SANDVIK/MÄRKER

Lime white in the shadow of the castle – for generations!

In the very shadow of Burg Harburg castle, located on the “Romantic Road” and along the picturesque banks of the River Wörnitz, some 300 employees work at Märker Group’s headquarters plant. The castle complex, one of southern Germany’s largest, oldest and best preserved, is first mentioned in twelfth-century documents, whereas August Märker founded his company in 1889 – exactly 125 years ago. The then young enterprise has now become firmly established as a self-sufficient and independent group producing cement and lime in Bavaria and Baden-Württemberg, its member companies dependable partners for the construction, steel, chemicals and paper industries, for environmental protection, and for agriculture, forestry and fish-farming. Investments in the future have been made at Harburg, to ensure that this success continues and that the group remains competitive alongside globally present corporations. One stone in the mosaic of the group’s success is the CR810 Hybrid double-roll crusher, produced by Sandvik, a steadfast and highly competent partner looking back on more than 150 years of industrial history.

Replacement of the previous crusher used in limestone preparation was scheduled during the 2013/2014 scheduled winter shut-down; the Sandvik CR810 Hybrid was included on the shortlist. Thanks to more than twenty years of satisfactory and uncomplicated cooperation with Sandvik, the machine was viewed well in advance in Switzerland, and tests performed in Belgium using Märker material. This empirical data was then used for detailed planning. The challenge, in addition to reducing undersized particles, was found in physically incorporating the high-performance crusher into the existing plant arrangement.

After due consideration of all the pros and cons of the various alternative suppliers, the decision was taken in favour of Sandvik and the CR810 ­Hybrid. “We were convinced not only by the crusher’s compact design, in relation to its performance, but also by the flexibility resulting from hydraulic gap adjustment and this crusher’s minimisation of the fines fraction”, notes Reinhold Ackermann, CEO at Märker Kalk GmbH. “Our target is a crusher throughput of 300 t/h”, adds Stefan Mahl, Lime/Cement process engineer and responsible for implementing the project, which was completed in July, 2014.

The structural-steel and modification work was completed, along with installation – including prior dismantling work – in close co-ordination with August Müller, of Rottweil, in quick succession within the available nine-day period, and the double-roll crusher was then commissioned. Material for crushing is fed on a single-shift basis into the CR810 Hybrid, crushed between the contra-rotating rollers and thereby comminuted primarily by compressive forces. The two crushing rolls are each individually driven by an electric motor, via a coupling and gearing system. An efficient hydraulic gap-adjustment system and an integrated overload protection system ensure that a range of particle-size fractions can be systematically produced, and eliminate damage to the machine caused by foreign bodies in the feed material.

“The easy and fast adjustability of the gap for attainment of the targeted product particle-size is one of the outstanding properties of this Sandvik crusher”, comments Stefan Mahl, drawing an initial balance. “It is a nicely completed project! The machine meets all our requirements and expectations, and we are extremely satisfied”, is Reinhold Ackermann’s conclusion. “And we also greatly appreciate Sandvik’s short reaction times if we have questions or need service”.

In addition to the new double-roll crusher, a Sandvik drilling unit has also been in use in the group’s quarry since 2007. With total dependability: Hole after hole after hole!

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