Recently, the EP project of a large Russian iron and steel group, designed and supplied by Allis Saga, has been officially commissioned! Join us in this video for an exclusive look at the project site and an in-depth analysis of this landmark China-Russia collaboration, powered by Allis Saga's technological expertise.

·Project Overview·

Russia ranks among the global leaders in mineral reserves, yet its complex geological conditions and harsh extreme cold climate impose particularly demanding requirements on mining equipment.

This is particularly true for the crucial crushing and screening stage, where standard equipment can no longer meet local production needs. There is an urgent need for higher-standard solutions that enhance the operational reliability of equipment under extreme operating conditions, improve efficiency, and achieve cost reduction and efficiency improvement.
 

Through years of exploration and practice in the Russian market, Allis Saga has mastered the key technologies for equipment operation and maintenance in extreme cold conditions. Leveraging rich practical experience in metal mining and aggregate sectors, along with intelligent and efficient crushing and screening solutions, the company has successfully secured orders from multiple large Russian mining enterprises—including the recently commissioned EP project.

In this project, the Allis Saga team was responsible for the design of the production process flow, workshop layout, and construction drawings, while coordinating the supply of the complete set of equipment for the production line.

Project Specifications

Client: One of Russia’s Top 3 Iron and Steel Groups

Project Environment: Extreme cold region (-35℃)

Ore Type: Iron ore

Designed Capacity: 500 t/h

Feed Size: ≤1000mm

Product Size: 0-5/5-20/20-60 mm

Equipment Configuration

Feeding System: PF1541H Pan Feeder & GS1622H Grizzly Screen

Primary Crushing: MJC1411N Jaw Crusher

Secondary Crushing: MHC600 Multi-Cylinder Cone Crusher

Screening: CSA2560T Circular Screen

Other Auxiliaries: GZG130-4 Pan Feeder, Iron Remover, Metal Detector, Robotic Arm Breaker, etc.

·Process Highlights·

01 Pre-screening & Feeding

Before crushing operations, the PF1541H Trough Feeder and GS1622H Bar Screen operate together to pre-remove fine materials with a particle size of less than 100mm from the raw feed. These fines are then sent directly to the secondary crushing workshop. This process significantly reduces the load on the primary crusher, improves crushing efficiency, minimizes the wear of liners and power consumption over long-term operation, and lowers costs.

❖ PF Pan Feeder & GS Grizzly Screen

▐ PF Series Pan Feeder

It features modular vibrators, with each vibrator equipped with double-row bearings and grease lubrication for enhanced operational stability. Its maximum feeding capacity reaches 1,000 TPH, and the maximum feeding size is 1,200mm.

• Used for primary crushing feeding in heavy-duty operating conditions
• Capable of processing highly abrasive materials
• Suitable for feeding wet, sticky, and even frozen ores
• Horizontally installed, applicable in environments with limited vertical space
• Can be used in conjunction with a bar screen for pre-screening
• Adjustable speed and amplitude

▐ GS Series Grizzly Screen

It is suitable for heavy-duty operating conditions, with a maximum feeding capacity of 1,500 TPH and a maximum feeding size of 1,500mm.

• High output, capable of processing highly abrasive materials
• Can be used in conjunction with a PF Trough Feeder
• Modular vibrators installed on the lower side of the machine body, ensuring reliability and durability
• Adjustable frequency and amplitude, delivering excellent pre-screening results
• Secured with anti-loosening Huck bolts to guarantee the overall strength of the frame
• Configurable with wear-resistant plate chutes or steel wire woven screens at the bottom of the bars

02 Primary Crushing

The MJC1411N Jaw Crusher is selected for primary crushing. Designed for heavy-duty operating conditions, it features a compact structure and a high-strength frame, operating reliably in temperatures as low as -35℃. It offers convenient operation and maintenance, along with exceptional stability.

Its maximum production capacity reaches 925 t/h, capable of crushing raw materials with a particle size of 100–1,000mm into materials of 0–225mm.

❖ MJC1411N Jaw Crusher

• Wedge-type discharge opening adjustment system for faster and safer operation
• Dedicated shock absorbers and limit stops for easy installation
• Integrated motor base to save space and costs
• Symmetrical crushing chamber design for larger feed size and reduced bridging
• Larger and more robust eccentric shaft and bearings compared to crushers of the same specification
• Optional centralized lubrication system for safe and convenient operation
• JCIS intelligent control system for remote control, ensuring convenience and safety

03 Secondary Crushing

The MHC600 Multi-Cylinder Hydraulic Cone Crusher is selected for secondary crushing, delivering high crushing efficiency. As a new type of high-performance multi-cylinder hydraulic cone crusher, the MHC series is innovatively designed by Allis Saga integrating advanced technologies. 

It is suitable for the secondary and tertiary crushing of various hard ores and rocks in fields such as metal mining, aggregates, and industrial slag processing. Equipped with the MCIS intelligent control system, it enables remote start/stop, real-time display of operating data, and intelligent diagnosis of abnormal data with graded early warnings.

❖ MHC600 Multi-Cylinder Hydraulic Cone Crusher

• Hydraulic cylinders and accumulators work in coordination to enable quick tramp iron release and prevent blockage
• Peripherally arranged hydraulic cylinders reduce overall height, lowering requirements for workshop height
• Top maintenance design facilitates liner replacement
• Precise discharge opening adjustment controls product size and assist in tramp iron release
• Interchangeable crushing chambers for flexible application adaptation
• High-performance non-contact labyrinth seal improves dust prevention, protects precision parts, and extends lubrication intervals
• MCIS intelligent control system supports remote control for convenience and safety

04 Screening

After crushing, the materials are classified by the CSA2560T Circular Screen. The finished product sizes are 0-5mm, 5-20mm, and 20-60mm. Materials with a particle size larger than 60mm are returned to the MHC600 for re-crushing.

❖ CSA2560T Circular Screen

• Simple design and robust structure facilitate inspection and finished product screening
• Centrally positioned vibrator achieves true circular vibration
• Huck bolt connections (welding-free) enhance safety and reliability
• Adjustable amplitude and frequency meet different processing capacity and screening requirements
• Optional automatic lubrication system, modular screens, and spray devices

·Commissioning Status·

At the project site, all steps of the production line operate smoothly in coordination. The actual capacity far exceeds expectations, and all process parameters meet the design standards, fully demonstrating Allis Saga’s strengths in intelligent and automated technologies.

·On-Site Photos·

#Finished Products#

①Thanks to its superior cold-resistant design, Allis Saga’s equipment has proven highly adaptable to the harsh environments such as extreme cold and permafrost in Russian mining areas. It maintains stable operation even at extremely low temperatures, overcoming common problems of conventional standard equipment like high failure rates and operational limitations under extreme conditions.

②During operation, the production line has demonstrated advantages including high processing capacity, superior product quality, advanced automation, and reliable operation. Its energy consumption is significantly lower than that of conventional standard equipment—a clear validation of the equipment’s reliability and advanced technology, providing solid support for cost reduction and efficiency improvement.

③The CIS intelligent crushing and screening system, independently developed by Allis Saga, dynamically adjusts parameters based on ore hardness and particle size to achieve precise crushing. Its operational efficiency is significantly higher than that of conventional standard equipment.

④Allis Saga’s local service team in Russia delivers comprehensive follow-up support. They monitor equipment operating data in real time, promptly optimize parameters based on on-site conditions, and assist technical personnel in mastering the equipment’s operating principles and operational procedures.

As a long-term partner of multiple major mining enterprises in Russia’s metal mining sector, Allis Saga’s crushing and screening equipment has become essential components for their core production lines.

For this EP project, Allis Saga achieved exclusive end-to-end supply, covering everything from production line design and layout to the complete set of equipment. Before the project launch, the Russian research team conducted an in-depth inspection in China. Eventually, Allis Saga stood out from numerous competitors due to four core strengths:

• European and American technologies meeting international standards
• Globally advanced processing technology and production management system
• Profound experience in the metal mining sector
• Local service team

To address the complex and harsh mining environment in Russia, Allis Saga leverages its rich experience in R&D of equipment for extreme cold operating conditions. From the cold-resistant design to the configuration of intelligent systems, the Company provides customers with customized operation and maintenance plans to ensure the stable operation of the production line under extreme conditions.

The successful commissioning of this project not only serves as a comprehensive verification of Allis Saga’s project management, coordination capabilities and technical strength, but also marks a milestone in its expansion in Russia’s extreme cold mining areas.

In the future, based on the experience gained from this project, Allis Saga will continuously optimize the cold and wear resistance of its equipment, overcome the equipment reliability challenges in various extreme environments, and provide global metal mining customers with comprehensive, efficient and reliable solutions—from equipment supply and production line design to commissioning and operation.