Fully electric mobile crushing and screening plants: key benefits and infrastructure challenges

Although the initial investment for electric equipment is higher, costs are typically recovered within six years or less

By
Slone Fox
September 10, 2024

Environmentally friendly operation is also possible at locations where electricity cannot be supplied due to a lack of infrastructure. Kleemann

All-electric mobile crushing and screening plants offer a sustainable alternative to traditional diesel-powered equipment, significantly reducing on-site carbon dioxide emissions. These plants are becoming increasingly important in the construction and demolition (C&D) and mining industries where low-emission solutions are in demand.

While the initial investment for electric equipment is generally higher than that of its diesel counterparts, companies can benefit from long-term cost savings through reduced fuel consumption.

The initial cost of the machine can also be recovered in approximately six years — even as soon as four years if it's powered by solar panels or a photovoltaic (PV) system. This makes electric-powered equipment a cost-effective choice for operators looking to stay competitive in a sustainability-driven market.

Powered by renewable resources

Tobias Böckle, head of product management at Kleemann, explains that a typical mobile plant set up — a jaw crusher (MOBICAT MC 120 PRO), a secondary cone crusher (MOBICONE MCO 110 PRO), and a screening machine (MOBISCREEN MSC 953 EVO) — consumes around 77 litres of diesel per hour.

The electric version of the plant uses about 302 kW per hour, with a maximum power demand of 542 kW. Böckle emphasizes that the energy supply should ideally come from renewable sources, such as the site's own solar panels or PV system.

"Electrical operation becomes a climate-friendly, cost-efficient concept in just a few years, which not only provides the operating company with monetary benefits but also reflects its efforts towards greater sustainability," adds Böckle.

Comparing diesel vs. electric-powered aggregate processing plants

The C&D and mining industries are witnessing a significant shift towards electric-powered aggregate processing plants, driven by the need for reduced emissions, lower operating costs, less maintenance, and improved safety.

Diesel-powered plants have been the traditional choice for aggregate processing, but these machines come with significant drawbacks: they emit high levels of greenhouse gases, contribute to climate change, and require regular maintenance to ensure optimal performance.

In contrast, electric-powered plants offer a cleaner and more efficient alternative, as well as offering a competitive edge by enabling emissions-free operations in areas where stringent emissions standards apply. Electric plants also enhance safety by eliminating the risks associated with handling and storing diesel fuel.

Electric-powered plants offer long-term savings

Electric-powered plants, though initially more expensive due to specialized equipment, transformers, and cable requirements, provide significant long-term savings. By reducing reliance on fossil fuels, companies benefit from more stable energy costs, especially when paired with renewable energy sources.

On the flip side, diesel-powered aggregate processing plants require minimal infrastructure investment beyond fuel costs, which vary by region. Savings from switching to electric plants depend largely on the price difference between diesel and electricity in the operating area.

Battery swapping systems and quick recharge capabilities are key

In locations with limited infrastructure, electric plants can operate in combination with renewable energy sources. Battery swapping systems — where a depleted battery is replaced with a fully charged one — can further enhance the efficiency of electric plants. Quick recharge capabilities are also essential for maintaining productivity.

Notably, Kleemann's electric plants can also be run autonomously using sustainable HVO diesel, providing flexibility and further reducing environmental impact.

An overview of the switch from diesel to electricity. Kleemann

The importance of designing electrical infrastructure in advance

Tobias Möß, head of technical consulting for Wolff & Müller, emphasizes the importance of planning infrastructure carefully to ensure efficient energy use. He suggests that companies should first assess the energy demands of both the new plant and any existing equipment before making any decisions.

"How much power is needed on the entire company premises? The load profile must also be taken into account," says Möß. "When are the power peaks, and when are the times with lower consumption? The individual load profile can be obtained from the power supplier or network operator."

Transformer capacity and a reliable, efficient power supply

Many companies operating mobile crushing and screening plants already have transformers on site that adapt voltage to the required levels, such as low voltage for plant operation. Once you calculate the power requirements for your electric crushing and screening equipment, it's essential to ensure the existing transformer is adequate. Check the transformer's type plate to verify if it delivers sufficient power.

Having a complete line of power solutions ensures that companies can adapt to various voltage requirements efficiently.

Location of power distribution

Efficient operation also depends on the location of the main power distribution and where the plant is used. Strategic planning can lead to significant reductions in maintenance costs. For example, instead of transforming energy to low voltage at the transfer station, routing it across the site via medium-voltage cables is more cost-effective and manageable. A secondary transformer near the mobile plant can then convert the current to low voltage, powering the equipment.

Developing a tailored energy solution

Creating a custom energy concept is key when using electric-powered crushing and screening plants in applications like mining and C&D. Expert support and tailored solutions are crucial for optimizing energy efficiency and reducing costs, too.

Key considerations for buying electric mobile crushing and screening equipment

What is the current power demand for existing equipment?
What power requirements will the new electric mobile crushing and screening plant have?
How much total power is needed across the entire site?
When do power peaks occur, and when are there periods of lower consumption?
Is the existing transformer adequate for the new plant's power needs?
Where is the main power distribution located, and where will the new plant be installed?
Is a battery-swapping system needed?

Understanding the key components of electric crushing and screening plants

Electric aggregate processing plants consist of several key components, including electric motors, gearboxes, and control systems. The electric motor is the heart of the plant, providing the power needed to drive the processing equipment. Gearboxes are used to transmit power from the motor to the processing equipment, while control systems monitor and regulate the plant's performance.

When selecting electric plant components, it is essential to consider factors such as power rating, efficiency, and reliability. The power rating of the motor and gearbox must be sufficient to handle the processing demands of the plant, while efficiency is critical to minimizing energy consumption and reducing operating costs. Reliability is also crucial, as downtime can result in significant losses.

By choosing high-quality, reliable systems, operators can enable the continuous and efficient operation of their electric plants.

Optimal plant performance

To ensure optimal performance of electric aggregate processing plants, several considerations must be taken into account. A reliable power supply is essential to ensure continuous operation of the plant. This can be achieved through connection to the grid or on-site power generation.

Cooling systems are also vital, as electric motors and gearboxes generate heat, which must be dissipated to prevent overheating and reduce the risk of failure. Cooling systems like air or water cooling can be used to regulate temperature.

Regular maintenance is critical to ensuring optimal plant performance. This includes routine inspections, lubrication, and replacement of worn parts. By maintaining reliable systems and addressing heat management, operators can maximize the efficiency and longevity of their electric plants.

Operational efficiency and productivity in mining and C&D

Electric aggregate processing plants offer several opportunities to enhance productivity and reduce operating costs. One key area is the use of advanced control systems, which can optimize plant performance and reduce energy consumption. These systems can monitor and regulate the plant's performance in real time, making adjustments as needed to ensure optimal operation.

Another area is the use of electric motors with high-efficiency ratings, which can reduce energy consumption and lower operating costs. Additionally, electric plants can be designed with modular components, allowing for easier maintenance and reduced downtime. This modularity not only simplifies the replacement of spare parts but also ensures that the plant can quickly return to full operation after maintenance.

Overall, electric aggregate processing plants offer a cleaner, more efficient, and more productive alternative to traditional diesel-powered plants. By understanding the essential components and considerations for optimal plant performance, operators can unlock the full potential of electric equipment and reduce their environmental footprint. Embracing electric systems not only aligns with sustainability goals but also provides long-term economic benefits through lower costs and enhanced operational efficiency.