| Place | Client Project | Operational Constraint | Equipment Deployed | Production Gain |
|---|---|---|---|---|
| Arabian Peninsula | Infrastructure Material Supply | Low fixed plant reliability and high internal hauling costs in extreme heat. | SE-1060 Mobile Jaw Crusher for Hard Rock | 40% increase in consistent daily output. |
Al-Joud Mining & Aggregates: The Operating Environment
Al-Joud Mining & Aggregates supplies critical construction materials for major public works in a developing region of the Arabian Peninsula. Their main quarry is situated in an extremely remote desert location, defined by abrasive rock, high silica content, and ambient temperatures exceeding 45°C. The isolation meant that efficient, autonomous operation was a paramount requirement, as logistical support and spare parts were weeks away.
The Problem: Fixed Plant Limitations
The client was reliant on an older, fixed-base crushing system. This setup created severe operational bottlenecks:
- Unreliable Throughput: The fixed primary crusher struggled with the highly abrasive feed material, necessitating frequent, manual adjustments. This inconsistency led to daily output lagging significantly behind project demands.
- Maintenance Crisis: The specialized nature of the stationary plant meant breakdowns often required sourcing components internationally. In this remote setting, minor failures resulted in production halts lasting three to five days—a catastrophic loss of time and revenue.
- High Logistical Expense: Every ton of raw, blasted rock had to be transported via a fleet of heavy-duty trucks from the blast face to the fixed plant. The high-mileage, repetitive hauling cycles consumed excessive fuel and generated high wear on the internal transport fleet, dramatically inflating the cost per ton of finished aggregate.
Al-Joud Mining required a comprehensive solution to increase their aggregate supply by over a third while stabilizing operating costs.
Implementing the SE-1060 Mobile Jaw Crusher
Following a rigorous analysis of the client’s material composition and pit geometry, our engineering team recommended replacing the aging fixed primary system with a robust, high-mobility solution: the SE-1060 Mobile Jaw Crusher for Hard Rock.
The SE-1060 was selected specifically for its capability to address the desert operational issues:
- Hard Rock Durability: Its design included enhanced wear materials, making it highly resilient to the extreme abrasion of the local silica-rich rock, ensuring the machine’s reliability in harsh conditions.
- Tracked Mobility: Being fully track-mounted, the SE-1060 allowed the crushing operation to move directly into the pit, following the active blast face. This strategic mobility directly tackled the internal hauling crisis by reducing the need for extensive site preparation.
- Energy-Efficient Operation: The machine utilized a modern, high-efficiency diesel power unit designed for extreme climates, ensuring a lower cost per ton of processed material.
Deployment Strategy and Execution
The deployment focused on speed and operational self-sufficiency:
- Immediate Commissioning: The track-mounted plant was deployed and made operational in under one week, avoiding the long construction timelines associated with fixed structures.
- Pit-to-Stockpile Flow: The SE-1060’s mobility strategy meant the raw material was crushed at the source, and only the finished aggregate required transport to the final stockpile. This fundamentally reversed the logistics chain.
- Local Expertise Transfer: Comprehensive on-site training was provided to Al-Joud’s engineers and operators, focusing on preventative maintenance schedules and rapid field-level troubleshooting, ensuring autonomy in the remote location.
Operational Performance Data
The introduction of the mobile crushing plant yielded immediate and measurable results that surpassed the client’s production goals:
| Operational Metric | Previous Fixed System | SE-1060 Mobile Plant | Performance Improvement |
|---|---|---|---|
| Consistent Daily Output | Baseline | +40% | 40% increase in production reliability. |
| Operational Uptime | 75% Average | Over 98% | Downtime reduced to near zero. |
| Internal Material Hauling | High Volume (Costly) | Negligible (Near Zero) | Substantial operating cost reduction. |
| Fuel Efficiency | High consumption (per ton) | Optimized consumption | 25% reduction in fuel costs per ton. |
The 40% production increase was sustained by the SE-1060’s exceptional reliability and the elimination of bottlenecks caused by the old hauling logistics. By moving the crushing power to the material source, the client significantly reduced the non-productive transport element, translating directly into higher output and a stronger financial position.
Quote from Client Leadership:
“The fixed plant was costing us project days and profitability. Switching to the SE-1060 mobile system transformed our operation overnight. The machine runs reliably in this heat, and by crushing right at the pit face, we’ve eliminated our single biggest operational expense. We met our target of a 40% production increase, a result we could never have achieved with our old system.”
— Jassim Al-Khalifa, General Manager, Al-Joud Mining & Aggregates
