SAVAGE STONE MAXIMIZES PLANT UPTIME & PRODUCTIVITY WITH BTI ROCKBREAKER SYSTEMS
Serving the demanding Baltimore and Washington D.C. markets, Savage Stone is a 400-acre facility that mines gabbro, a granite-like rock that’s preferred for coarse road base. To meet production goals and cost-per-ton requirements, its management team meticulously monitors the performance data of each processing circuit – determining whether their equipment is boosting productivity or becoming a bottleneck. “Uptime is the name of the game, and we count on reliable equipment that delivers what we need day after day,” says Savage Stone Plant Manager Gary Long.
When the operation relocated crushing circuits closer to the deposits, Breaker Technology Inc. (BTI) rockbreaker systems were placed before the primary and secondary crushers to ensure maximum uptime and productivity. “We mine gabbro from five 43-ft-tall benches with chemical rock hardness increasing with each lower level,” says Long. Previously, they had hauled the shot rock about a half-mile uphill for processing. Since placing crushers at the bottom of the pit (380-feet below surface grade), the operation realizes the costs-per-ton benefits of faster downhill hauling, and less fuel consumption. Long says that the facility realizes further cost-per-ton reductions by using BTI rockbreaker systems to efficiently reduce oversize rock, keeping material moving into the crushers for optimum tonnage per hour.
BOOST CRUSHING PRODUCTIVITY
Haul trucks dump shot rock into a hopper which feeds the primary crusher. A BTI MRH25 Pedestal Rockbreaker System with a BX40 Hammer/Breaker is positioned at the primary to reduce oversize; rake material into the crusher; and relieve any potential jams while minimizing any downtime. “The BTI rockbreaker system boosts our production capacities as it has the boom and the reach to break up the oversize material in the dump hopper - before it gets to the crusher. This provides a steady flow of material to the crusher and keeps production up,” says Long.
ELIMINATE MATERIAL BRIDGING
From the primary, processed material is conveyed approximately 100-yards to the secondary crushing circuit where a BTI MBS 12S Rockbreaker System with a BX10 Hammer/Breaker is positioned at the secondary cone. “With the BTI system, we can prevent any material bridging and ensure that the cone is choke fed for maximum crushing efficiency,” says Long. He explains that the operator uses the combined reach of the boom and the breaker to rake the material and prevent or relieve material bridging; while the impact of the hydraulic breaker is used to break up any oversize that could become jammed in the cone crusher. From the secondary crusher, material is conveyed to the surface deck of the pit for further processing and final product stockpiling.
ACCESS EXPERT SUPPORT & SERVICE
Savage Stone was introduced to BTI equipment in 2005 when a BTI rockbreaker system was installed at the primary crushing circuit of the original surface plant. “The initial BTI system, which is still in operation, has always been reliable and has improved our production,” says Long. When the latest MRH and MBS rockbreaker systems were installed in early 2018, Long says that they were delivered according to schedule, and that BTI service technicians spent considerable time onsite to run a battery of tests, ensuring that all hydraulic and controls systems were adjusted properly and were functioning according to the required specifications. “They also worked closely with us to review proper operation and maintenance practices for the systems,” he adds.
ENSURE SAFE OPERATION
Long notes that his operator safely operates the rockbreaker system in a dust-free environment, via remote control from a separate pedestal located in the control room, eliminating the need to work near the crusher. Prior to the development of rockbreaker systems technology, the processes of reducing and raking material was often a very time-consuming and hazardous manual task.
Savage Stone counts on reliable equipment and efficient operation to maximize profitability and minimize costs-per-ton. “Bottom line, BTI has good products and good people – and they have helped us to maintain our high operational standards,” says Long.