Quarry Jun 2019

What are the three most important aspects of screen performance?

PORTABLE SCREEN BOOSTS THE BIG BOY QUARRY

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RUNNING YOUR SCREENS AT OPTIMUM CAPACITY

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OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

What does an operation do when its best saleable products are buried in tonnes of sand?

JUNE 2019

MOBILE SCREENS EXCEL IN ALLUVIAL DIAMOND MINING How six mobile screens have ‘kicked goals’ deep in remote diamond mining regions.

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IN THIS ISSUE JUNE 2019

VOLUME 27, ISSUE 06

FEATURES 26 OEM EXPANDS GLOBAL MINERAL PRESENCE A screening and washing systems provider has established a new product brand channelling its expertise across three continents.

32 MOTORBASE SOLUTIONS FOR SCREEN DRIVES Richard Sharp outlines the best drive options for vibrating and incline screens.

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SCREEN OPTIMISATION What are the three most important aspects of screen performance today?

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BOOST FOR ‘BIG BOY’

38 EIGHT REASONS TO USE DEWATERING SCREENS

A portable vibrating screen has alleviated an operation’s suffering production rates.

Why dewatering screens are recommended for drier, cleaner and ultra-fine products.

40 SAND PRODUCER MEETS GOALS WITH HYDROSIZER A supplier of turf to world-famous sporting events acquires a new plant for more efficient, cost-effective cuts.

42 PRODUCING SPAWNING STONES FOR TROUT A mobile screen has proven its versatility with an unusual contribution to the freshwater environment.

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MOBILE ‘GEMS’ Six mobile screens ‘kick goals’ in South Africa’s alluvial diamond mining industry.

What are the three most important aspects of screen performance?

PORTABLE SCREEN BOOSTS THE BIG BOY QUARRY

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RUNNING YOUR SCREENS AT OPTIMUM CAPACITY

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16

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

What does an operation do when its best saleable products are buried in tonnes of sand?

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ELECTRIC INNOVATIONS Supplier showcases nine electric-powered processing plants at bauma 2019.

46 MANAGEMENT INTELLIGENCE Effective two-way communication is the answer to encouraging best performance in an operation and workforce. Mike Cameron explains.

JUNE 2019

MOBILE SCREENS EXCEL IN ALLUVIAL DIAMOND MINING How six mobile screens have ‘kicked goals’ deep in remote diamond mining regions.

COVER ADVERTISER: The “compact with impact” EvoQuip Cobra 230 is suitable for primary, secondary and tertiary crushing. It has a 2.6m3 hopper size, and features a twin apron screen with variable speed drive.

Visit: triconequipment.com.au

EVERY MONTH 04 FROM THE EDITOR

50 IQA CALENDAR

06 FROM THE PRESIDENT

52 IQA NEWS News from NSW, Queensland, and Western Australia

08 NEWS THIS MONTH 14 PRODUCT FOCUS 49 FROM THE IQA CEO

50 GEOLOGY TALK Poop sand happens!

Quarry June 2019 3

EDITORIAL

’FISHING’ FOR SOLUTIONS TO THE ENVIRONMENTAL CONUNDRUM

W

hether you agree with the science or not, climate change and the environment were prominent issues in the recent federal election campaign. Despite the strong result in the Morrison Government’s favour, they figured consistently among voters in polling across five weeks.

In the last 10 days of the campaign, the United Nations released a global biodiversity and ecosystems assessment report. It warned that up to a million species are endangered and threequarters of land globally has been significantly altered. The study by more than 450 scientists and diplomats also asserted that humans, by reducing the fertility of land, are making themselves vulnerable to disease, drought and other climatic conditions.

While quarrying was not specifically mentioned by name in the report, “unsustainable practices” in mining, forestry and agriculture were attributed to the decline of the world’s ecosystems.

Governments were encouraged to address this through reviewing and renewing agreed environment-related and evidence-based international goals and “mainstreaming biodiversity and sustainability across all extractive and productive sectors, including mining, fisheries, forestry and agriculture”.

If you have any doubts that nature and society are interdependent, I refer you to two stories in this issue. Bill Langer (page 54) discusses the contribution of the parrotfish to natural sand that is an important building block. However, page 42 also shows the positive impact an extractive operation can have on the natural environment – a crushing contractor is using a mobile scalper to provide spawning stones in freshwater courses for an endangered trout. The stories are examples of nature aiding and abetting quarrying – and vice versa!

It could also be reasonably argued the quarrying industry contributes to replenishing the diminishing environment.

As much as the industry complains of “red” and “green” tape, environmental 4

Quarry June 2019

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approvals across Australia’s jurisdictions are among the most rigorous, evidencebased in the world, and quarries today undertake to protect neighbouring natural habitats for flora and fauna, including many native species.

Quarries must also gradually repurpose land for the benefit of future generations.

In Victoria’s Bellarine Peninsula (page 8), Adelaide Brighton is involved in transforming a century-old quarry into a freshwater lake that will become a significant link to three other waterways.

By the time the lake is complete it will be a popular spot for human and animal activity, in much the same way that other quarries are being repurposed worldwide as wetlands and wildlife havens. Hanson in the UK is very active in this space, and its parent company HeidelbergCement awards annual grants (the Quarry Life Awards) for biodiversity projects in quarries globally.

Can we – as humanity in general and quarrying in particular – do better?

Probably. It’s the age-old environmental conundrum, isn’t it? How do we satisfy the hunger for resources from burgeoning populations against limiting the impact on nature?

The escalation of Australia’s urban population has pushed the industry further into fertile regions for quarrying reserves. It’s all about how those reserves are extracted without irreparably destroying the local environment and unravelling the social fabric. That’s where a responsible approach to sustainability, in concert with regulators, and embracing of new technologies is vital. It strips away the industry’s many myths (as Clayton Hill related last month) and shows quarries are trustworthy corporate citizens.

The UN report indicates that a “business as usual” approach isn’t enough. By adopting a triple bottom line model, quarries can be role models in sustainability without impacting profitability.

DAMIAN CHRISTIE Editor

Official publication of the Institute of Quarrying Australia Publisher Coleby Nicholson Associate Publisher Angela Han

IT’S THE AGEOLD DILEMMA: HOW DO WE SATISFY THE HUNGER FOR RESOURCES AGAINST IMPACTING NATURE?

Editor Damian Christie damian.christie@quarrymagazine.com Journalist Tim Robertson tim.robertson@gunnamattamedia.com Advertising Sales Toli Podolak sales@quarrymagazine.com

Quarry is published by: Gunnamatta Media Pty Ltd Locked Bag 26, South Melbourne, VIC 3205 AUSTRALIA Phone: +61 3 9696 7200 gunnamattamedia.com info@gunnamattamedia.com Design & Production Manager Jo De Bono art@gunnamattamedia.com Accounts Paul Blewitt finance@gunnamattamedia.com Subscriptions info@gunnamattamedia.com Press releases damian.christie@quarrymagazine.com Copyright: All material appearing in Quarry is subject to copyright. Reproduction in whole or in part is strictly forbidden without prior written consent of the publisher.

Disclaimer: The views and opinions expressed by authors are not necessarily those of the publisher. All statements made, although based on information believed to be reliable and accurate at the time, cannot be guaranteed and no fault or liability can be accepted for error or omission.

Gunnamatta Media Pty Ltd strives to report accurately and fairly and it is our policy to correct significant errors of fact and misleading statements in the next available issue. Any comment relating to subjective opinions should be addressed to the editor where the opposing position may be published to encourage open debate.

The publisher reserves the right to omit or alter any advertisement and the advertiser agrees to indemnify the publisher for all damages or liabilities arising from the published material.

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PRESIDENT’S REPORT

IQ CONNECT TO PROMOTE GLOBAL GROWTH, OPPORTUNITIES The Institute of Quarrying Australia

I

recently had the pleasure of representing the IQA at the Institute of Quarrying Southern Africa 50th annual conference and International Presidents’ Meeting in Durban, South Africa.

The opportunity to liaise with our international peers is one I look forward to and have put much energy into since being elected chair of the International Presidents Council in 2018.

There is great consensus that we are stronger as an international group, and my focus in leading the council has been to assist in ensuring we get leverage from being an internationally affiliated group, providing networking opportunities and moving towards setting standards of education and competence globally for our industry.

During the conference, the international presidents participated in a panel session (now a common event when attending affiliated conferences as a group) to discuss global issues facing the industry. We were each asked to respond to a number of questions: • How is each Institute of Quarrying (IQ) attracting the next generation to the industry?

• What competencies and training did each IQ provide for improvements in skill and competence, and as a pathway for career development?

While we have a changing and often challenging legislative landscape with regards to competency requirements across the country, we are well advanced in supporting the next generation of members and industry participants through our Young Members and Women in Quarrying networks, and our training packages and relationships with industry-relevant training providers.

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It was encouraging to hear we are at the forefront of training and attracting people to our industry and valuable to hear from the other countries as to their environments, including South Africa’s proposed changes to its mining legislation and competencies.

The international group has been working on harnessing the global pool of training content to assist each IQ, and also as part of its global expansion aspirations.

In previous issues of Quarry I have spoken about the e-branch initiative of the International Presidents Council, which now has support and agreement on establishment. It is to be known as IQ Connect.

It is a digital platform that will give quarrying professionals in other nations without a physical IQ access to professional development, technical forums and industry relevant information.

Following my term as international chair, I have been requested by the international presidents to remain involved with this initiative and have accepted the role as chair of IQ Connect.

I’m looking forward to seeing this exciting project come to fruition and to continuing my contribution to the industry. Further information on IQ Connect, which will be available to IQA members, will be provided later this year.

Have a safe and productive month ahead!

CLAYTON HILL President Institute of Quarrying Australia

Educating and connecting our extractive industry

quarry.com.au IQ CONNECT WILL GIVE QUARRYING PROFESSIONALS IN OTHER NATIONS ACCESS TO PROFESSIONAL AND TECHNICAL DEVELOPMENT PROGRAMS

The Institute of Quarrying Australia’s goals are: 1. To provide world class professional development for the extractive industries.

2. To establish an Australasian Academy of Quarrying.

3. To align service offerings with industry needs.

IQA CONTACTS: Chief Executive Officer Kylie Fahey PO Box 1779 Milton BC QLD 4064 Phone: 0477 444 328 ceo@quarry.com.au Company Secretary Rod Lester Phone: 0408 121 788 rgl@rlester.com.au Finance Officer Gemma Thursfield Phone: 0402 431 090 gemma@quarry.com.au Web Maintenance, Graphic Design, ePrograms, IT Support Ryan Spence Phone: 0422 351 831 ryan.spence@quarry.com.au General, membership and financial inquiries should be directed to admin@quarry.com.au or phone 02 9484 0577.

A brief introduction to Montabert’s V3500/V4500 two-speed breakers Montabert breakers are renowned throughout the quarrying and civil construction industries for their innovative design, low operating costs, and high productivity.

Two models ideally suited to quarrying applications – whether mounted on an excavator for in-pit rock breaking, or pedestal-mounted for breaking oversize materials before they enter a crusher – are the V3500 and V4500 two-speed breakers.

They offer two operating speeds with automatic selection: high energy for breaking hard materials and high frequency for softer materials.

They are specifically engineered to provide high energy per blow, surpassing the performance of other rock breaker brands in their class.

Both the V3500 and V4500 are equipped with a heavy-duty housing, the lower part of which is protected with steel wear plates and incorporate soundproofing as standard.

The V3500, with an operating weight of 3500 kg and a 175 mm tool diameter, is designed for carriers from 35 to 60 tonnes.

The V4500 has an operating weight of 4500 kg, a 190 mm tool diameter, and suits 45-80 tonne carriers.

Montabert has always had a strong commitment to offering high productivity, along with enhanced performance and reliability.

Both the V3500 and V4500 achieve these through some innovative solutions such as Montabert’s patented automatic frequency adaptation system – which delivers from the first blow – and a diaphragm accumulator that does not need to be refilled on a regular basis.

In addition, both units have an energy recovery system which increases the strike power using the energy generated by the piston rebound – a feature which is particularly effective on very hard material.

A number of features on both the V3500 and V4500 contribute to longer lasting protection across all aspects of operation.

They include blank firing protection, which helps extend the lifespan of the carrier, breaker, tool and retainers, as well as reinforced suspension that absorbs vibrations transmitted to the carrier, providing added boom protection.

Montabert dealers are specialists who put their breaker expertise at your service, offering advice to help achieve the best performance and to optimise breaker operating costs and lifespan.

Montabert’s commitment to customer service ensures technical support is close at hand to assist with initial breaker set up, operator and maintenance training, and aftermarket support. Our success is driven by the success of our customers.

For more information please contact your nearest Montabert dealer

Luke Preston: 0408 135 984 | montabert.com

NEWS

SITE TO BE TRANSFORMED INTO A FRESHWATER LAKE ‘WE WANT TO LEAVE SOMETHING BEHIND FOR FUTURE GENERATIONS’

BEFORE

BILL MCCANN AFTER

new lime and fine sand resources markets. “Batesford Quarry limestone” is a soft, friable material, with a high percentage of calcium carbonate, that was formed from an ancient coral reef up to 20 million years ago.

Since 2001, the limestone has been quarried and split into agricultural lime, mining lime and mineral addition.

Batesford Quarry also produces fine sand products, thanks to the sand deposits beneath the limestone.

The Victorian Government, the McCann family and ASX-listed aggregates and cement producer Adelaide Brighton have developed plans to rehabilitate the quarry.

Before: Batesford Quarry, as it is today. Image courtesy of The Geelong Advertiser.’ After: What the quarry may look like once the proposed lake meets its depths. Artist impression courtesy of bay939.com.au

The century-old Batesford Quarry, near Geelong, Victoria, will become a large freshwater lake.

Pumps are being used to keep the site dry for works but they will soon stop, allowing the quarry to fill with lime-filtered groundwater. It is estimated the quarry will take several years to reach its final depth.

Under the rehabilitation plans, the lake will be 30m deep, 164ha in area, 5km in perimeter and hold 48 billion litres of water. Once filled, it will be more than twice the size of Mount

Gambier’s Blue Lake. The future lake and surrounding green spaces will become part of a link to three local waterways: the Barwon and Moorabool Rivers and Cowies Creek.

The McCann family first established the quarry in 1888 as a source of limestone for cement manufacturing works near Geelong. Over its life, more than 100 million tonnes of limestone and overburden were excavated from the quarry.

When cement production ended in 2001, Batesford Quarry established

Adelaide Brighton will manage the rehabilitation until the water level is fully recharged. It will also design some edges of the lake for recreational access.

“Adelaide Brighton and our partners would like to ensure that following completion of rehabilitation, the quarry site can be an asset for the enjoyment of the Geelong residents and visitors,” Adelaide Brighton chief executive officer Nick Miller said.

Bill McCann told the Geelong Indy that his family had enjoyed the area along the river for generations. “We would like to leave something behind that future generations of people can continue to use and enjoy,” he said. •

FEEDBACK SOUGHT ON LAND NEAR INDIGENOUS QUARRY The Wagga Wagga City Council (WWCC) is undertaking community consultation on plans to develop an area of council-owned land adjacent to the Bomen Axe Quarry.

The Bomen Axe Quarry is of cultural, spiritual and historical significance to the Wiradjuri Aboriginal people in Wagga Wagga, New South Wales. Stone axes were manufactured there and it is held in high esteem because of the insights it provides into past Wiradjuri stone tool technology, Aboriginal trade routes and land management practices.

The council is seeking feedback on how it can use the site to further protect significant artefacts, provide cultural education facilities and promote tourism opportunities.

“There is currently approved funding available through the [NSW] Office of

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Quarry June 2019

Environment and Heritage to enhance the council-owned land adjoining the Bomen Axe Quarry, which was applied for by a member of the local Wiradjuri community,” the WWCC’s city strategy manager Tristan Kell told Quarry.

“The project will include extensive native plantings, an access path, interpretive signage, shelter construction for a Scar Tree and seating area as well as a simulated demonstration area for tool making,” Kell added. “This public space will be available to the Wiradjuri nation and broader community for cultural purposes, education, tourism and celebration of our indigenous heritage.”

The WWCC is seeking community suggestions on the concept plans. “Once the concepts for the site have been

Hammerstones from Bomen Axe Quarry.

finalised, council will contribute funds for the Scar Tree shelter, as per the Riverina Intermodal Freight and Logistics Hub project plans and the approved Aboriginal Heritage Impact Permit,” Kell said. •

PRODUCER TO APPEAL ‘DISAPPOINTING’ DECISION Barro Group has appealed the Sunshine Coast Council’s (SCC) decision to refuse a planning application to expand its operations at Burrum Quarry, 60km north of Brisbane. The company had applied to extract more than one million tonnes of materials per annum from the 23ha site in Beerburrum, near the Glass House Mountains.

Ian Ridoutt, the Queensland general manager at Barro Group, said the hard rock quarry has the capacity to supply construction materials to meet the local community’s growing needs.

In 2017, 60.5 per cent of the SCC population lived in the southeast corner of the Sunshine Coast, which has a land area of just 13.5 per cent of the council’s total territory.

It is estimated that by 2031, this population rate will rise to 83 per cent.

To deal with this growth, the SCC has endorsed the Regional Economic Development Strategy, which includes significant investment in infrastructure development.

Ridoutt believes Burrum Quarry should be part of this planning. “What I tried to show the councillors was that they have ... a good plan, but they have to actually resource that plan, otherwise they get dysfunctional effects,” he told Quarry. “There’s a shortfall [of hard rock products in the local area] at the moment and the demand is about to increase.”

He pointed out that Hanson’s Glasshouse Quarry, which is only 6km away, had to stop sales for several weeks before Christmas last year because it had reached the threshhold it was permitted to despatch under its consent terms.

In that period, material had to be brought in from distant locations.

“If that happens in the longer term, then the cost of infrastructure, housing and all development goes through the roof,” Ridoutt said.

The only other local quarry supplying hard rock products to the southeast corner is Holcim’s Sunrock Quarry which, Ridoutt said, is “very busy”.

Cr Rick Baberowski said the council’s decision to refuse the planning application was based on information that existing Sunshine

COST ESTIMATES REVEALED FOR SAND PROCESSING PLANT The ASX-listed VRX Silica Ltd (VRX) has received an independent design, engineering and cost estimate for a processing plant at three silica sand projects north of Perth.

CDE Global has undertaken the independent processing test work, circuit design and engineering.

Ian Ridoutt says there is a shortfall of hard rock products on the the Sunshine Coast.

Coast quarries are licensed to extract 6.65 million tonnes of product a year, yet are extracting between two million and three million tonnes per annum.

Ridoutt dismissed this reasoning as disingenuous. “While that may be the available extraction, some of those quarries can’t supply to those markets. Some of them are a long way away from the southeast corner markets.

“Some of them haven’t got plant and equipment capable of extracting to those types of limits or don’t have the quality of materials. That adding up of theoretical capacity doesn’t give you the right information for that particular market area … [where] there is already a shortfall.”

The assessment process – from the time it was lodged to the day of the council’s decision – took 28 months.

At the end of that process, council planning officers recommended that councillors should approve the development with conditions.

Ridoutt said the ruling was “disappointing”. He pointed out the site is a key resource area and has been nominated as “an important resource for the future development of Queensland”.

He conceded it is very difficult to get approval for extractive projects, which is compounded by the fact that there are local council elections next year.

“I think we’ve got caught up in politics again,” Ridoutt said. “The community need quarry products and the associated local economic and employment opportunities but the decision-makers don’t want to take responsibility for approving extractive projects, it is easier to leave the those decisions to courts.” •

Three iterations of test work have been carried out on the Arrowsmith North and Central and Muchea projects, 270km and 50km north of Perth respectively. According to VRX, the attritioning cycle has been effective in removing impurities from the quartz grains.

VRX personnel have reported that the plant design for the production of a high purity silica sand product is suitable for the glass-making industry. CDE Global estimates that the cost of constructing the modular two million tonne per annum processing plant will be about $18.2 million.

According to VRX, estimates costs for the plant feeder, water supply and contingency will increase the total capital cost for a processing plant to about $25 million. Further testing will finalise the requirements for the magnetic separation component but this will not materially affect the costs.

The processing plant will wash, screen and attrition sand and remove heavy minerals to create a final product. It includes a thickener that will recycle up to 95 per cent of process water.

VRX Silica will assess various options for associated production and shipping requirements at its projects. It will finalise bankable feasibility studies for all three projects in the September 2019 quarter. •

VRX Silica has commissioned CDE Global to design a 2mtpa sand processing plant.

Quarry June 2019 9

NEWS

HISTORIC GRANITE SITE COMES FULL CIRCLE IN NEW PROJECT A quarry that famously supplied pink granite for the pedestal of the Statue of Liberty has been reenlisted to supply the stone for a new museum honouring the monument.

Stony Creek Quarry in Branford, Connecticut, has been contracted to provide its unique pink granite for the $USD70 million ($AUD99m) Statue of Liberty Museum, with its stone used in the construction of walkways, staircases and seating.

Stony Creek granite, which was first quarried in 1858, is part of a Mesozoic era deposit formed between 225 million and 650 million years ago. It was first excavated for the Statue of Liberty pedestal in 1884, before later providing the foundations of other iconic New York landmarks, including the Brooklyn Bridge and Grand Central Station.

For the 2415m2 museum project, Stony Creek supplied about 450 tonnes of pink granite. It cut the raw blocks — typically 25 tonnes each — before passing them over to the North Carolina Granite Corporation, which has formed the architectural cut-to-size product for cladding and paving.

While project leaders considered sourcing cheaper granite, Stony Creek’s historic association with Liberty Island eventually ensured it secured the contract.

Nicholas Garrison, from the project’s managing company FXCollaborative, said the stone was the optimum choice, containing flecks of quartz and feldspar. “It’s just very beautiful, clean. It really takes on different colours depending on how it’s cut,” he said. •

xxx Stony Creek Quarry granite features heavily in the Statue of Liberty Museum.

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INNOVATIVE RACING SURFACES UNDER THE SPOTLIGHT IT MIGHT SEEM IMPLAUSIBLE BUT SYDNEY HARBOUR BRIDGE COULD HOLD A RACE MEETING!

A Victorian horseracing track will be revamped with new turf over a course of sustainable asphalt – as elsewhere a “pop-up” track is floated for Australia’s most iconic overpass.

Alex Fraser Group is completing works at Melbourne’s Flemington Racecourse to provide sustainable solutions to the track redevelopment.

Working with the Victoria Racing Club’s principal contractor, T James & Son Constructions, Alex Fraser Asphalt initially profiled 10,000 tonnes (correct weight) from the track.

The profiled material was then recycled and stockpiled for use in the new track, providing the most sustainable outcome for the project.

An open graded asphalt is now being laid. This porous asphalt mix is formulated to provide large voids (in excess of 20 per cent) to provide better drainage and improve the safety for horses and riders. Once the sustainable asphalt is complete, a rubber compound will be laid on top to provide a safe and durable training track for the horses.

“We’re very happy to be working with T James & Son Constructions again, on such an interesting project,” Alex Fraser’s profiling manager Andrew Barbara said. “It’s great to hear from our customers that we’re winning their jobs because of our customer service, quality and reliability.”

Flemington Racecourse isn’t the only iconic piece of turf to be recycled within Australia. It might seem implausible but Sydney Harbour Bridge could potentially hold a race meeting. Racing NSW will reportedly meet with representatives of English events company City Racing in the next couple of months to discuss the possibility.

Peter Phillips, the grandson of Queen Elizabeth II, has been planning the street-racing concept for the past couple of years. He had the idea after staging an equestrian event on a similar surface on Horse Guards Parade in London.

He told BBC News that the event demonstrated how safe “pop-up” conditions for horses in a competitive environment could be installed and removed within three days. Working

Alex Fraser Asphalt is involved in resurfacing the track at Flemington Racecourse.

with equine surface manufacturers Andrews Bowen, a successful trial was held at Aintree racecourse in November 2018.

A special synthetic surface would be laid on the streets, topped with a thick layer of sand to withstand the weight of thoroughbreds racing at speed.

“The surface has been rigorously tested and the feedback from jockeys and trainers has been positive,” Phillips told the BBC. “We are dealing with horses who are athletes and injuries happen but we have to make sure we put all the checks and balances in place.

“Equine safety is paramount. We have a veterinary advisory board and a gold standard welfare framework.”

Phillips said the track, surface, sub-layer and railings would all require sanctioning from the British Horseracing Authority.

France Galop, the governing body of flat and steeplechase horse racing, is understood to have a working date of 16 September for a race meeting on the Champs-Elysees in Paris.

It’s understood that Racing NSW doesn’t want to be the first to use the synthetic paletted racing surface.

The track will have to be used somewhere else in the world before the NSW racing authority commits to holding a race meeting and seeking the approvals from various levels of government. If Paris held a meeting it would accelerate Racing NSW’s involvement.

The Harbour Bridge event would almost certainly be held under lights and be proposed as a six-race meeting. •

NEWS

MULTIMEDIA EXHIBITION ILLUMINATES INACTIVE QUARRY A former limestone quarry in Les Baux-de-Provence in southern France has been transformed into an immersive multimedia exhibit space dedicated to art and music.

The Carrières de Lumières (Quarries of Lights), as it’s now known, ceased operations in the 1930s, after demand declined following the First World War. In the 1960s, the French filmmaker Jean Cocteau was so entranced by the site’s beauty that he made it the setting for his cinema masterpiece The Testament of Orpheus.

In 2012, the town of Baux-deProvence entrusted Culturespaces, a global producer of temporary exhibitions and artistic projects, with the management of “digital art centres” at the quarry. Projectors mounted around the quarry paint the walls, ceiling and floors with light, bringing both still and animated images of artwork to life across the entire space. The digital exhibitions at the quarry receive more than 500,000 visitors each year.

Recent exhibitions have included immersive exhibitions of some of the most iconic artists and periods: French impressionism; Italian Renaissance; the Dutch masters; the Spanish masters; and, recently, Vincent van Gogh. •

ELECTRIC INNOVATIONS ON SHOW AT BAUMA 2019 THE ELECTRIC POWER TREND IS STRONGER IN URBAN-BASED MACHINES

The bauma 2019 construction and mining machinery exhibition in Munich, Germany, broke plenty of attendance and exhibitor records.

The trade fair, from 8 to 14 April, attracted more than 620,000 visitors from 200 countries, and 3700 exhibitors from 63 countries.

According to show organisers, there was a significant rise in overseas visitors, particularly from China, Japan and Australia.

The exhibition filled 614,000m² of the Munich fairgrounds, making it the largest ever in terms of floorspace.

There were a number of innovations and new products launched at the trade fair. One of the key trends was an increased interest in alternative power and drive systems, particularly electromobility and driverless vehicles.

Some of the main drivers towards electrification include: legislative pressures for zero-emission vehicles in city centres; their suitability for indoor demolition and basement projects; and the preference for low noise machines required for nighttime work and in quiet zones.

“We have identified that electromobility and driverless vehicles are two areas that are increasingly gaining traction with manufacturers and service providers in the construction machinery industry,” bauma 2019 project director Mareile Kästner said.

“As such, we intend to provide these hot topics with a platform at bauma 2019. The important thing to note is that we won’t only be showcasing the diverse range of possible applications of leading exhibitors’ products but will also be providing a platform for discussing the aims, potential and sustainability of new technology.”

The trend towards electrification was strongest in machines best suited to civil construction applications; these often operate in cities where there are emission and noise restrictions.

xxx An immersive exhibition of Vincent van Gogh’s work at Carrières de Lumières.

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“There are a lot of machines, excavators, even construction vehicles that operate purely electrically, or as hybrids. This is especially important for inner city construction sites,” Klaus Dittrich, CEO and chairman

bauma 2019 attracted more than 620,000 visitors from 200 countries.

of Messe München, said. “But also in mining, it is important to test such equipment, and tremendous progress has been made in the last three years.”

Caterpillar unveiled more than 20 new products, including a number of electric-driven machines, including the D6 XE dozer with high electric drive, the 988K XE wheel loader, with a high efficiency electric drive system with switched reluctance technology, and the concept 906 compact wheel loader, with a fully electric drivetrain powered by a lithium-ion battery.

The first of Volvo Construction Equipment’s compact electric drive machines were also on display at bauma. This was in the wake of encouraging results from a joint research project it conducted at the “emission-free” Vikan Kross Quarry, near Gothenburg in Sweden.

In addition to the electric innovations on show, a number of suppliers to the quarrying industry also launched or showcased numerous crushing, screening, washing and mobile products, eg: • The McCloskey Washing Systems CSP 120 plant.

• Haver & Boecker Niagara’s N-class vibrating screen.

• The McLanahan UltraWASH modular plant.

• The thyssenkrupp eccentric roll crusher.

• The Terex Washing Systems AggWash 60.

• Metso’s MX3 cone crusher.

• The solar-powered Keestrack S5e tracked stacker (see page 44).

The next bauma will be held from 4 to 10 April, 2022, at Messe München Exhibition Centre, in Munich. •

Terex Jaques Modular Feeders Flexible, Robust Design with Logistics in Mind •

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PRODUCT FOCUS VIBRATING SCREEN EXCELS IN HEAVY-DUTY APPLICATIONS Haver & Boecker Niagara’s N-class vibrating screen, unveiled at bauma 2019, is capable of scalping and classifying minerals, stones, sand and gravel in aggregates applications. The N-class features an advanced single eccentric shaft design that is supported by four high performance, double-spherical roller bearings to minimise structural vibration and maintain constant g-force, even through fluctuating material feed rates. It offers one to three screen decks and is dynamically balanced to minimise energetic loads transferred nto the structure. It allows multiple screens to be placed side by side in the same building.

More information: Haver & Boecker Australia, haveraustralia.com.au

VIBRATOR OFFERS SIMPLE, INEXPENSIVE SOLUTION Enmin truck vibrators are easy and inexpensive to install on new or existing vehicles. Pneumatic, hydraulic and electric vibrators provide a simple, cost-effective solution for side tippers, dump trucks, spreaders and bottom dump trailers. One of the most common solutions is a 12-volt or 24-volt DC vibrator, which is mounted to the truck body’s underside. A few seconds of power from the in-board battery enables compacted materials to be vibrated loose without damage to the truck or trailer.

For more information: Enmin Vibratory Equipment, enmin.com.au

WASHER CAPABLE OF HIGHER CAPACITY, GREATER EFFICIENCY The McCloskey Sandstorm 620 sand and aggregate washing system has features for optimised production, easier maintenance access and reduced servicing intervals. This electric-powered, modular washing solution can typically handle up to 450 tonnes per hour of mixed sand/aggregate, with 150 to 200 tph of sand. A large 6m x 2m (20’ x 6’) triple-deck screen with five conveyors allows for the production of up to three aggregate sizes, as well as two sand products.

For more information: 888 Crushing & Screening Equipment, 888cse.com.au

STEEP ANGLE CONVEYING EFFICIENCY The Chevron-MegaPipe steep-angle conveying system provides more efficient haulage solutions for quarries. Depending on the inclination, the conveyor bridges are mounted perpendicular to the benches of the open pit. An inclination of up to 40 degrees is possible and a service cab driven by a rope winch is provided for maintenance and inspection along the structure. The Chevron-MegaPipe steep angle conveying system can also be designed for large-scale conveyance applications.

For more information: thyssenkrupp Industrial Solutions, thyssenkrupp-australia.com

14

Quarry June 2019

Industrial Solutions for the aggregates and mining industry

Your partner for world-class crushing and screening solutions At thyssenkrupp we not only offer a comprehensive range of products for processing aggregates and minerals but also work closely with you to develop the right solution for your specific application. We supply all the equipment you need from a single machine to integrated plant solutions. Moreover, our highly qualified processing experts and service teams will be your reliable partner through the entire service life of your equipment.

For more information see www.thyssenkrupp-crusher.com Or contact sales-is-australia@thyssenkrupp.com

SCREENS & FEEDERS

Pegging happens when near sized particles fall into apertures and the machine doesn’t have enough stroke to throw them back out.

ARE YOUR SCREENS RUNNING TO THEIR OPTIMUM CAPACITY?

Screen optimisation is a vital cog in the quarrying process. Darren Toth discusses the three most important aspects of screen performance – and provides advice that can increase an operator’s awareness of just how well their screen plant can run.

D

o you know what speed and stroke your vibrating screens are running at? By far the most common answer I hear when I ask this question on sites is “no”. Before I continue, I want to point out that my customers are predominantly, but not restricted to, quarries. Although there are exceptions within this industry, most sites are not aware of how their screens are running. I should also add that testing screens is not a new practice and there are several businesses that carry out this type of work to varying extents.

It is important to know how your screens are running. From a screen “health” perspective it is important to know that each screen is behaving the same on both sides (left and right) and that they are not running too hard, with excessive acceleration. Both lead to higher internal stress levels which means a significantly reduced service life.

It is also important to know how your screens are running from a productivity and screening efficiency standpoint. Several parameters affect screen productivity and efficiency: stroke, running speed (frequency 16

Quarry June 2019

of vibration), acceleration (Gs), deck inclination angle, stroke angle (oval and linear motion machines), direction of rotation (circular motion screens), type of screening media, etc.

If you don’t know the stroke, speed and acceleration of your screens then you don’t really know how they’re running. I will concentrate on these three.

STROKE To maximise screening efficiency the aim is to encourage under-size particles (within the feed material) to contact with the screening surface as many times as possible. Therefore it is logical to minimise the stroke of the machine so the material is being thrown only a short distance with each rotation of the machine.

So, what drives the “minimum” value of the stroke? It’s the need to avoid “pegging”.

Pegging occurs when near sized particles fall into (but not through) apertures and the machine doesn’t have enough stroke to throw them back out. The bigger the aperture (and therefore the near size

particles) the greater the stroke required to avoid pegging.

This is why screens in coarse applications need more stroke and why machines in fine screening applications can run with less stroke.

Stroke also plays a key role in conveying the material along the screen decks. More stroke leads to an increase in the transport velocity of the material. For a given material throughput, lower transport velocity means higher material bed depth.

Excessive bed depths prevent effective stratification. This is where the bulk material loosens (opens up) and fine material can fall between the larger particles.

Excessive stroke leads to a reduction in the number of times under-size particles present themselves to apertures. Too little stroke leads to inadequate stratification resulting in many of the under-size particles not falling down to the screening surface anyway.

Strokes typically range from about four millimetres up to 20mm. Note that high frequency screens run outside the range of typical operating parameters.

ACCELERATION Vibrating screens are designed to operate within a specific range of acceleration.

Exceeding these limits will significantly shorten the service life of the machine.

Acceleration is also a significant factor in the dynamics at (and above) the screening surface. The relationship between the acceleration of the screen mesh and gravity influences how the bulk material and individual particles behave. Gravity doesn’t change, which is why screen manufacturers recommend that their screens run at specific Gs or within a range of accelerations. The general rule of “more throw, less speed” comes into play.

Recommended accelerations vary between screens with different shapes of motion (ie circular, oval and linear) and between inclined and horizontal machines. Every screen manufacturer should be providing a recommended acceleration (or speed/stroke combination) for its machine (most do) and ensure it is supplied as such. This provides a benchmark to compare with when the equipment is tested over its service life.

Another consideration around acceleration is “blinding”, which occurs when the adhesive force between fine material and the screening media exceeds the force applied to these particles by the screening surface. It’s a bit like getting something sticky on your hand and not being able to flick it off! As the fine material builds up around the apertures it eventually blocks the mesh. This has a “snowball” effect as the load increases on the screen and the acceleration then decreases, making blinding even more likely.

Sometimes blinding occurs simply because of unusually wet conditions or a change in other properties of the feed material. Quite often though, the machine not running as intended causes it.

SPEED This is simply the rotational speed of the mechanism that is causing a screen to shake.

In typical applications, it can range from 700 revolutions per minute (rpm) to 1200 rpm (or 11.7 Hz to 20 Hz).

The laws of physics have stroke, speed and acceleration (Gs) tied together in the following way: Gs = stroke x speed2/1,789,000.

There are other methods and formulas for calculating Gs. You may already know (or notice from the formula) that Gs and stroke are directly proportional. Increase the stroke by 10 per cent and you’ll increase Gs by the same proportion. Increasing speed 10 per

Blinding occurs when fine material builds up around the apertures and eventually blocks the mesh.

A close-up of a blinded mesh.

cent however will increase Gs by 21 per cent because acceleration is proportional to the square of the speed. Be cautious when you are changing screen speed.

As far as screening dynamics are concerned, speed takes a “back seat ride” with stroke and acceleration up the front.

VIBRATIONS MONITORING There are businesses (such as ToThink Engineering) that have their own vibration meters. Some are simple and some are quite sophisticated. Within reason, all are useful. For some vibrational issues you need someone to test with more accurate equipment that also has a frequency analysis capability. Nevertheless, for gross checking of screen motion, scribing circles/ovals/lines on

For gross checking of screen motion, scribing circles/ovals/lines on a piece of paper stuck to the side of a screen is useful.

Quarry June 2019 17

SCREENS & FEEDERS

a piece of paper stuck to the side of a screen is useful too. With a bit of practice you can record the motion (magnitude and shape) of a screen. Just make sure you only hold the pen on the paper for very short periods so you can see individual circles/ovals/lines.

Then measure the maximum dimension.

That’s your stroke.

Use a tachometer or one of the vibration apps available on your smart phone and you will then have the speed. If the app gives you Hz then multiply it by 60 to get rpm. Use the formula above to calculate the Gs and check these numbers against the information provided in your equipment operation manual or contact the supplier of the screen.

Having these facts puts you in a better place to understand any issues and know where to turn to resolve them. I often hear about minor disputes between quarry sites and screen media or equipment suppliers when those involved don’t know how the screen is running. Some such issues have been known to linger for years. This is simply

Vibration meters with frequency analysis capability are recommended for some vibrational issues.

an indication of where our industry is at with vibrating equipment and the opportunities we have to do things better and smarter. Good information leads to good decisions.

Occasionally sites will change screen mesh on a deck to a more exotic and more costly

product in an attempt to solve an issue (eg blinding) but they didn’t know if the screen was running at the appropriate Gs before they decided to make the purchase. Please don’t get me wrong. There are some fantastic screen media products available that can help with blinding, pegging, etc, but you should always make sure a screen is running correctly before you consider going that extra strep by changing the media type.

If you buy a new screen, make sure the supplier provides the intended stroke, speed and Gs for that machine and make sure that’s how it’s running before they leave it in your hands. That’s your benchmark. Either get someone in to test and record these parameters or carry out your own tests.

Unless there is good reason to change any of those parameters then make sure they stay that way. That means you need to repeat these checks periodically. • Darren Toth is the director of ToThinkEngineering.

Email: darren.toth@tothink.com.au or visit tothink.com.au

PORTABLE AGGREDRY® WASH PLANT Increased Sand Throughput www.rivergumindustries.com.au

jim.hankins@ rivergumindustries.com.au

Ph 02 9548 2233

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SPECIAL REPORT

The F-class vibrating screen features fourbearing technology, which minimises structural vibrations and delivers a consistent stroke.

PORTABLE SCREEN PROVIDES ‘BIG’ BOOST FOR THE BIG BOY

What does an operation do when its best saleable products are buried in millions of tonnes of sand and its equipment has to be portable enough to move on a moment’s notice? A daily challenge for one quarrying business has been alleviated by the acquisition of a portable vibrating screen.

L

onesome Prairie Sand & Gravel has been operating since 1982.

The company was founded with the purpose of providing high quality products to its customers in a safe and highly efficient manner. It has earned a reputation as a top aggregates provider throughout Saskatchewan and Alberta, in the west of Canada.

The mountains of sand are especially troublesome for the company’s operation in Big Boy Quarry, Wakaw, Saskatchewan, one of five pits the company owns. The quarry is far deeper than most pits. The average quarry in the region drops three to nine metres (10 to 30 feet). Big Boy Quarry is more than 30m (100 feet) deep.

Profits are a challenge because, although crews sift through more than one million tonnes of material every year, only about 200,000 to 300,000 tonnes is saleable aggregates for concrete and asphalt. In most circumstances, the quarry would also sell the sand, but because the company is too far from large sand-buying markets, it is

only able to sell about 50,000 tonnes a year, severely limiting profitability.

The site is in western Canada, where pits are generally non-sustainable and gravel is becoming harder and harder to find. This means most aggregates operations must use portable equipment so they can quickly move to the next job. A single Lonesome Prairie crew could operate in as many as 15 to 20 pits per year, spending anywhere from two weeks to two months in a single spot, so it’s important that they can set up, take down and transport everything in as little time as possible.

Lonesome Prairie had been using two portable vibrating screens in the Wakaw location, but the equipment wasn’t holding up to conditions, causing decreased performance and productivity. The sandy environment required screening equipment that not only produced maximum amounts of saleable rock, but also stood up to blinding and surging to eliminate material contamination. The machines were regularly bogged down, leading to sand going through

the crushers and contaminating the saleable material, resulting in wasted product and lost profit.

To maximise yields, the operation used screen media with opening sizes as large as seven, eight and nine millimetres and overloaded the screens with as much as 5000 tonnes of material per day. The larger opening sizes meant smaller rock – about five to eight per cent of the saleable rock – was falling through with the sand the operation considers waste material. The issue cost Lonesome Prairie about $CAD200 ($AUD212.67) per hour in production losses.

The larger openings were a quick fix for the material surges, as well as blinding problems exacerbated by weather. Regular rain, frost and snow dampen the sand, contributing to material clumping together and blinding screen media.

Production rates and lost revenue were only compounded by increased maintenance costs. The sand caused the vibrating screens to wear quickly and require nearly continuous replacement of screen media. Crews needed Quarry June 2019 19

SCREENS & FEEDERS

to change screen media every two weeks, resulting in two to three hours of downtime and 1000 to 1500 tonnes of lost production for each change-out.

“The many issues were frustrating for our crew and our customers,” said Henry Derksen, the Lonesome Prairie Sand & Gravel operations manager. “Contamination meant our material wasn’t as clean as it should be, and we were concerned the issues would drive away our buyers. Production amounts were also not as high as we wanted them to be. We were tired of throwing away rock, so we began looking for a solution.”

A BESPOKE SOLUTION Lonesome Prairie management approached Hikon Industries, an equipment manufacturer and supplier it works with regularly that specialises in manufacturing aggregates and frac sand processing and handling equipment.

The company’s product line includes portable chassis for screen decks, jaw crushers and cone crushers, as well as feeder plants, conveyors, cold bin feeders and surge bins. Hikon also completes custom fabrication projects to suit individual customer needs.

Lonesome Prairie personnel explained to the Hikon representatives what they were looking for: a user-friendly, portable vibrating screen that would meet production requirements and be manufactured out of as many modular components as possible to allow for inexpensive repair.

Lonesome Prairie provided its desired tonnes per hour (tph), gradation samples and other specifications, and Hikon searched for a vibrating screen to match. The dealer talked to several manufacturers, including Haver & Boecker, a company it has worked with in the past.

Hikon representatives knew Haver & Boecker had a reputation for building high quality equipment and listening to customers’ needs, and they were also aware of the company’s Tyler F-class vibrating screen, which features an advanced double eccentric shaft design, supported by four high performance, double spherical roller bearings.

The technology minimises structural vibrations and delivers a consistent stroke, virtually eliminating surging, blinding, pegging and material contamination.

Hikon and Haver & Boecker agreed to work together and started to design a Tyler F-class portable plant.

20

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Lonesome Prairie Sand & Gravel screens about 500 tph of material, of which about 350 tph is sand.

The chassis Hikon Industries manufactured for the Tyler F-class includes a hydraulic system to position the vibrating screen at the optimal angle.

“There are quite a few off-the-shelf portable vibrating screens out there,” Hikon Industries president David Hildebrandt said.

“They’re often less expensive to purchase, but rarely finetuned to an individual pit.

The customisation we do to match each application is important to achieve the highest levels of productivity and profitability.”

Hikon custom-built the chassis around the 6m x 3m (20’ x 6’) three-deck F-class screen.

Haver & Boecker engineers factored in the desired tonnage and the material Lonesome

Prairie processes to determine what the machine’s stroke should be, the speed and general mounting guidelines. Hikon took feedback from the aggregates company, including adding a specially sized jaw crusher on the chassis. Lonesome Prairie also asked that the bottom deck of the vibrating screen be end-tensioned. In the company’s operation, the design results in longerlasting screen media and 30 per cent more productivity than side-tensioned machines.

Haver & Boecker customised the machine

MCLANAHAN ULTRAWASH SYSTEMS

McLanahan UltraWASH Modular Washing Systems offer the same worldclass washing technology we’ve been supplying since 1835, but in containerized modules for shorter lead times, quick setup and ease of transport if producing at multiple locations or one very large site. Produce up to five products – three clean aggregate and two washed sand products. Additional modules for crushing, screening scrubbing, thickening, and tailings management are also available.

SCREENS & FEEDERS

for Lonesome Prairie’s specific needs. When the engineering design was in place, both manufacturers got to work.

The finished system was inclined rather than horizontal, like many portable systems, allowing for a higher production capacity.

The machine included a hydraulic system to lift and position the vibrating screen at the optimal angle. The F-class utilises a base frame that attaches to the chassis. Crews use the hydraulic system to set up the portable vibrating screen in less than 30 minutes, with the entire plant – including conveyors and other peripheral equipment – taking about half a day. The same task can take about two weeks for fixed equipment – which Derksen said could mean a loss of about $CAD300,000 ($AUD320,432) in production during the busy season for a 24/7 operation.

POSITIVE TESTS The F-class portable plant arrived at Big Boy Quarry in April 2016, and Lonesome Prairie began testing immediately.

Prior to receiving the F-class portable plant, Lonesome Prairie Sand & Gravel experienced regular maintenance and contamination problems with its vibrating screens due to the challenging material conditions.

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SCREENS & FEEDERS

Most aggregates operations in western Canada use portable equipment, as many quarries are nonsustainable and crews need to be able to move quickly to the next site. A single Lonesome Prairie crew could operate in as many as 15 to 20 quarries a year.

Big Boy Quarry is one of five quarries Lonesome Prairie owns. The 30m pit sharply contrasts with others in the region that average 3-9m.

The quarrying team was sceptical about the results the manufacturers had promised, thinking it was too good to be true – especially considering the warm, dry weather during initial testing. Doubts vanished when they found the single vibrating screen increased aggregates production by about 25 per cent, even as rain came and went.

The improved screening action allowed the operation to maintain needed production rates while using screen media with an open area of about 4mm, preventing waste of the smaller 24

Quarry June 2019

saleable material the company lost while using larger open-area screens.

“Price can be a problem in western Canada because our competitive market often calls for cheaper equipment that fits the budget,” Derksen said. “Despite the higher price tag, I have no doubts we’re improving profits with this machine.

“We couldn’t believe our eyes – bad weather didn’t even faze it. People don’t believe us when we tell them our costs are so far down and we’re getting more productivity out of one

20’ x 6’ vibrating screen than the 20’ x 6’ and 16’ x 6’ [5m x 2m] units we were using before.”

Derksen said the two prior units together produced about 400tph, but they were plagued with problems that often resulted in wasted or contaminated material. The F-class virtually eliminated blinding and maintained consistent G-force during surging. This boosted material processing to 500 tph, including about 300 tph to 350 tph of sand, with the rest being clean, saleable material.

The new machine also dramatically reduced maintenance and contamination problems.

Screen media change-outs went from every two weeks to every six weeks – saving the operation $10,000 per month. Replacement times on the end-tensioned bottom deck – which requires the most change-outs – dropped from two to three hours each screen media change-out to only 30 minutes.

Replacement times for the top two decks stayed about the same.

Derksen said Haver & Boecker technicians helped choose the best screen media combination for his application, which has helped improve wear life and reduce contamination. He also attributed reduced change-outs to the F-class deck’s engineering, saying it spreads material better than other machines.

In addition, Derksen said Haver & Boecker technicians followed up with the company’s Pulse Vibration Analysis service on the F-class, to ensure the machine was running to factory specifications.

“We’re always looking for ways to improve our customers’ profits and productivity,” Haver & Boecker’s certified sales manager Steven Cwiak said. “Whether it involves working with another company on a custom vibrating screen, helping choose the best screen media for a job or solving maintenance challenges, we’ll never shy away from finding the best solution for our customers.”

The F-class portable plant will stay at Big Boy for some time unless Lonesome Prairie encounters similar sand and productivity problems elsewhere. Looking ahead, given the success Derksen has seen, he anticipates a fast ROI. He said he now knows whom to call to solve unique problems preventing his operation from getting the most out of mountains of sand.

Haver & Boecker’s screening, washing and pelletising solutions are available through its Australian subsidiary, headquartered in Perth. • Source: Haver & Boecker

SCREENS & FEEDERS

VIABLE FEEDERS FOR STOCKPILING

R

eclaim feeders are a flexible, economical option for the metering of stockpiled aggregates, with fewer setup and installation costs, and quick and easy relocation around a site.

After Komatsu’s acquisition of Joy Mining in 2017 to form Komatsu Mining, the company significantly expanded its product line to include a range of handling, processing, conveying and crushing products.

According to Daniel Hurse, Komatsu’s product support manager for crushing, the company can draw on a heritage of more than 100 years of processing systems development. This gives it the expertise to provide materials handling solutions suitable for a wide range of quarrying, mining and civil construction applications.

“Our range of Joy reclaim feeders are ideal for quarry stockpile operations and

aggregates handling across a wide range of product types and mixes,” he said.

Joy reclaim feeders provide volumetric metering of stockpiled aggregates using a drag-chain conveyor.

Typically, reclaim feeders are surge-loaded with material, which then feeds onto a conveyor belt, Hurse says.

“Reclaim feeders act as the transition between batch haulage and continuous haulage, and are capable of being loaded using a range of equipment types, including dozers, wheel loaders, dump trucks, belt conveyors, or excavators,” he said.

“No hopper is required for reclaim feeder operation, as the material being fed creates its own stockpile around the intake.”

He said Joy’s range of reclaim feeders could be supplied in varying configurations of conveyor widths, intake lengths, and

discharge heights. Throughput can range from 40 tonnes per hour (tph) up to 4000 tph, depending on material density; it can be varied using either an adjustable flow gate on the intake end or a variable speed drive.

“A common practice is to stockpile different products on separate reclaim feeders, which can load the material on the belt as required by the mix specifications,” he said.

Hurse says reclaim feeders have a very low installation cost, as they only require flat, level ground to operate.

“They are skid-mounted, which allows them to be easily moved around a worksite using the loading equipment,” he said.

“It’s simply a matter of setting the reclaim feeder in position, supplying power and begin feeding.” • Source: Komatsu Mining

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SCREENS & FEEDERS

OEM EXPANDS GLOBAL MINERAL

PROCESSING PRESENCE WITH NEW BRAND A provider of screening, washing and primary crushing systems has established a global brand that will encompass the product offerings of its engine rooms in North America, Europe and South America.

H

aver & Boecker, formerly WS Tyler and a provider of materials handling and processing systems in the extractive sector, has established a new global brand – Haver & Boecker Niagara – to combine the engineering expertise and product portfolios of its three mineral processing locations in Brazil, Canada and Germany.

In the past, the three locations acted individually for their respective regions and territories. Customers around the world will now benefit from shared innovative technology, more in-depth consultations, greater parts availability and better delivery times.

Haver & Boecker announced the formation of Haver & Boecker Niagara at bauma 2019, in Munich, Germany.

“Niagara now stands for a new, global drive in processing technology,” said Haver & Boecker OHG’s director of corporate business development Adrian Gamburgo. “These three Niagara locations will join forces and together focus on developing innovations in screening, washing and pelletising technology, as well as increasing their regional service reach.”

The word Niagara means “thundering water”, echoing the sound of the famous waterfalls on the border between the USA and Canada.

Due to the similarities between water running over the edge of the falls and the mined product coming off the deck of a vibrating screen, Niagara was chosen as the brand name for Haver & Boecker and WS Tyler’s vibrating screens almost 85 years ago.

“Finding the name for this entity was easy – we went back to our roots,” Gamburgo said.

“The name Niagara carries so much heritage, but at the same time holds so much promise for the future.”

Haver & Boecker OHG’s managing partner Florian Festge said: “All companies that share the Haver & Boecker name are dedicated to providing premium solutions and first-class service to every industry we serve.

“Combining the best of three worlds into one processing powerhouse means only 26

Quarry June 2019

Originally conceived in Germany, heavy-duty screening technologies, such as the Niagara eccentric, offer some of the lowest costs per tonne in scalping.

good things for our customers, allowing for improvements in terms of unique process design, state of the art engineering services, increased product quality and improved service.”

Haver & Boecker Niagara combines talents and skills in four major areas: • Heavy-duty scalping. Originally conceived in Germany, heavy-duty screening technologies, such as the Niagara eccentric, offer some of the lowest costs per tonne in scalping. Using this key technology, Haver & Boecker Niagara designs complete scalping plants, customised to meet every aspect of a quarrying operation’s product requirements, as well as preferences.

• Full-circle consultation. Created in Canada, Haver & Boecker Niagara’s PROcheck invites the producer on a complete tour of its own screening process. It starts with a review of the process design, including the application of the correct vibrating screen, such as the F-class. It then covers high performance screen media deck set-ups using Tyler engineered media. PROcheck

provides service tools and strategies to any customer’s plant, which include uptime warranties.

• Wide-body screening. Innovated in Brazil, Haver & Boecker Niagara’s XL-class high capacity vibrating screen is driven by in-house designed and built exciter units targeted at improving overall screening efficiency. With a total capacity of up to 15,000 tph, the XL-class is the largest vibrating screen in the world.

• Washing and pelletising. Haver Niagara has also introduced new approaches to washing and pelletising using the awardwinning Hydro-Clean washing system and the unique Scarabaeus pelletising disc. Both technologies are designed to minimise the waste of resources by transforming materials that were previously dumped into new products for sale at attractive prices.

SHARING INNOVATION, EXPERTISE Haver & Boecker OHG managing director Peter Grotjohann was enthusiastic about the new opportunities of a worldwide portfolio for

Our rental fleet includes the latest equipment from the world’s leading manufacturers.

Hydraulic Excavators Hitachi and Komatsu 30 to 90 tonnes, Volvo EC480DL

Haver Niagara has introduced new approaches to washing and pelletising using its Hydro-Clean washing system (pictured).

Haver & Boecker’s multinational customers.

“By sharing technology, knowledge and processes, Haver & Boecker Niagara allows our customers access to industry-leading innovations while at the same time increasing local insight and service they can only come to expect from Haver & Boecker,” he said.

Haver & Boecker Latinoamericana’s managing director Ronaldo Camargo de Souza said: “Haver & Boecker Niagara has earned the trust and respect of customers in Brazil and across Latin America with our robust, high capacity machines, tailor-made solutions and dedicated service.

“With this unity, we are looking forward to sharing our XL-class vibrating screen technology, as well as our entire portfolio of solutions, products and services with the rest of the world.”

Haver & Boecker Canada’s president Karen Thompson predicted it would be easier to share each company’s expertise and minimise redundancies in many areas of the business.

“Each location has different yet complementary strengths,” she said. “The union allows us to combine these strengths for better results for our customers and the industries we serve.”

Festge said: “Our goal is to continue to find ways to improve our customers’ businesses and daily lives, whatever industry they work in.

Tapping into and combining our global network of experience gives us the ability to solve even the most unique of problems. The only question our customers and we should ask ourselves is, why did we not do this a lot earlier?”

Haver & Boecker Niagara’s first mission was exhibited at bauma in Munich.

Driven by the motto “perfect flow for our planet blue”, Haver & Boecker Niagara seeks to provide “memorable” customer experiences to its guests and visitors by taking them on virtual tours around the globe that highlight various plants and locations that have successfully minimised their impact on the environment by reducing waste and conserving resources.

Haver & Boecker Niagara falls under Haver & Boecker’s machinery division, headquartered in Oelde, Germany. Beyond the processing equipment offered by Haver & Boecker Niagara, the machinery division specialises in materials-handling technology for the cement, building materials, and mining industries. The company’s wire weaving division produces thousands of various types of wire mesh for screening, filtration, automotive applications and laboratory technology.

Haver & Boecker’s screening, washing and pelletising solutions are available through its Australian subsidiary, headquartered in Perth. • Source: Haver & Boecker Niagara

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SCREENS & FEEDERS

SMARTER SCREEN MEDIA FOR OPTIMAL PRODUCTIVITY

W

ithin bulk materials handling, particularly aggregate processing operations, the importance of minimising downtime can never be underestimated. Every minute, hour, day of unscheduled downtime translates to lost profitability and money down the drain.

Screen cleaning is a vital production process and has been identified as a key area of routine maintenance and monitoring for processing plants to achieve optimal productivity and long-term viability.

Vibrating mesh screens can be exposed to frequent build-up or blinding, or moisture accumulation within the mesh, which means the product gets stuck and fails to progress to the next step in the production process.

Neglect and failures by site operational

personnel in keeping screen meshes clean can slowly but surely become a recipe for disaster. It’s not a matter of whether blinding will take place, but when, with the potential to halt the screening process and disrupt the site’s productivity. Screen mesh blinding problems are very common. Blinding occurs when fine particles find themselves settling and becoming trapped inside the screen mesh holes, restricting other fine particles from passing through.

“Failure to identify these screening inefficiencies can result in significant costs due to repeat screen cleaning of the bulk material, slowing the whole production process,” Kinder Australia CEO Neil Kinder said.

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The K-Deblinding Rods can keep bulk materials flowing during the screening process.

blockage within screen mesh holes is key to keeping bulk materials flowing.”

Kinder Australia’s conveyor componentry range also includes screen media targeting the aggregate and mining industries. Its K-Deblinding Rods act as the “secret weapon” for keeping bulk materials flowing during the screening process. Featuring elastic polyurethane rods that are fixed to the screen, this type of screen media takes advantage of the machine’s vibration to move and bounce on the surface of the mesh, avoiding particles wedging and blinding screens. To avoid tangling of separated K-Deblinding Rods, they are joined using separators, according to the number of mobile rods. • Source: Kinder Australia

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SCREENS & FEEDERS

Nylon chains draped along the screen panels create a “snaking” motion during normal operation that reduces the opportunity for material to build up.

THREE WAYS TO PREVENT BLINDING, PEGGING ON YOUR VIBRATORY SCREEN

B

linding” and “pegging” can cause losses of screen efficiency and production. The terms are often used interchangeably in describing material covering screen surface area during any type of screening process, but there is a difference between the two.

“Blinding” is typically caused by moisture or static energy in which a particle (or particles) adheres to the screen media. “Pegging” is caused when particles are stuck or wedged in between the wires of the screen media.

The McLanahan MD vibratory screen has screen decks at progressively steeper angles, and employs larger screen opening sizes than the actual size separation. This by itself reduces the potential for material to cause pegging.

However, screens with slotted openings can further reduce the potential for pegging

because they offer more screen surface area, and the shape of the opening reduces the potential for a particle to get “wedged” inside the opening created by the four wires.

Three ways to assist with clearing screen surfaces from a build-up of material include: 1. A ball deck, a tray installed underneath the screen media that contains balls (of various materials) that bounce up and into the bottom surface of the screen media. The rapid, continuous action of the balls beating against the underside of the screen media helps dislodge material.

2. Nylon chains, which are useful in blinding situations because of their motion on top of the screen surface during operation.

Multiple strands of nylon chain (or rope) are draped along the length of the screen panel and, during normal operation, a

“snaking” motion occurs, assisting with keeping the screens clear of material that otherwise could slowly build up and create a blinding situation.

3. A pneumatic tensioning system that governs the tension of a screen cloth such that it is periodically slackened and then retensioned. This slackening will enable the screen cloth to rattle, thereby removing sticking or pegged particles. Both the slackening and tensioning periods can be adjusted at the control panel. Moreover, the pneumatic tensioning system is tied in with the machine’s control logic, such that the machine will shut down when the air pressure is insufficient to maintain proper tension on the screen cloth. • Source: McLanahan Corporation

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SCREENS & FEEDERS

MOTORBASE SOLUTIONS FOR VIBRATING SCREEN DRIVES

A

lmost 30 years ago, I designed some of the first stored-energy motorbases for vibrating screens. These were simplistic in design, using rubber torsion springs that were well known for providing wheel suspension in caravans and trailers for many years.

I have since used and built many motorbases, such as tilt bases, slide bases and other configurations of the same in quarries and extractive industry operations.

In times past, inclined screens dominated the quarrying industry. Today, there is a range of new generation screening machines, including horizontal/variable slope and banana screens. Many new types of screen are driven via lay or jack shafts.

For the purpose of this article, I will focus on those screens and/or feeders directly connected from the screen to the electric motor by vee-belts. These will be referred to as dynamic applications.

LINEAR-ACTION SCREENS More than 25 years ago when visiting a mining operation, the manager showed me a problem he was experiencing with breaking the motor shafts on his linear-action screens.

These were 30kW, D200L four-pole motors, which were fitted with six-groove, B-section belts. They were driving 2400mm x 4800mm horizontal dewatering screens (Figure 1). The motor was adjusted with slide rails. Breaking of motor shafts occurred during resonance (stopping or starting) when a significant percentage of the mass of the screen was transferred to the electric motor shaft. To resolve the problem, I designed a simplistic stored-energy motorbase consisting of a rubber torsion spring, to which a flat plate was welded to carry the electric motor. The spring was pre-positioned to provide sufficient force to tension six vee-belts. There was enough resilience left to allow the electric motor to follow the wild movement of the screen during resonance. No more motor shafts were broken. The client went on to fit up to another 28 screens.

LINEAR-MOTION FEEDER DRIVE A quarry maintenance supervisor contacted us about problems with a 55kW, D280S,

32

Quarry June 2019

Figure 1. Linear-motion horizontal dewatering screen.

Figure 2. A linear-motion feeder drive.

Figure 3. A circular-motion screen. The correct method of tensioning the drive is to apply sufficient force (tension) to allow the screen to start without the vee-belts slipping.

six-pole motor fitted to a linear-motion feeder drive (Figure 2).

A site visit and a check of the stroke angle revealed the vee-belt drive angle was incorrect and that it resulted in energy from the feeder being transmitted via the vee-belts into the supporting structure.

This resulted in the cracking of steelwork and welds and an ongoing maintenance problem.

To correct the problem, we relocated the drive position 90 degrees to stroke or line of action and fitted a stored energy motorbase.

The mounting position was vertical down.

In this position the mass of the electric motor assists in tensioning the vee-belts.

The driven pulley now pivots around the

drive pulley centre line and minimises the transmission of energy to the supporting structure.

INCLINED SCREENS Inclined screens are most recognised in quarries. Larger screens may have twin shafts (drives). These are circular-motion screens in which gravity is used to assist the screening process (Figure 3). Horizontal screens are becoming more popular and depending on the type of action produced, whether linear or elliptical motion, the positioning of the motorbase can be critical to the vee-belt and pulley life.

A passing conversation with a quarry manager resulted in a site visit to investigate

Figure 4. Correctly tensioned vs over-tensioned screen motor drives.

Figure 5. With all screen drives, the most common fault is an incorrect drive angle/motor mounting position.

the high wear of vee-belts and pulleys on an inclined vibrating screen. Upon inspection it was clear the screen was overtensioned (Figure 4), resulting in the screen being skewed on its suspension springs, leading to the drive and driven pulleys becoming misaligned. Maintenance staff had been advised to tension the vee-belts by the deflection method, according to the vee-belt manufacturers’ specifications. This method is incorrect for this type of drive.

The correct method of tensioning the drive is to apply sufficient force (tension) to allow the screen to start without the vee-belts slipping. To ensure they are in good condition, the pulley grooves and vee-belts should be checked beforehand (Figure 5). The OEM would have designed the drive with pulley diameters and vee-belt numbers to start the screen direct online without the belts slipping.

Overtensioning may pull the drive and driven pulleys out of line, resulting in extreme belt and pulley wear.

DRIVE ANGLE/MOTOR MOUNTING POSITION With all screen drives, the most common fault is incorrect drive angle/motor mounting position (Figure 5). Inevitably, this may have one or more of the following consequences: • High belt wear.

• Reduced drive and driven pulley life.

• Belts slippage on start-up.

• Belts jumping off.

• Energy (vibration) being transmitted to the supporting structure.

• Mechanical failure.

• Integrity of the supporting structure at risk of failure.

• Higher maintenance costs than would be expected.

• Unplanned downtime.

• Motor failures. • Richard Sharp is the managing director of Leverlink.

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SCREENS & FEEDERS

MOBILE SCREENS PROVE THEIR METTLE IN ALLUVIAL DIAMOND MINES Up to six Terex Finlay mobile screens are “kicking goals” in alluvial diamond mining for two operations on either side of Kimberley, in South Africa’s Northern Cape.

I

n alluvial diamond mining, as with any other mining or quarrying operation, a lower cost per tonne of pay-dirt produced would find favour with those whose purse is affected.

Therefore, for one operation to save a massive ZAR40,000 ($AUD4000) per week in diesel fuel costs by employing a duo of Finlay screens instead of an electrically driven static screen run off a diesel generator surely makes a lot of sense (not just cents!).

There is fertile ground for alluvial diamond mining near the present run of the Orange River, south of the town of Douglas in the Northern Cape of South Africa.

In 2017 four experienced diamond miners formed a consortium under the name of Nelesco 318 to mine the elusive gemstones in the reddish earth known locally as Rooikoppie. The group mines two pits, at Remhoogte and Saxendrift.

“With the formation of the mining company Nelesco 318, each partner sold some of his equipment, especially articulated dump trucks (ADTs), into the mix and we took over a variety of wheeled loaders and excavators from the mining group which had previously mined this ground,” Remhoogte Mine manager Cobus Botha said.

“We have a fleet of 10 Bell B40D ADTs running here at Remhoogte and 10 Bell B50D ADTs at Saxendrift. All the machines have between 12,000 and 25,000 hours of service, which is testament to their longevity.”

Mining at the Remhoogte site is done in two shifts for 20 hours per day, five days per week. Topsoil is stripped and stockpiled for use in later rehabilitation.

According to Botha, the calcrete gravels and deeper basal gravels are relatively

34

Quarry June 2019

Remhoogte Mine manager Cobus Botha (left) with Bell Equipment’s Eric van der Merwe and the 694+ (background).

shallow, which means stripping ratios are less critical.

“We load the diamond-bearing gravel with an excavator and this is hauled to a stockpile, from where it is fed into a Finlay 883+ screen,” he said. “We bought the Finlay 883+ screen first, as it is used as a scalping screen and removes the oversized material out of the system at the start of the screening process.

This oversized material is fed back into the mining area and forms the base of our later rehabilitation.

“We chose the Finlay 883+ screen for a number of reasons, but most important was that the brand is backed by Bell Equipment.

We knew we could count on the technical and parts back-up that would ensure maximum

productive uptime for us.”

Botha added some of the Nelesco 318 partners also had Finlay screens in their previous operations, so suggesting the Finlay brand as a first choice was an easy sell.

The operators at the Remhoogte mine have found that a high sand content makes processing the gravels difficult. For this reason, the mine recently took possession of a Finlay 694+ inclined screen.

Once through the Finlay 883+ screen, the material is fed directly into the Finlay 694+ inclined screen, where it is split into -34mm, +22mm and +4mm products. The separation protects the bottom deck of the 694+ against potentially too much weight.

“The way in which the 694+ separates

out the sand is quite phenomenal, and we can honestly say that its purchase has only added value, as we are assured of feeding our four, 16-foot [5m] pans with diamondbearing gravel of a far better quality,” Botha said. “Another noteworthy feature is the amount of fuel and subsequent money we’re saving. Before we used to feed all the material through a static screen that ran off a generator powered by a diesel motor, and this machine consumed 1000 litres of diesel per day. Running the two Finlay screens, we’re now saving up to ZAR40,000 per week.

“The feed to our four pans needs to be approximately 100 tonnes per hour, but our two Finlay screens running in tandem are easily pushing out up to 300 tonnes per hour, which means that we’re always ahead of our processing capacity in the pans.

“This just goes to show that the 883+ and 694+ are the correct tools for our application.

With the huge saving in fuel costs, they really do add value to our mining operation by lowering our production costs.”

The 694+ inclined screen splits material into -34mm, +22mm and +4mm products.

‘FLAWLESS GEMS’ A separate quartet of Finlay screens are also proving to be “flawless gems” for mining giant Steyn Diamante at the Schutsekama diamond mine on the Riet River, near the village of Ritchie, south of Kimberley.

It is not a mine where the skyline is

dominated by a shaft tower. In fact, the only raised portion shows four large, red mobile Finlay screens processing a constant stream of rock, gravel and sand that is separated onto different moving belts, which spew the material into heaps.

Archaeological data shows the narrow Riet River ran a lot wider some centuries ago.

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SCREENS & FEEDERS

Schutsekama Mine manager Wikus de Winnaar (right) chats to Eric van der Merwe.

Alluvial diamonds from as far as the presentday Jagersfontein and Koffiefontein were pushed into the surrounding areas as the river flooded the plain en route to joining the Vaal River further downstream.

This is where Schalk Steyn of Steyn

Diamante, doyen of alluvial diamond mining in South Africa, established one of his mining operations in 2015.

“Compared to traditional alluvial mining methods, we’ve gone considerably bigger on this site, using a 240-tonne excavator

for loading 100-tonne rigid dump trucks,” Schutsekama Mine manager Wikus de Winnaar said.

“They, in turn, deposit the diamond-bearing gravel onto stockpiles, from where huge 50-tonne excavators feed the material into Finlay 893 screens for separation.

“Anything larger than 125mm is returned to the mining pit to form the basis of rehabilitation, and finer material than that is sent to the processing plant.”

De Winnaar said that in April 2018, almost 160,000 tonnes of run-of-mine material was fed through three of its Finlay 893 screens.

This proved, in de Winnaar’s mind, that “we couldn’t mine so sustainably and on such a large scale if it weren’t for our fleet of Finlay 893 screens. We have four in a row here, but use only three actively, keeping the fourth in reserve for when any of the others need maintenance. Regular rotation also takes place so that the load is spread among the four machines.”

The Schutsekama mine works daytime shifts

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Two of Schutsekama Mine’s 893 screens have been involved in the separation of up to nearly 160,000 tonnes of total run of mine materials.

from Monday to Saturday, with month-end long weekends. Machine hours are clocked relentlessly, especially on the Finlay 893 screens.

At the time of writing, the newest machine showed 340 hours and the oldest 5477 hours.

The 893 screens are placed as close to the mining areas as possible to shorten the haul distance. This works, as the rigid trucks run full in both directions, bringing mined material to the stockpiles beside the Finlay screens and returning with oversized material for rollover rehabilitation.

“Because of the area where we mine, we come across a lot of wet clay, sand and shale in the diamond-bearing gravels, but we can throw anything at these Finlays and they separate what we don’t want from that which goes to the plant. They are simply amazing,” de Winnaar said.

The four Finlay 893 screens were bought as replacements for four older Finlay machines that were subsequently sold on the preowned market.

“Schalk [Steyn] first used Finlay 883 screens back in 2004 when he started mining alluvial diamonds in South Africa,” de Winnaar said. “He knows the machines’ capabilities and while going on to the larger 893 machines has stayed with Finlay, as he has absolute faith in the brand.”

Fuel is a major cost factor for any miner and this site consumes 8500 litres of diesel per day. The Finlay 893 screens have been recording fuel burn of about 20 litres per hour and, given what they produce, this is considered low.

“What we appreciate, as the mining teams and those working with the Finlay screens daily, is that we have the backing of Bell Equipment in terms of technical support and parts supply,” de Winnaar said.

“Mining equipment always needs attention and can surprise you at any time, but knowing Bell Equipment is close by allows us to do what we do best – mine diamonds and rehabilitate the land afterwards.”

In Australia, Terex Finlay mobile crushers and screens are available through Finlay Crushing & Screening Systems (ACT, NSW, Queensland, SA, Victoria and Tasmania) and OPS Screening & Crushing Equipment (WA and the Northern Territory). • Source: Terex Finlay

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SCREENS & FEEDERS

EIGHT REASONS TO USE A DEWATERING SCREEN IN YOUR APPLICATION Dewatering screens have long been considered important instruments in sand processing – and an effective means for producing drier, cleaner end products, particularly in the capture and retention of ultra-fine materials.

T

he dewatering screen’s origins may be in the coal industry, but it has made a home in the aggregates world. Since appearing in the North American market in the late 1970s, the dewatering screen has become the “go to” piece of equipment for economical removal of water from sand. Here are eight reasons why dewatering screens play such a large role in the production of clean quarry products.

1. A DRIER MATERIAL Several pieces of equipment are used to reduce moisture content in sand. A separator or siphon-assisted hydrocyclone produces an underflow material of 22 to 35 per cent moisture. The material can be stacked on a drainage field or discharged to a dewatering screen for additional moisture removal.

Discharging the material directly onto a conveyor belt usually creates a housekeeping issue due to the remaining free water.

A fine material screw washer produces a discharge with a 15 to 30 per cent moisture content. While the product can discharge onto a conveyor directly, material can cling to the belt and create a housekeeping issue.

The dewatering screen achieves between eight and 20 per cent moisture, depending on the material’s physical characteristics.

Despite the retained moisture range, the dewatering screen discharge is drip-free and can be easily conveyed, loaded into a truck or placed in a bin.

A dewatering screen is a low cost solution when feeding dryers, putting material on conveyors, loading trucks or discharging to other equipment that requires the lowest percentage moisture.

2. HANDLING MULTIPLE PRODUCTS The use of longitudinal dividers allows up to three products to be dewatered on one screen. Many applications feature a twostream process where fine and coarse streams can be kept separate or blended to create specialty products. Utilising one 38

Quarry June 2019

Dewatering screens are a low cost solution for producing a drier material.

dewatering screen for multiple products reduces the overall footprint of equipment and reduces capital and operating costs.

3. INTEGRATION WITH EQUIPMENT Dewatering screens fit well into many applications to yield a drier product, capture ultra-fine material or allow better control in the process.

The combination of a hydrocyclone or separator with a dewatering screen creates a wash system with a higher efficiency level and a drier product yield. The screen underflow can be recirculated into the hydrocyclone feed for recovery or removed as undesired.

to recover ultra-fine material before it goes to a settling pond. Even though some of the fines will pass through the screen media, they will remain in the system. The hydrocyclone overflow is the only exit point for the fine material, and it is operated at a high pressure to retain the material.

Equipment such as attrition scrubbers will not operate at optimal levels when the material is too wet. A dewatering screen will produce a predictable moisture, which will allow better process control. The material can be adjusted to the correct percentage moisture through the addition of water at a controlled rate.

Ultra-fines recovery plant Generally, a screen will make a classification based on the media openings. When trying to capture material that would normally pass through the media, a dewatering screen can be used in combination with a hydrocyclone

4. WIDE RANGE OF SIZE GRADATIONS Since the main purpose of a dewatering screen is to reduce the percentage of moisture in material, it can handle a wide range of particle sizes. From as large as 13mm (0.5”) down to 37 micron (400 mesh)

fines, a dewatering screen can be configured to handle material in the size that is needed.

As the dewatering screen is designed to blind off the media openings, material that would normally pass through is retained while the water flows through. When used with a hydrocyclone or separator, a dewatering screen is extremely effective in retaining material and producing a dry product.

5. MEDIA ALIGNMENTS FOR SIZING CUTS A dewatering screen is set up to blind the screen media, to retain material to the overs and allow the water to report to the unders.

With this mind, it is still a screen, and the media can be adjusted to perform sharp size classification. The inclined discharge continues to promote the removal of water from the material. The media does not have to be continuous in purpose. One section can be configured for size classification, while others are configured for the dewatering requirement. Spray water can be used to increase the size classification efficiency.

6. ADDITION OF SPRAY WATER While it is preferable to address fines removal upstream, there are situations when fines remain in the product. Adding water to a dewatering screen may seem counterproductive but it can have a significant impact on removing unwanted fines. The media will retain the desired material, while the fines will travel with the water and report to the screen’s underflow.

The water amount and the added location will have an impact on the effect but, generally speaking, water is added at the feed end.

7. LOW POWER Fitted with two vibrating motors or a single motor to drive exciters, dewatering screens record significantly lower total power usage (in kilowatts) than similar capacity equipment.

With the recommended percentage moisture in the feed of 50 per cent or higher, a dewatering screen can accept a variety of feed sources. Under some circumstances, the feed can go below 50 percentage solids,

but it can affect the final product dryness or total capacity. When the feed’s water content is too high, it may require more equipment, such as a hydrocyclone, to decrease the moisture percentage prior to introducing the material to the dewatering screen.

8. LOW MAINTENANCE The screen media and springs/buffers are the main items that will need replacing.

These items, along with the sideliners and discharge lip, are the only wear parts, and all have a long lifespan. Motors and structural components are designed for heavy-duty applications and have a low rate of failure.

For these eight reasons, a dewatering screen can be a welcome addition to a quarry plant when producers are striving to remove moisture and improve productivity.

In Australia, the Lincom Group is the newly appointed national distributor of McLanahan’s sand and aggregates processing range. • Source: McLanahan Corporation

SAND PRODUCER MEETS GOALS WITH HYDROSIZER PLANT

M

ansfield Sand Company has been quarrying sand in north Nottinghamshire, England, for more than 170 years.

The company is a renowned supplier of materials for top-class sports and sporting venues across the United Kingdom and Ireland. It supplies sand to 16 Premier League clubs, 16 Championship clubs and 120 other football (soccer) league and nonleague clubs, for use in their stadiums and training facilities.

Besides sand for football stadiums, Mansfield Sand also produces a wide range of products for landscaping and equestrian uses, including championship golf and world-class show-jumping arenas, as well as asphalt sand, foundry sand, and sand for

concrete and brick products.

In 2014 Mansfield Sand wanted to upgrade its plant and control system to process a new deposit. The company required a plant that would process 300 tonnes per hour of -65mm sand to manufacture its various products, including golf sand that meets United States Golf Association standards, block pavior sand and asphalt sand.

In addition to this requirement, the local planning commission set a noise restriction that the new plant would not disturb some rare birds nesting near the boundaries of the site.

At this time McLanahan applications engineer Neill Rowland was liaising with Mansfield Sand about purchasing a Hydrosizer sand plant.

“One of the things that sold the plant was McLanahan’s technical ability to offer plant that would produce five different products in one pass,” Rowland said.

He said experience and confidence also played a role in Mansfield Sand’s decision to work with McLanahan. The company was familiar with Hydrosizer systems from an existing plant it had been operating for several decades.

“When you start getting down to really fine sizing, Hydrosizer classification is really more efficient and more cost-effective,” Rowland said.

“The Hydrosizer is the only piece of equipment suitable for the application to achieve the tight tolerances.”

McLanahan installed a Hydrosizer plant

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SAND PROCESSING

“Anything bigger than 40 microns is recovered,” Rowland said. “Anything less is going to the lagoon.”

Since commissioning the Hydrosizer plant, Mansfield Sand has not received a single customer complaint about the performance of the equipment.

The plant’s modern control system enables the producer to adjust the product to meet consumer demands.

“The plant does have quite a bit of functionality for them to develop product and potentially react to market changes,” Rowland said.

In five years of operation, the Hydrosizer plant has been stable and reliable. It produces a consistent material at 280 tonnes per hour, and to date the plant has produced two million tonnes of sand. Furthermore, the ultra-fines recovery system has doubled the life of the lagoon by allowing Mansfield Sand to capture fine material.

“It’s a low value product, but it’s a product they can sell, and it’s a product that isn’t filling their lagoon, which is the real benefit

incorporating pumps, sumps, hydrocyclones, separator, dewatering screens and a blending system capable of blending to one per cent accuracy, to help Mansfield Sand meet the strict specifications required of its final products. The end products are discharged at less than 15 per cent moisture, which creates stockpiling efficiency and allows for further drying processes.

To meet the planning commission’s requirements, the entire plant is housed within a galvanised structure, clad and insulated to reduce the noise level. The plant’s components are also lined with rubber for protection from the sand’s abrasiveness.

After some calculations from Mansfield Sand’s laboratory technicians, the company discovered the waste from the wash plant would fill its lagoon within 18 months, so it turned to McLanahan for help with water management.

McLanahan provided an ultra-fines recovery system to recover fines down to 40 microns, to extend the life of Mansfield Sand’s lagoon system.

to them,” Rowland said.

Overall, the Mansfield Sands team is pleased with the Hydrosizer plant and ultrafines recovery system.

“A good team effort by both parties and a professional working relationship providing a technologically advanced plant gives Mansfield Sand flexibility, controllability and future-proofing for the estimated 30-year life of the site,” Mansfield Sand managing director Richard Abraham said.

“Now, four years on, we continue to have a fantastic working relationship together. Our process plant continues to manufacture our premium quality sands to Mansfield Sand’s exacting standards.

“The partnership between Mansfield Sand and McLanahan has rested on the McLanahan team’s awareness of the importance we place on the reputation of our products and our respect for their experience.

The partnership had a lot to prove, and it proved to be a great success.” • Source: McLanahan Corporation

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SCREENS & FEEDERS

PRODUCTION OF SPAWNING

STONES FOR FRESHWATER TROUT

A

mobile screen is proving its versatility by making an unusual contribution to the freshwater environment.

For the past three years, Veljekset Kokkonen, a crushing contractor in Lieksa, eastern Finland, has used its Metso Lokotrack ST2.8 mobile scalper to screen various sizes of crushed stone for sand, gravel and soil, and for a highly specialised use – spawning stones to help endangered freshwater trout breed.

These spawning stones aim to restore the extremely threatened freshwater trout in the Naarakoski rapids, on the Lieksanjoki watercourse. The beautiful territory is on the lower course of the famous Ruunaa fishing and nature conservation area.

The freshwater trout wander from the lakes to the upper courses of rivers to breed. For this, they need proper-sized stones. The smaller stones are needed to successfully lay their eggs and the larger stones, about the size of a human head, protect the precious first moments of the trout babies.

Juha-Pekka Kokkonen, the man in charge of crushing and screening at Veljekset Kokkonen, has overseen the operation of the Lokotrack ST2.8 screen at the company’s Pekkilä soil extraction area in Lieksa.

“We screen three sizes of natural stones from the gravel bank,” Kokkonen said. “The sizes of the spawning stones vary between 30-60mm, 20-100mm and 100-250mm. More than 1300m2 of gravel is being processed.

“Working with the screen is fast. We use an eccentric throw of 14mm, and the screen accepts as much feed as the excavator is capable of putting in.

“We use punch plates in three sections on the screen’s upper deck and a steel mesh in one section, as well as on the lower deck.”

Veljekset Kokkonen purchased its first mobile crushing equipment from Metso in the early 1980s and then acquired a trackmounted two-stage plant. The Lokotrack ST2.8 screen was delivered in 2016.

“Based on our first experiences, ST2.8 is a screen that gets the job done,” Kokkonen said. “So far, everything has worked well. A Finnish product is a safe choice, because it means that spare parts and maintenance services are locally available when needed.

42

Quarry June 2019

The Lokotrack ST2.8 screen quickly produces spawning stones of different sizes.

Juha-Pekka Kokkonen.

The fry stones, sized 20-100mm, will make it safer for the landlocked trout to reproduce in the rapids.

“Good fuel economy is an added bonus for us, enhancing the cost-effectiveness of screening. The efficient screen consumes about 12 litres per hour, which is not much for an hourly screening capacity of more than 200 tonnes.”

Veljekset Kokkonen’s operations are based on three pillars: construction sector transport services, contracting, and crushing and screening.

The family company operates mainly in eastern Finland and employs 20 people. It crushes and screens roughly half a million tonnes of aggregates annually.

As many of Veljekset Kokkonen’s clients are small producers, the equipment is transported from one place to another about 40 times a year.

Veljekset Kokkonen screens the spawning

stones for Kuopion Teho-Louhinta, the company in charge of submerging the stones in the Naarakoski rapids, commissioned by the Centre for Economic Development, Transport and the Environment for North Karelia.

The work has provided the landlocked fish with new and better spawning sites.

The spawning stones meet an important need: natural stocks of landlocked trout can be found in only a few headwaters in Finland.

In rapids with a stone and gravel bottom, only about one per cent of the fish stock develop into fry.

The Metso Lokotrack ST2.8 scalping screen is available in Australia through national distributor Tutt Bryant Equipment. • Source: Metso

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SCREENS & FEEDERS

MOBILE PLANT SUPPLIER UNVEILS

ITS SUITE OF ELECTRIC INNOVATIONS

European mobile plant manufacturer Keestrack recently displayed nine electric-powered processing plants for quarrying and recycling applications at bauma 2019, in Munich, Germany.

T

he company in particular was keen to show customers its work in the development of cost-effective hybrid and plug-in electrification of plant drives, which it not only implements in new generation models and innovations, but consistently in all of its crushing, screening and handling solutions.

As part of its “e” (for electric) series portfolio in mobile crushers, Keestrack presented diesel-electric full hybrid plug-in models of its track-mounted jaw, impact and cone crushers. According to Keestrack, the new and enhanced models are not only suitable for 60to 70-tonnes transport weight in terms of size, output, product quality and variety, but are also setting standards for cost-efficient operation with sophisticated drive concepts.

Without restrictions in portability and tracked on-site mobility, the diesel-electric heavy crusher range satisfies the requirements for volume-intensive recycling jobs on construction sites, plus multi-stage production of mineral aggregates in pits and quarries.

For the first time internationally, the 700 tonne per hour (tph) Keestrack B7e jaw crusher was unveiled. Replacing its predecessor, the B6e, the B7e’s core comprises a tried and tested CJ412 single jaw crusher, with a 1200mm x 830mm inlet for feeding sizes up to 700mm and a wide, hydraulically adjustable closed side setting (CSS) range of 75mm to 250mm.

In the B7e – only available as plug-in hybrid – the crusher is driven by a 132kW electric motor. Another 55kW electric motor powers the hydraulic system for the tracks, the lifting cylinders, the vibrating feeder with two-deck pre-screening and all conveyors.

The diesel-electric power is delivered by an on-board Volvo diesel engine (optional 273kW 44

Quarry June 2019

EU IIIa or 285 kW EU IV) and on-board 330kVA generator. The engine house is available in a detachable drop-off module, to be positioned away from the crusher, in a dust- and vibrationfree environment.

Thanks to constant and low engine speeds, even under full diesel-electric load, the Keestrack B7e operates with low fuel consumption. According to Keestrack, energy-saving costs of up to 80 per cent can be obtained in emission-free plug-in operation from mains or external gen-sets. The plant, with a total weight of just below 69 tonnes (with options), is highly mobile; by detaching the 6m3 feeder unit, including pre-screen, the weight drops below 60 tonnes.

Complementing the B7e at bauma was the full hybrid Keestrack H6e cone crusher. The H6e offers high production capacities in the secondary and tertiary crushing phases. With a maximum feed size of 215mm, variable crushing chamber configurations and stroke settings (a CSS of 6mm to 44mm), the specially adapted Keestrack KT-H6 crusher, based on proven Sandvik technology, can process up to 400 tph of raw materials. An optional three-deck post-screen module (with a 24.5m2 surface) with oversize recirculation provides high quality end products, thus guaranteeing high added value. The powerful e-motors for crusher drive, plant hydraulic (220kW/2 x 30kW) and all other directly electric-driven components are powered by a detachable diesel/generator module (345kW) or plug-in via mains or external gen-set. With a total weight of 62 tonnes with all options (51.5 tonnes without the final screen), the large cone can be operated economically at various jobsites.

This versatility is also a feature of the compact and highly mobile R6e impact crusher, with double pre-screening and double-deck post-screen modules, including oversize recirculation. Still available as a diesel-hydraulic as well as partially electric model with crusher direct drive (“rotor by diesel”), the R6e is a fully hybrid plug-in version (439kW). Despite its extensive electrification, including the 970mm x 1300mm crusher (250kW), the hydraulic system (2 x 55kW), and almost all conveyor drives and ancillary units, the 62-tonne plant can be flexibly dislocated with the optional dolly system.

The fully hybrid R3e impact crusher and the B3e jaw crusher were examples of Keestrack’s compact range of mobile units. The R3e, which was introduced in 2018, is fitted with a single-deck post-screen and oversize recirculation (total of 32 tonnes).

The 30-tonne B3e jaw crusher features a 1000mm x 600mm feed opening and accepts feed size up to 500mm. It can be fitted with an electric-driven double deck, with new independent pre-screen (1.6m2 + 1.2m2). The electrical equipment on the predominantly diesel-hydraulic plant includes a 42.5kVA generator for all conveyor drives and ancillaries and a 16A plug-out connection for downstream screens or stackers.

ELECTRIC-DRIVEN SCREENS Compared to conventional diesel-hydraulic units, diesel-electric plants save up to 40 per cent of fuel. While working in production trains, the attributable fuel consumption may even decrease by 70 per cent when the hybrid screens are powered directly via the plug-out

supply of an upstream or downstream diesel-electric crusher. To fully exploit this potential, Keestrack offers six models of its double-deck scalpers (250 tph to 1000 tph) as optional full hybrid plug-in versions.

New to the “e” program is the Scalper Keestrack K6e. With an 8m3 standard feeder and a 4500mm x 1800mm double-deck screenbox (2 x 8.1m2), the 30-tonne plant produces three fractions with 600 tph and can be adapted to a wide range of materials and applications with a variety of screen media and additional equipment.

A full hybrid screen solution with high potential for economical semi-stationary operation from the mains is the Keestrack K5e flipflow screen (of about 29.5 tonnes). The specially adapted BIVITEC technology in the large double-deck screenbox provides a wide range of applications in the economic recycling of residual materials (eg glass, slag) or the processing of difficult materials with high basic moisture.

The flexible screening equipment also allows the efficient and economical production of minimum grain sizes of less than 2mm, handling hot materials (eg slag) or generally the production of large quantities of mineral standard products (up to 450 tph).

SOLAR-POWERED PLANT Positioned close to possible power sources, stackers, with their rather low power requirements, are particularly suitable for economical alternative drives.

That is why Keestrack equipped its tracked stackers with dieselelectric plug-in drives at an early stage.

Brand new emission-free models in stockpile handling were presented in Munich. The semi-mobile electric S1e feeder/stacker is installed on a height-adjustable pedestal with lifting and 180-degree swivel hydraulics. The light 10.2m belt feeder (5.45 tonnes) conveys up to 280 tph of sand or gravel (a maximum size of 200mm) and creates kidney-shaped piles of maximum 2900 tonnes.

The S5e “solar” tracked stacker was also premiered at bauma. It is possibly the first directly solar-driven processing plant in the world, with photovoltaic modules mounted above the 23m long conveyor feed, and a 23kWh battery installed in the chassis. The battery powers all electric driving, lifting and conveying functions.

In case of bad weather or intensive continuous operation, the system can be powered or recharged via available external sources, such as upstream diesel-electric crushers and screens, or via mains plug-in.

There are two distributors of Keestrack plant and equipment in Australia: Screenmasters Australia (ACT, New South Wales, Queensland, Victoria and the Northern Territory) and Bost Group (South Australia and Western Australia). • Source: Keestrack

The S5e solar-driven stacker is fitted with photovoltaic modules above the 23m long conveyor feed, and a 23kWh battery in the chassis.

SMART BUSINESS

MANAGEMENT INTELLIGENCE:

A KEY TO SUCCESSFUL LEADERSHIP

For quarries to succeed in today’s competitive world, a unilateral way of doing business is invalid.

To get the best out of an operation and a workforce requires effective two-way communication.

Mike Cameron explains the importance of management intelligence in the modern environment.

M

anagement Intelligence (MI) is the ability to lead “change” through effective communication and interpersonal awareness. It includes evaluating challenges, implementing strategies, empowering and developing team members, monitoring performance and constantly evaluating the situational relevance to future customer needs and business planning.

MI is guided by numerous tenets of wisdom: • Dwight D Eisenhower (1944), who stated that leadership “is the art of getting someone else to do something you want done because that person wants to do it”.

• Gareth R Jones, whose Organizational Theory (1995) defines management in terms of its functions and objectives, ie: “Management is the planning, organising, leading, and controlling of resources to achieve goals effectively and efficiently.”

According to Jones, efficient organisations manage resources to maximise their utility in the process of producing goods or services. Effective organisations achieve qualitative goals and targets that are customer-centric, such as satisfaction.

• Peter Drucker (1994) summed up efficiency and effectiveness as doing things right.

In other words, it is not a question of how much but rather how well the organisation achieves its goals.

• The Value Cycle model, which identifies six key management commitments, six key management responsibilities and the organisation’s need to interrelate with their customers’ ever-changing requirements.

The key components of MI are: • Competency in effective communication and interpersonal awareness.

• Proficiency in the four behavioural competencies of the Plan, Organise, Lead and Control (POLC) model: Conceptual and Strategic (Thinking and Evaluating), and Tactical and Operational (Doing and Adapting).

• An understanding of how to apply the 46

Quarry June 2019

Figure 1. The Plan, Organise, Lead and Control (POLC) model.

Value Cycle and utilise the process to transform and empower workplace teams, their interaction with the organisation’s management and others across the business, customers, suppliers, regulators and other important stakeholders.

POLC MODEL For the purposes of this article, the original POLC model (Figure 1) has been modified to suit the extractive industry’s prevailing management structure.

Planning This is all about questions - “Where are we now? Where do we need to be? How do we get there?” - that will obviously differ in complexity, depending upon the person’s level of management within the organisation.

The higher your status, the more the focus will be conceptual and strategic in nature, and at an operational level the more strategic and tactical it will be.

At the operational level, questions may be as basic as: “What’s to be done? Who’s going to do it? How will they complete the task?”

It is a manager’s key responsibility to articulate the daily, weekly and even monthly

plans associated with sales requirements, production output, blasted rock on ground or available raw material, the immediate steps in the quarry’s development, and any issues of importance to the safety, security and long-term wellbeing of employees and others associated with the operation’s success.

Great planning is the foundation for both efficiency and effectiveness.

At a higher level, management needs to regularly review its medium- to longer-term planning, while monitoring progress against expectations, as well as the business, social and governmental environments, to identify new opportunities for their organisation.

Organising An important management function is to organise the workplace in a way that enables groups of people to work together and achieve predetermined goals (established during the planning stage).

To succeed, when measured in terms of effectiveness and efficiency, the organisation must deploy its resources (human, equipment and materials) in a way that maximises its ability to produce the best possible outcome.

Leading Leadership is about behaviours and creating the conditions for success. Great achievements will not be accomplished without leadership, in some form or function.

The key responsibility of leadership is to create a vision for the organisation, or to articulate that vision in language or terms that are easily understood by employees within their workplace. It is about setting the focus and direction that will encourage employees to work at their best and ensuring their activities are co-ordinated to achieve maximum results for the organisation. It is also about being seen by employees as a “walking the talk” leader, not a “do as I say, not as I do” manager!

Figure 2. The cropped value cycle model.

Controlling Control cannot exist without plans, goals and objectives, which must be communicated, implemented and monitored across all levels of management within an organisation.

From the perspective of executive management, creating exceptional plans,

developing the perfect organisational matrix and finding the perfect leader is of little value unless “critical success factors” and “key performance indicators” are measured against agreed targets and predetermined goals.

However, from a quarry manager’s viewpoint, the performance monitoring may be:

• To clearly define the delegated task(s) required to achieve the planned outcome that was communicated at the morning’s “toolbox meeting”.

• To check on understanding of the requirements and the employee’s ability to satisfactorily complete the task(s).

• To determine that the employee has accepted accountability for completing the delegated task(s) “in full and on time”.

In my opinion, a quarry manager must adopt a leadership approach to the “controlling function” to ensure they empower the employee, build trust and improve the team’s skill levels.

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Installed in half the time, it does the same job as mesh but with less blinding, less pegging, fewer inspections, and a fraction of the media changes.

Find out more at ROCKTECHNOLOGY.SANDVIK/WX6500

VALUE CYCLE MODEL The hub, with the three rotatable components of the Value Cycle model (Figure 2), represents the core beliefs of an effective workplace team or business unit, particularly values and trust.

Each of the “spokes” on the model’s inner component represent the six key management responsibilities, namely planning, productivity,

SMART BUSINESS

quality, leadership, talent management, and communication.

The blue disc represents the six key management accountabilities, namely performance and results, continuous improvement, innovation and change, learning and leadership, relationships and teamwork, and safety and security.

The outer yellow ring represents the external focus of the business, namely: • Customers (external and new). Value has to be created, and new products or services developed, to keep existing external customers and attract new ones.

Internal customers’ expectations must also be fulfilled.

• Research and awareness. Organisations have to research their customers’ current and future needs, and scan internal and external environments to build awareness of trends, catalysts and changes.

• Resources and providers. Raw materials and other resources are required from various internal and external providers.

Employees can be seen as both a resource to assist in the achievement

of goals and as providers of expertise, innovation, loyalty, passion and commitment.

• Structure and systems. These must be in place to convert the resources into one or more final end products or services.

• Equipment and technology. Throughout the value creation cycle, equipment and technology are required to achieve the greatest performance.

• Marketing and sales. Products and services have to be marketed and sold to existing and new external customers.

• Delivery and service of products or services to customers. The manner in which the products or services are packaged, delivered and serviced impacts on the retention of existing customers and the attraction of new customers.

To illustrate the power of the Value Cycle model, see the following “root cause” analysis.

ROOT CAUSE ANALYSIS A customer has complained that crushed rock deliveries for his road construction project have been intermittent, creating much

frustration on-site and difficulty in achieving the appropriate degree of compaction within a reasonable time frame.

To evaluate the potential “root cause” prior to a more formal team review: • Move the blue ring so that “Performance and Results” are directly below “Delivery and Service” on the outer yellow ring. Now move any of the inner spokes to align with “Performance and Results”.

• Select “Communication”. This process quickly identifies that there may have been a poor level of communication between the weighbridge and the customer.

• Select “Planning”. This process quickly identifies that there may have been too few trucks ordered or available to deliver the quantity of crushed rock ordered, as a continuous supply to the road-laying crew on-site, as expected by the customer and promised by the sales team. • Mike Cameron is an IQA member and an executive coach for Strategically Yours. Email mike@ strategically.com.au or visit strategically.com.au

The Institute of Quarrying Australia

FROM THE CEO

THE VALUES OF MEMBERSHIP, EDUCATION INTO 2020 AND BEYOND

I

nstitute membership has many benefits.

Primarily, IQA membership is a formal recognition of an individual’s professional achievement and competency. As a corporate member, you will have access to broader networks, education and career advice. Members are updated with the latest technical, health and safety, environmental and commercial developments in the industry, through participation in Institute activities and by access to a broad range of information.

Networking with other members gives rise to great friendships. Members meet regularly at a local, national or international level.

As part of the IQA’s focus on The Future of Quarrying, it is now easier than ever to join or renew your membership. For new members it is as simple as a visit to our website: quarry.com.au/IQA/Membership/join_now/ For membership renewals, log into your member account at quarry.com.au and follow the easy steps to renew.

We welcome all feedback from members, expressing what being a member brings to them personally. In the words of some: Dan Rensburg-Phillips |Territory sales manager, Hanson “I was fortunate enough to recently attend the Young Member Network’s tour of Hillgrove Copper Mine and Hanson Kanmantoo Quarry in South Australia. It was a fantastic day spent with a great bunch of young and enthusiastic Young Members. I truly value the opportunity to network and knowledge share with such an amazing group of the quarrying family. I am grateful for all the IQA does to increase the professionalism and knowledge of our industry!”

Chris Prowse FIQ |Principal consultant, CK Prowse & Associates “As a member for over 25 years, I enjoy and feel privileged to be a part of the IQA, meeting and learning from a family of fantastic people.

Certainly, the technical and networking opportunities keep me at the forefront of the industry as it develops.”

Jason Egan | Area manager, Quarry Solutions “For over 20 years I have been a member

of the IQA across three states. Early on in my career the technical knowledge gained was extremely helpful in teaching a young bloke that literally started on a shovel digging spillage under a conveyor belt. Over the years I have been fortunate to have made many life-long relationships with some terrific quarry people with the guidance offered to me through those years being invaluable.”

IQA Awards 2019 Each year the IQA recognises the contribution of individuals and sites to the growth and improvement of the extractive industry through a number of awards. The awards process recognises the significant achievements across the industry that promote leadership and excellence. The awards profile the valuable contribution of our industry to our community and aim to further the discussion about quality improvement, environment and safety.

To register as a delegate for the 2019 national conference, visit conference.quarry.com.au The conference retains the successful format of previous meetings while implementing new initiatives. The IQA acknowledges the many companies involved in sponsoring this event:

Nominations are now open for the 2019 Awards – the deadline is 6 August, 2019.

• Event platinum sponsors - Hitachi, Komatsu and Caterpillar.

The IQA’s industry awards will be announced at this year’s IQA national conference in Geelong, Victoria, from 1 to 3 October, 2019.

• Partner sponsor - Orica.

To submit applications or nominations for the awards, visit quarry.com.au/awards 2019 annual conference The 2019 conference in Geelong will support and invigorate the IQA’s vision of providing valuable educational, networking and promotional content to help businesses to make the most of opportunities in the industry.

New or emerging technologies, resource constraints, health and safety, community and regulatory requirements and more, combine to provide opportunity for the quarrying industry. How do we unlock these opportunities and what is best for businesses, people and customers? The 2019 conference will provide a great opportunity for members and their businesses to better understand changing customer requirements, network with key decision-makers and industry professionals, and discuss business products and services.

• Other sponsors in Epiroc, Weir Minerals, Terex and Liebherr.

• Trade exhibitors, including AEG, AVWeld, Carlson, Kinder, Lincom, Metso, Minprovise, Precisionscreen, Trimble, and Wirtgen Group.

For inquiries about sponsorship or the trade exhibition, visit conference.quarry.com.au/sponsors/ Furthering education Are you looking to advance your skills further? The IQA offers programs for completion of Diploma Certificates 3 & 4 in Surface Extraction Operations, the Diploma of Surface Operations Management and Advanced Diploma of Extractive Industries Management, plus numerous Professional Development Programs (PDPs) and wPDPs. For more information, turn to page 50 or visit quarry.com.au/rii KYLIE FAHEY Chief Executive Officer Institute of Quarrying Australia

Quarry June 2019 49

2019 IQA EVENTS ACT BRANCH

NORTH QUEENSLAND BRANCH

WESTERN AUSTRALIAN BRANCH

12 July 15 Nov

19 June Safety & Health Seminar, Townsville 26 July Annual Golf Day, Cairns 13 Aug AGM and dinner meeting, Townsville 13 Sept Annual golf day, Townsville 8 Oct Technical and dinner meeting, Townsville 30 Oct Technical and dinner meeting, Cairns 15 Nov Christmas Party, Townsville

21 June Brikmakers clay brickworks site visit and sundowner 7 Aug Breakfast meeting, Beaumonde on the Point, East Perth 3 Sept AGM and dinner meeting, Imperial Court Restaurant 22 Nov Annual golf day, Joondalup Resort

Dinner meeting (Venue TBA) Dinner meeting (Venue TBA)

NSW CENTRAL WEST SUB-BRANCH 14 June

Women in Quarrying seminar

NSW ILLAWARRA SUB-BRANCH 17 July AGM and dinner meeting (Venue TBA) 30 Nov Races day (Venue TBA)

QUEENSLAND BRANCH 14 June Quarrying Safety & Health Conference, Brisbane 7 Aug Dinner meeting & AGM, Brisbane Sept CMEMC 2019

CENTRAL QUEENSLAND SUB-BRANCH 19 July

Annual golf day, Rockhampton

SOUTH AUSTRALIAN BRANCH 12 July Women in Quarrying Conference, Adelaide Pavilion 30 Aug AGM/dinner, National Wine Centre

All dates and venues for the above branches are correct at time of press. Not all branches had confirmed their activities/ dates. For further information about IQA branch activities, contact your local branch representative (see IQA branch contacts on page 51) or visit quarry.com.au

VICTORIAN SUB-BRANCH 25 July 12 Sept 21 Nov

Dinner meeting, Bendigo Dinner meeting, Ballarat Dinner meeting, Bendigo

PDP WORKSHOPS & EVENTS To register for the events below and for further information, visit: quarry.com.au, click on link to ‘Education’, followed by ‘Upcoming Professional Development Programs’.

QUARRYING SAFETY & HEALTH CONFERENCE

MANUFACTURED SAND WPDP

Geelong Football Club, Kardinia Park Geelong, Victoria 1-3 October (Tuesday to Thursday), 2019

14 June 2019

“The Future of Quarrying” will be the theme of the IQA’s annual conference which this year will be hosted at the home of the Geelong Cats AFL Football Club. The conference program will focus on numerous topics, including: the maximisation of limited natural resources through technology; the benefits of effective management of workplace diversity; new developments in emerging fixed and mobile plant technology; environmental and economic trends impacting on the industry; and much more. In a first, the conference program will be hosted on a Tuesday, Wednesday and Thursday.

For more information, visit quarry.com.au

The Quarrying Safety & Health Conference,

Manufactured sand is increasingly used in the construction materials industry as the availability of natural sand deposits declines.

This webinar outlines the uses and typical properties of manufactured sand, and briefly covers operational issues during production and use of the product. This webinar is suitable for managers, supervisors, testers and operational management employed or seeking employment in the industry.

IQA 62ND ANNUAL CONFERENCE

50

Quarry June 2019

Brisbane Convention & Exhibition Centre

which is co-hosted by the CCAA, the IQA and the Queensland Department of Natural Resources, Mines and Energy (DNRME), is now into its 17th year. This year’s day-long event will include thought provoking keynote speakers, a DNRME update and other presentations on practical issues affecting the quarrying industry. The conference will be held in the Boulevard Room at the Brisbane Convention & Exhibition Centre.

For more information and to register, contact Cassandra Koutouridis, CCAA, email cassandra.koutouridis@ccaa.com.au or Jennifer Milward, IQA, tel 0419 782 688 or email qld-admin@quarry.com.au

17 June 2019

CCAA CONCRETE PRACTICE COURSES & WORKSHOPS 19-20 June, Brisbane 2-3 July, Adelaide 24-25 September, Perth This course - developed in consultation with the industry for the industry - has been designed to provide participants with a detailed understanding of concrete

The Institute of Quarrying Australia

material and behaviour in relation to physical properties, production, placing and associated on-site operations such as reinforcement and potential causes of failure. It comprises of two parts: (i) 14 eLearning modules that have been developed to enhance the industry’s knowledge of concrete and featuring embedded activities and assessments in a sequential, easy to follow, and easy to navigate format; and (ii) workshops held around the country that will feature presentations from industry experts, Q&A panel sessions with industry experts, group work and case studies, and a final assessment. Participants will be required to complete all modules prior to attending the workshop (as learnings will be referred to and enhanced during the two-day workshop) and should allow five to six weeks to complete all of the modules. Registrations will close five weeks prior to each workshop and attendance at the two-day workshop is a requirement to complete the course. A personalised certificate will be issued upon successful completion of parts 1 and 2 of the course. The cost of admission is $1800 (inc GST) for CCAA members and $2200 (inc GST) for non-CCAA members. For further information, contact the CCAA’s learning and development manager Ceridwen Jones, tel 02 9667 8319, email ccaaeducation@ccaa.com.au

of mine transport and the aspiration for zero emissions mine fleets. Key note speakers for the event include: Darren Miller, CEO of the Australian Renewable Energy Agency; Grant Nicholas, director of the ANZ Bank’s Natural Resources Group; Kevin Jamieson, the National Australia Bank’s natural resources director; Michael Dolan, hydrogen innovation and development lead for Fortescue Metals Group; Michael Scotton, Rio Tinto’s energy strategy senior manager; and Kirsten Rose, BHP’s head of low emissions technology. For more information, contact delegate director Olivia Mendoza, tel 08 6102 7568, email olivia.mendoza@ energyandmines.com

ENERGY AND MINES AUSTRALIA SUMMIT

8 July 2019

Westin, Perth 19-20 June 2019 Now in its third year, the Energy and Mines Australia Summit enables miners to meet energy providers to develop affordable, reliable, low carbon energy projects for gridtied and remote mines. In Australia, in particular, the economics of renewable energy in mining is compelling and the mining sector is actively looking for experienced, and reputable partners to address their energy challenges and take advantage of the affordable, reliable power delivered by renewables and storage.

Topics to be discussed at the event include: Australia’s hydrogen economy and mining sector opportunities; changing energy economics and options for mining operators; low cost electricity with solar and storage; the role of renewables to address cost and supply challenges; energy challenges and options for new and existing mines; global developments in hybrid power for mines; advancing remote power solutions for mines; and the decarbonisation

PERFORMANCE IMPROVEMENT WPDP 24 June 2019 This webinar doesn’t require an in-depth knowledge of statistics, pareto analysis, or six-sigma. It provides grassroots basic tools that will help participants to identify opportunities and manage the improvement cycle. It is suitable for managers, supervisors, operational employees, and operational management employed or seeking employment in the industry.

QUALITY CONTROL & STATISTICS WPDP Effective quality control forms an essential part of professional quarry production processes. Conformance with specifications, predictability, and repeatability of product results helps quarry managers to control costs and ensure repeat business. This webinar is suitable for managers, quarry/ laboratory supervisors, testers, and operational management employed or seeking employment in the industry.

QUARRYNZ 2019 17-19 July 2019 ILT Stadium Southland Invercargill, New Zealand Registrations for the annual joint conference of the Aggregate and Quarry Association of New Zealand and the Institute of Quarrying New Zealand are now open to delegates, partners, sponsors and distributors.

The conference is an opportunity for all those involved in the industry to interact and exchange ideas, take the opportunity to hear the experiences of guest speakers and to socialise with old friends and colleagues

and to make new contacts. The theme of the conference will focus on the region’s contribution to the New Zealand economy: Southern Rock anchoring NZ. The social program will include three functions, tickets for which will be included in delegate and partner registration packages. For more information, visit quarrynz.com

COST MANAGEMENT FOR QUARRIES WPDP 22 July 2019 With increased pressure on productivity, profitability, efficiency and asset utilisation, the focus on cost control has never been more important. Quarry managers are the front line in cost management.

Daily decisions directly influence monthly profit outcomes. This webinar defines the various cost terms used in the industry, discusses how they are influenced, and provides potential system solutions to increase cost and performance visibility.

It is suitable for managers, supervisors, operational employees, and operational management employed or seeking employment in the industry.

SPECIFICATIONS WPDP 5 August 2019 Specifications provide the basis for conformance of most construction materials. This webinar will take the participant through the various documents that affect and influence quarry products.

It will cover specifications as dictated

by Australian Standards and state road authorities, and how to read and interpret specification documents. It is suitable for sales managers, technical/laboratory managers, quarry supervisors, testers and operational managers.

TEST METHODS WPDP 19 August 2019 Many product issues encountered by quarry operators can be traced back to having a good understanding of the material and its properties. Having an understanding of how each test is performed and corresponding results determined can assist quarry personnel in recommending products to customers, as well as limiting future product technical claims or issues. It is suitable for sales managers, quarry managers, quarry supervisors, testers, and operational management employed or seeking employment in the industry.

Quarry June 2019 51

IQA NEWS should have taken from the day were that: • Diversity and inclusion play a significant part in the ongoing success of the business.

• All people are capable of being agents of positive change.

• Challenge is an access point for growth.

Fiona Robertson spoke about leadership in the resources sector.

NSW WOMEN IN QUARRYING CONFERENCE The New South Wales Women in Quarrying (WIQ) conference was attended by 170 persons throughout the NSW quarrying industry. It was held on the 8th of February 2019 at the Hyatt Regency Sydney.

The conference acknowledged and celebrated the contributions of women to the extractive industry and created a platform to further encourage their involvement in the industry. It also provided an opportunity for people across the industry to connect, network and share their experiences. While the program is designed specifically with women in mind, the conference welcomed attendance from all industry colleagues.

IQA CEO Kylie Fahey opened the conference, followed by the national WIQ coordinator Tegan Smith, who gave an overview of the WIQ’s work in 2018 and discussed its national strategy for this year.

Other speakers on the day included: • Clarity and perspective coach, speaker and teacher Vashti Whitfield, who conducted workshops on the impact of unconscious bias on sustainable long-term success, and the mitigation of unconscious bias through legacy leadership. Participants responded that “Vashti was great and held the whole event together” and “Vashti is a superstar”. Vashti successfully weaved a narrative throughout the day that highlighted the importance of diversity and how all people can be agents of change. The sessions were geared towards personal accountability and her workshops throughout the day were designed to be challenging and stimulating.

• Fiona Robertson, the non-executive director for mining and energy at Whitehaven Coal, who spoke about leadership in the resources sector. Fiona has 40 years’ experience in corporate 52

Quarry June 2019

(l-r) Dallas Wilkinson, Tegan Smith, Kylie Fahey, Ali Burston, Fiona Robertson, Chloe Quinn, Peter Lawlor and Vashti Whitfield.

finance, including 30 years working with emerging and mid-tier resource companies as a banker, chief financial officer (CFO) and non-executive director.

After graduating with a degree in geology, she joined The Chase Manhattan Bank in London. Her early career included corporate banking, risk management and resource industry financing roles with Chase in London, New York and Sydney, before moving into CFO roles with various ASX-listed mining and oil and gas companies. Currently, she is a non-executive director of three companies - ASX-listed Whitehaven Coal and Heron Resources, and private equity-backed MPC Kinetic. Fiona has played an active role in the the Australian Institute of Mining and Metallurgy Women in Mining Network (WIMnet), sitting on the national WIMnet committee from 2012 to 2017 and chairing WIMnet NSW, the state-based networking and mentoring arm, from 2012 to 2015. She continues her involvement in co-ordinating WIMnet’s very successful mentoring program in NSW. Fiona was named the gender diversity champion in Australian resources at the 2017 Women in Mining and Resources National Awards, and the gender diversity champion in NSW mining at the 2017 NSW Minerals Council’s Women in Mining Awards.

• Dr Dallas Wilkinson, the Asia-Pacific managing director of the Dennemeyer Group, who discussed mentoring programs for diversity and inclusion.

• Chloe Quinn, Orica’s NSW and ACT territory manager for quarries and construction, who outlined business strategies for improving diversity.

• Dr Ali Burston, who spoke about the WIQ’s NSW mentoring program for 2019 and called for registrations for both mentors and mentees.

The NSW WIQ co-ordinator Natalie Hansen said that the key messages that members

Work is underway to finalise the WIQ mentoring initiative aimed to support women in the industry to align with senior mentors to assist and support their development.

The conference was sponsored by Orica, Hy-Tec, Holcim, Boral, Hanson, Groundwork Plus, VGT, Komatsu, 888 Crushing & Screening Equipment, Cement Concrete and Aggregates Australia and the Australian Institute of Quarrying Education Foundation.

Simon Kuestenmacher will speak at the Quarrying Safety & Health Conference in Brisbane.

QUEENSLAND BRANCH NEWS Quarrying Safety & Health Conference The annual Quarrying Safety & Health Conference is on again at the Brisbane Convention & Exhibition Centre on Friday, 14 June. With the support of the conference’s gold sponsors - Komatsu, Astec Australia, and Evolution Mining – the conference planning committee has ensured this year’s program provides the latest in case studies and information relevant to safety and health in the extractive industry.

This year’s technical program includes: • Case studies by Andrew Macqueen, the head of safety, environment and quality for Wagners; Kristin Devlin, risk manager for Hanson; and Rakeev Ramankutty, the general manager of Sunstate Cement.

• Crucial behaviours safety program, featuring Greg Scanlan, the general manager of safety and sustainability at Oceana Gold.

The Institute of Quarrying Australia

• Skills for Australia update – skills required in the extractive industry – presented by Juliet Kwang, of PwC Australia.

• Current status and future of critical control management in the quarrying industry, presented by Sharyn Cobbin, the education and training manager of the Minerals Industry Safety and Health Centre at the University of Queensland.

• Inspectorate updates, legislation and competencies, featuring Lucha Rocchi, the Queensland Chief Inspector of Mines and Herman Fasching, the Deputy Chief Inspector of Mines.

• Findings of crystalline silica/improvements, with Greg Manthey, the Inspector of Mines specialising in occupational hygiene.

• Education for the extractive industry, presented by IQA CEO Kylie Fahey.

• Collision management risk evaluation for mobile equipment, with Chris Doran, the managing director of Mitacom.

• Drone technology, with Dave Arnott, resource manager for Holcim.

The closing address will be made by Simon Kuestenmacher, from The Demographics Group. Simon will outline how new technologies, new generations and new skills are changing the workplace.

The conference will also feature a trade exhibition comprising suppliers such as Komatsu, Groundwork Plus, Cotral Australia, the MinRes Training Institute, Coolfog ( Access Environmental Systems), Breathe Safe, GroundProbe, Kinder Australia, Global Road Technology, Astec Australia, Hammersley Australia, Clean Space Technology, OHMS Hygiene and Evolution Mining.

Registrations for the conference are now open. Visit the IQA website – quarry.com.au – or contact the Queensland branch secretariat, tel 0419 782 688 or email qld-admin@quarry.com.au

By Jennifer Milward

competencies, featuring Lucha Rocchi, the Queensland Chief Inspector of Mines and Herman Fasching, the Deputy Chief Inspector of Mines.

• Findings of crystalline silica/ improvements, with Greg Manthey, the Inspector of Mines specialising in occupational hygiene.

• Education for the extractive industry, presented by IQA CEO Kylie Fahey.

• Current status and future of critical control management in the quarrying industry, with Assoc Prof Carmel Bofinger, of the Minerals Industry Safety and Health Centre at the University of Queensland.

• Drone technology, with Dave Arnott, resource manager for Holcim.

• Mental health in young Australians, presented by Nicole Thomas, the community development leader of Headspace.

The seminar will conclude at 4.00pm, followed by informal drinks and snacks through to 6.00pm.

To register, visit the IQA website – quarry. com.au – or contact the Queensland branch secretariat, tel 0419 782 688 or email qld-admin@quarry.com.au

By Jennifer Milward

clay preparation through to final packaging.

Be sure to keep the evening of Tuesday, 3 September free. The branch will be holding its AGM at the Imperial Court Restaurant and – drum roll – coming back to perform for us is Freddie (Mercury), aka Thomas Crane, the front man for Queen tribute band Bohemian Rhapsody. He last entertained the branch in 2013.

For information about these events, or any of the activities of the WA branch, contact the branch secretariat, tel 0417 027 928 or email wa-admin@quarry.com.au

By Celia Pavri

IQA NEW MEMBERS GRADE

NAME

BRANCH

T/Member Student Associate Member Associate Member Member Associate Associate Associate Associate Associate Member Member Associate Associate Member

Gene Joseph Howard NSW Stephanie Kriznjak NSW Mark Arnold NSW Hendrik Lourens NSW Greg Burnett QLD Michael Greelish QLD Nicholas James Bamford QLD Adrian Parkin SA Megan Coles SA Jake Samuel Schmidt SA Zachary John Sims SA Dominic Carl Barro VIC Elizabeth Gibson VIC Daniel Zanin VIC Jan Averhaus WA Jesse Sullivan WA Edoardo Sommacal WA

IQA BRANCH CONTACTS

Richard Sellers (right), with WA branch chairman Phil Harris.

ACT

Peter Hewson: 0429 001 476

NSW

Gemma Thursfield: 0402 431 090

Northern Gemma Thursfield: 0402 431 090 Hunter Gemma Thursfield: 0402 431 090 Illawarra

Dylan Treadwell: 0418 632 057

Central West Mitchell Bland: 0428 462 987

NORTH QUEENSLAND BRANCH NEWS

WESTERN AUSTRALIAN BRANCH NEWS

Safety & Health Seminar, Townsville The annual Quarrying Safety & Health Seminar, co-hosted by the IQA and the Queensland Department of Natural Resources, Mines and Energy, will be held in Townsville on Wednesday, 19 June, commencing at 9.30am at Rydges South Bank.

About 55 members attended the WA branch’s breakfast function on 8 May to listen to Richard Sellers, the director general of Transport WA discuss the state’s transport priorities, including Metronet and the Westport Strategy.

Gladstone Jennifer Milward: 0419 782 688

The branch’s next function, on 21 June, is a site visit to Brikmakers clay brick works, where members will have the opportunity to see the modern brick-making process from

Victoria

The topics of the seminar program will include: • Inspectorate updates, legislation and

NT

Darren McKenna: 08 8988 4520

QLD

Jennifer Milward: 0419 782 688

Townsville Jennifer Milward: 0419 782 688 Cairns SA

Chris Wilson: 0438 134 752 Marie Cunningham: 08 8243 2505

Tasmania Nicholas Palmer: 0418 126 253 Eli Carbone: 03 8637 4723

Vic Sub-branch Craig Staggard: 0407 509 424

WA

Celia Pavri: 0417 027 928

Quarry June 2019 53

GEOLOGY TALK

POOP SAND HAPPENS!

Figure 1. ‘Star sand’ forams have star-shaped shells.

The sand on Rainbow Beach, on Queensland’s Sunshine Coast, features a myriad of colours.

Image courtesy of S Newrick, Wikimedia Commons.

Figure 2. Some foram tests have a reddish-pink colour when they collect on the beach.

As winter sets in down under, Bill Langer and his wife are visiting east coast beaches in the US, where (to quote Lewis Carroll) there are “such quantities of sand, indeed” – and also lots of poop!

foram tests (Figure 1), hence the name “Star Sand Beach”.

In some other areas, such as Bermuda, the foram tests have a red tinge to them, so when they collect on the beach they give it a reddish-pink colour (Figure 2).

To top things off, some sand is made of poop – fish poop, to be a little more technical. A major poop sand specialist is the parrotfish, those blue and yellow fish that populate tropical coral reefs.

Parrotfish eat the hard calcium carbonate skeleton of the coral, the soft-bodied coral organisms (called polyps) that cover the skeleton, the zooxanthellae (algae) that live inside them, and the bacteria living inside the coral skeleton. The soft organisms, algae and bacteria are absorbed, but the chewed-up dead coral shoots straight through the parrotfish pretty much unchanged. It comes out as sand-sized pieces of coral – and a lot of it. One large parrotfish can produce upwards of 453kg (or 1000 pounds) of poop sand a year!

However, don’t worry, you don’t necessarily need to abandon your coral reef island. Poop sand is not unsanitary or dangerous in any way. As they say: “Poop sand happens!” •

T

his northern summer my wife Pam and I are going to be visiting some sandy beaches on islands in New England.

Beach sand originates from many sources and environments. In New England, most of the sand comes from rocks that were eroded into small pieces by the glaciers during the Ice Age. The different colours of the sand come from the different types of rocks that the glaciers eroded.

Outside of glaciated areas, many beaches are made of sand that forms over millions of years as bedrock erodes through slow but persistent weathering. Once freed from the bedrock, the small rock fragments travel down rivers and streams. Softer minerals decompose, while hard minerals such as quartz and feldspars remain behind.

Once they make it to the ocean, the more resistant mineral fragments further erode from the constant action of waves and tides. Eventually, the resulting sand grains are thrown up on the beach by the waves.

Because quartz and feldspar are the most resistant minerals, beaches commonly are white (from the quartz) or tan (from the feldspar).

In contrast, there are some really beautiful black sand beaches in places with nearby volcanoes such as in Alaska, the Canary

54

Quarry June 2019

Islands, Hawaii, Iceland, Martinique, New Zealand, Puerto Rico and Tahiti. Hawaii also has green beaches made of a green volcanic mineral called olivine. Moreover, for a multitude of coloured sands, you should try Rainbow Beach on Queensland’s Sunshine Coast.

Instead of forming from grains eroded from rocks, oolitic sand (made from oolites) is unusual sediment that “grows” in shallow, very saline waters. An oolite resembles a tiny onion consisting of concentric layers of calcium carbonate that precipitated around a nucleus, or central core.

The nucleus is usually a mineral fragment, or could even be a tiny shrimp faecal pellet. Oolites form in warm tropical waters surrounding the Bahamas, the eastern Mediterranean Sea, the Persian Gulf and even in the Great Salt Lake of Utah.

Some sands are biological in origin, as they are formed from single-celled organisms called foraminifera (forams for short).

Forams have a shell or “test”, usually made of calcium carbonate, that mostly encloses their cytoplasmic body. When the critters die, the shells fall to the sea floor and eventually wash up onto the beaches.

In some places, such as Hoshizuna-noHama in Japan, the forams have star-shaped

Bill Langer is a consultant geologist.

Email bill_langer@hotmail.com or visit researchgeologist.com

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