, Karelpriodresurs targets production in 2012 of up to 6 million tons of high-quality aggregates. The fifth quarry will be built this year in Ihala, in the Leningrad region, some 200 kilometers from the multi-million city of St. Petersburg.
“We are the quality leader”
Sergey Popovich, responsible for the operations of Karelpriodresurs’ quarries, proudly explains the company’s quality achievements:
“We can honestly say that we are the quality leaders in aggregates production in Russia. Recently, our company won a nationwide competition held among the main producers.”
“In fact, our quarries were the only ones accepted to supply aggregates for the new Sapsan speed train network, operating a 200 km/h network between Moscow and St. Petersburg,” Popovich stresses.
In addition to railway networks, the aggregates produced by Karelpriodresurs are widely used in demanding highway projects executed by VAD, one of Russia’s leading road construction companies.
After blasting, the hard gabbro feed is crushed by the Lokotrack LT125 jaw plant.
Standardized Metso portable plants
In close cooperation with Karelpriodresurs and Metso, a standard for a portable crushing and screening process has been developed. It usually consists of a track-mounted Lokotrack jaw plant at the primary stage, a secondary stage operated with a cone crusher, and a vertical shaft impactor to guarantee cubicity at the tertiary stage.
“Metso’s general plant design has been good and reliable for us, and our cooperation is seamless. Metso listens to us carefully to solve any problems that may occur,” Popovich notes.
“For example, Metso’s experts have been willing to redesign some product conveyors for more stability during the assembly and operational stages.”
The Nordberg NW550GP, featuring Metso’s biggest GP series cone crusher, handles the secondary crushing.
A new Metso DNA automation system
The new Kaalamo portable plant, delivered by Metso, was started in late August 2011. Today, it refines hard gabbro into a wide variety of end products at a rate of 5,000 tons per 12 hour working day.
For the first time, the whole plant process is steered using the new Metso DNA automation system. The control cabin is placed so that the operator, Sergey Horyy, has, in addition to the crystal clear process screens, a direct view of most of the plant.
“Metso DNA software looks good. Some fine tuning will be done with Metso to achieve the best functionality,” Popovich adds.
The Kaalamo portable plant features a Metso DNA automation system. Sergey Horyy has excellent visibility over the whole plant from the automation cabin.
Preventive maintenance
| Karelpriodresurs Kaalamo quarry: |
- Location: Karelia,
western Russia
- Feed material:
Hard and heavy gabbro
- Feed size: 0-900 mm
- Production 2011:
600 000 tons
- Quarry lifetime: 50+ years
- Main end products:
0-5 mm, 5-10 mm,
10-20 mm, 20-70 mm, also 10-15 mm and
10-20 mm for the upper level of road base materials.
- Metso system and equipment in the quarry:
Metso DNA automation system
1 Lokotrack LT125 jaw plant
1 NW550GP portable plant
1 NW2060CVB portable screen
1 NW7150 portable plant
1 CVB1875-4 screen
2 hoppers, 13 conveyors
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 |
To keep the quarries running in the middle of the remote Karelian forests, preventive maintenance is a key issue to ensure the availability of the equipment.
All wear parts for the jaw, cone and vertical impact crushers are stocked at Metso’s warehouse in Petrozavosk. Karelpriodresurs’ own service personnel usually handles changing the wear parts.
Every three months, Metso’s engineer goes through the quarries, and opens and checks the functionality of all the crushers. This minimizes the risk of sudden failures.
“Actually, spare part deliveries are our main concern. Customs clearance between the Finnish and Russian border usually takes too much time,” says Popovich.
By Eero Hämäläinen, Metso Minerals
Pls feel free to ask for more information. We also appreciate your feedback in all automation related issues.
For more information:
Nikolay Volkov
Tel. +7 911 000 90 62
nikolay.volkov@metso.com
