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McLanahan receives repeat order of its DDC-sizers for Queensland coal mine

Published by , Assistant Editor
World Coal,

McLanahan’s DDC-Sizers have been proven effective for a Queesnland coal mine. The customer has placed its second order less than a year after commissioning the first. With the duplication of the crushing circuit, the site now boasts three McLanahan feeder-breakers and four McLanahan DDC-sizers.


The mine will be processing a maximum of 715 tph of raw coal through the new McLanahan DDC-sizers. The secondary sizer will receive - 250 mm raw coal from the McLanahan ROM coal feeder-breaker, with the final washable product size from the tertiary sizer being a nominal 50 mm. (No screening between stages).

Brad Anstess, Coal Specialist for McLanahan Corporation, stated: “Not only will the customer increase their production, but they will run the equipment in a parallel configuration, that is, having two three-stage crushing modules - ensuring consistency of supply and meeting annual production goals.”


The ROM coal will be delivered into each ROM receival hopper.

Below these receival hoppers, a McLanahan feeder-breaker is installed where it will receive a grizzly-controlled top size of approx. 600 x 600 x 1000 mm.

The feeder-breaker will metre the feed of these large lumps and break them to a nominal 220 x 220 x 300 mm size.

These nominal 220 mm lumps of rock and coal from the feeder-breaker are then processed by the secondary sizer to a nominal 110 mm and then to a tertiary sizer for a nominal 50 mm product ready for washing in the CHPP. 

The sizer assemblies were finalised in April this year and each machine was then prepped for the customer who was invited to the McLanahan Workshop located in Cameron Park (New South Wales). 

Each sizer underwent 3.5 hr of factory acceptance testing. Vibration and temperature were monitored across a range of components including the bearings, motor couplings and gearboxes. Both the secondary and tertiary sizers ran as expected by the customer, with some minor adjustments made upon test completion.

McLanahan Project Manager and Mechanical Engineer, Chris Raines, monitored both sizers for the duration of the factory acceptance tests, and made relevant adjustments to optimise performance on each machine. 

“The McLanahan workshop team took additional care to focus on ensuring roll centre adjustment was accurate as this was important to the client.”

“The customer is very happy with the finished product. Particularly with the design improvements we’ve made over previous machines” said Chris. 

The sizers are awaiting shipment from the McLanahan workshop and are due to be commissioned before 2Q20.

McLanahan equipment was selected for this project because of a combination of attributes that sets our organisation apart from other OEM providers.

Some of these unique attributes include the following:

Local engineering and support

Feeder-Breakers and DDC-Sizers are designed, engineered, project managed and assembled in Australia. Our local service centres are located close to our customers and staffed by highly qualified McLanahan Field Service Staff.

Off-the-shelf spare parts

McLanahan equipment is designed to operate using internationally recognised brands for Bearings, Motors, gear reducers and couplings making it cost-effective and more efficient to source spare parts.

State-of-the-art crushing tooth and segment options

McLanahan crushing segments are easily replaced and can be removed in situ without having to access the underside of the machine. Tooth patterns are also unique offering greater traction for tertiary DDC-Sizers.

Efficient roll and comb adjustment

Whether inward or outward crushing, McLanahan offers efficient roll adjustment and comb adjustment to ensure the integrity of product sizing as crushing segments wear. Feeder-breaker, crushing heads can also be adjusted to account for differential in feed lump size.

Wear components

McLanahan offers bolt in and plug welded liners for both sizers and feeder-breakers with significant access points which make replacement faster and safer. The latest design reduces the number of different wear plates to reduce inventory and improve efficiency. McLanahan also offers a wider variety of crusher tooth and liner material such as chromium carbide and carbide impregnated alloys to ensure extreme life expectancy if the client requires optimum wear rates.

Condition monitoring packages

There are a number of packages available to deliver on board sensing and condition monitoring for both DDC-Sizers and feeder-breakers. These packages range from basic sensing such as zero shaft speed and thermal coupling over loads to more comprehensive instrumentation and data capture.

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