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First CI512 Prisec™ HSI crusher for Russia

World Cement,

Koelga Marble has acquired the first Sandvik Construction CI512 Prisec™ HSI crusher in Russia. Supplied by Sandvik’s Russian distributor, Quarry Service, the CI512 Prisec™ operates 24 hours/day, has improved the cubicity of the end product and increased productivity by up to 50% whilst decreasing noise pollution.

Sandvik Construction recently launched the all new range of CI500 Prisec™ Horizontal Shaft Impact (HSI) crushers. These new generation crushers provide customers with a low capital cost solution, optimum performance and good cubical shape, whilst ensuring the lowest operating cost/t for a wide range of materials and applications. The new HSI crushers possess the ability to be configured into either a primary or secondary crusher operating mode, and with this patented design they provide customers with high adaptability. The CI512 Prisec™ has proved to be particularly successful at improving the product quality and efficiency of one of the world’s largest marble producers in Russia.

First in Russia

Koelga Marble is the biggest producer of marble and related products in Russia, with the company itself being created over 90 years ago. One of the largest in the marble quarries in the world, and the largest in Russia, the marble products produced at the Koelga Quarry are used widely for in building, construction and decoration all over Russia and, increasingly, abroad. The company is a market leader in the production of micro-powders, producing and selling 40 000 t of these materials each month, as well as 25 000 t of various ‘rubble’ fractions. The latter, when crushed, are used in the production of home building panels, or concrete floors with marble chips.

Since acquiring the CI512 in November 2013 the HSI has been in almost continuous operation 24 hours/day. Scheduled and proactive service stops have meant that productivity has increased and operational efficiency maximised as only one operator is needed to supervise the process. Furthermore, the CI512 Koelga Marble has managed to increase the quality of the end product in terms of the cubic shape, and decrease the noise pollution by a significant amount. At the same time the productivity of the production process has increased by 40 – 50%.

Exceptional reduction ratios

The company is now able to produce a consistent 0 – 2.5 mm fraction, which was not possible with its existing cone crushers. This is due to the fact that the Prisec™ crushers can easily produce impressive reduction ratios through the use of two uniquely designed curtains, which have traditionally required a three curtain configuration crusher. As well as enhanced productivity, this means fewer wear parts and reduced maintenance.

Energy efficient overload protection

The CI512 Prisec™ used by Koelga Marble is equipped with an infinite hydraulic curtain adjustment combined with a brake positioning system that relieves pressure and setting when un-crushable objects enter the crusher. No hydraulic power is required during normal operation, thus saving on operating power and reducing total power consumption. Both first and second curtains are infinitely adjustable via Sandvik’s patented adjustment/braking system, which is located on the cross beams of the crusher. This system gives hydraulic adjustment of both curtains via the standard supply electric hydraulic power pack.

Dealing with crusher blockages

Crusher blockages have historically been a problem at Koelga Marble, especially when operating in a primary mode. Removal of the blockage, with the combined downtime and health and safety risks encountered, are now eliminated with the new generation crusher. Due to the features of the CI512, it is not necessary to stop the crusher, with no operator intervention inside the crusher, no heavy lifting gear required, all resulting in maximum uptime and reduced health and safety problems. This allows the Koelga Marble CI512 to be operated by a single person.

Rotor and hammer design

The rotor and hammers can be considered as the heart of the crusher; this is why those used on the Prisec™ range are both robust and efficient. Rotors have superior weight and design, essential for delivering the high inertia required for optimum crusher performance, thus ensuring stability and smooth operation during production. The unique ‘banana’ shaped self-sharpening hammer design helps to keep the contact heads sharper during operation, resulting in more effective shearing of the incoming material and hence improved production.

Easy and safe maintenance

A unique key safety interlock system ensures safe maintenance of the crusher and prevents accidental opening of the crusher and inspection doors even in multiple installations. It also has the ability to raise curtains during operation without stopping the crusher to clear blockages, and re-set automatically to operating setting. This maximises uptime and reduces the need for heavy lifting gear and operator/maintenance intervention, thereby reducing further health and safety risks.

Maximum uptime, maximum breakage

Due to the modularised nature of the Prisec™ range, wear parts can be turned for maximum life/usage with the same size being used across the whole range of crushers. In addition, Sandvik’s technology in the hammer and liner material composition provides options far surpassing the old industry standard of manganese, resulting in even lower operating cost/t and the ability to operate efficiently with a variety of materials.

Customer focused development

Koelga Marble has benefited from the benefits and advantages of the CI512 Prisec™ Horizontal Shaft Impact crusher. Low operating cost/t, improved cubicity of the end product and increased productivity by up to 50%, as well as reduced noise pollution, are provided through Sandvik Construction’s patented technology.

Adapted from press release by

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