From early 2019 on, Etrack’s new assembly plant in Neemrana will produce Keestrack hybrid crushers for the Indian and South Asian Markets.
Keestrack, the international specialist for mobile mineral processing, will illustrate its strong commitment to the Indian and South Asian aggregate and recycling industry at Bauma Conexpo India 2018 (Gurgaon, Dec. 11 to 14 2018). Represented by Etrack Crushers Ltd., the company's Indian subsidiary, established in 2017, Keestrack will focus on its advanced electric drive concepts, offering huge savings for all contractors and offering operational advantages for larger multi-stage mobile plant lay-outs.
Etrack Moves Forward in India
Headquartered in Gurgaon, next to the capital New Delhi, Etrack Crushers Ltd. was established in November 2017 as part of the Keestrack Group to promote the manufacturer's comprehensive program of track-mobile crushers, screeners and related equipment. Supported by the group's global experts in application-engineering and after-sales resources, local experts work on nation-wide projects in the Indian mining sector and mineral aggregates and recycling industry. In only a few months, the Etrack team, led by Managing Director Swapan Das and General Sales Manager Topor Basu, increased brand awareness and provided good perspectives for Keestrack's next steps in India – the establishment of local assembling and manufacturing.
In August 2018 construction started at Etrack's new manufacturing facility in Neemrana, around 100 km south of New Delhi. With modern offices and extensive parts storage facilities, the new complex will provide 10.000 sq. m. total area to be operational in early 2019. The new site offers several options for further expansion, e.g. the gradual extension of hall space in coming years. The production program starts with the full hybrid crushing plants; Keestrack B4e (jaw) and H4e (cone), identified to meet the demands of Indian contractors in terms of productivity, transport and on-site mobility. Fully integrated into Keestrack's global R&D, production and logistics network, with four international competence centers in Europe and Asia, Etrack's assembly is based on core OEM modules (crushers, frames, chassis, etc.) delivered from the group's European factories. The local staff of production engineers and qualified technicians shall assemble all plants with components of international technology partners (engines, drives, etc.) or local suppliers. This set-up guarantees shorter lead times and allows full flexibility to comply with technical specifications or individual customer requirements.
Electrifying Market Approach
Entering the Indian market with Etrack Crushers, Keestrack decided to promote its advanced range of hybrid and plug-in processing solutions. Earlier than other suppliers, the Belgium-based manufacturer recognized the conceptual advantages of diesel-electric drives for highly mobile track-mounted plants from 15 to 70 tonnes transport weight, most typical for applications in the mineral aggregates and recycling industries. Starting with partially electrified models, Keestrack added “e”-versions to all its ranges of mobile crushers (jaws, cones, impactors), scalpers, classifiers and stackers.
Today, the majority (80 percent) of the 24 Keestrack models in seven product lines are optionally available as diesel-electric hybrids, most of them (75 percent) providing full-electric “plug-in”-operation. All latest innovations – such as the cone crushers H4e/H6e, jaw crushers B4e/B7e and impact crusher R3e – provide electric drives as key design characteristics, optimizing the important effects of the zero-emission and low noise technology.
Significantly lower energy costs are the most obvious advantage over conventional diesel-hydraulic plants: according to Keestrack savings up to 80 percent can be obtained when operating diesel-electric – with constant low engine revs – or opting for full electric plug-in-operation via external gen sets or accessible mains. In diesel-electric operation hybrids offer additional savings by supplying electricity to secondary e-plants (screeners, stackers) through their external plug-out functionality. Keestrack's concept of using powerful electric motors for the crusher/screener units and the necessary plant hydraulics (lifting cylinders, tracks, etc.) combined with several smaller e-drives for conveyors and ancillary equipment (water pumps, compressor, etc.) provide many other benefits in terms of safety, ease of operation and maintenance, availability and long-term total cost of ownership.
By being able to use a significant smaller hydraulic circuit the reduced oil volume minimizes leakage risks, optimizing the plants' environmental impact and maintenance costs. Reduced running hours of the onboard diesel extends service intervals and increases the resale value. All electric components are directly connected to the plant's PLC controller, which avoids sensor failures (pressure, speed) and allows safe, fully monitored automatic operation even under most demanding conditions. The fully integrated systems also provide a better remote access for service technicians via the remote-monitoring telematics tool Keestrack-er, gives access to real-time comprehensive machine data and makes reporting possible.
Spotlight on Benefits
At Bauma Conexpo India Etrack will highlight its revolutionary full hybrid technology with the Keestrack B4e jaw crusher and the Keestrack H4e cone crusher. Both track mobile models represent the latest generation of diesel-electric Keestrack plants and provide “Plug-in” operation without starting the onboard diesel. The 44-tonne B4e is the midsize-allrounder in Keestrack's jaw range. Equipped with a double-deck vibrating pre-screen (2300 x 1000 mm) and a proven 1100 x 700 mm jaw crusher unit (max. feed size of 600 mm) it provides a capacity up to 400 t/h and perfectly suits various recycling applications or primary crushing solutions in quarrying or smaller mining operations. A productive operation and high-end product standards are guaranteed through the patented N.S.S. release system and the automatic hydraulic gap adjustment, which continuously monitors plate wear. The B4e provides a detachable power module with a 212 kW onboard-diesel combined with a 225 kVA alternator. Positioned remotely from the plant, the running diesel engine and gen set are well protected against dust and vibrations – when working “plug-in”, the whole power module can be removed and stored away. A 110 kW electric motor drives the crusher, a 55 kW e-motor/pump unit supplies the hydraulic drives for pre-screen, tracks, lifting cylinders and other hydraulic components. To optimize productivity the B4e can be optionally equipped with a single-deck post-screen with recirculation conveyor.
With a capacity of 250 t/h in secondary crushing the Keestrack H4e is the perfect match for the B4e. Here also, an optionally detachable power module (328 kW/330 kVA) supplies energy for the electric crusher drive (132 kW) and the separate 45-kW E-motor/pump unit for all hydraulic drives on the plant. The H4e features the KT-H4 cone crusher, adapted and supplied by a world-leading cone specialist. The fully automated unit provides a maximum feed size of 185 mm and allows, with a wide variety of concaves, a high flexibility in secondary or tertiary production of defined end fractions. To optimize production the plant can be optionally equipped with a pre-screen with fines chute and with an efficient three-deck secondary screen module with recycling conveyor for closed-circuit processing. The large dimensioning of the hanging screen (eff. area: 3 x 5.4 m²) and large stockpiling capacities of the conveyors prevent bottle-neck effects in producing up to four highly defined quality end fractions.
Visit Etrack Crushers at bauma Conexpo India 2018 at: Huda Ground, Sector 29, Booth O.C03.