Quarry Dec 2019

DECEMBER 2019

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

DECEMBER 2019

PARTNERSHIP OPENS DOOR FOR ULTRA-FINE SOLUTIONS

ALL-IN-ONE PLANT ADVANCES M-SAND

A partnership of two family companies will offer sand producers even more scope

How the driest of quarries can now benefit from wet processing options

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A producer has overcome dry conditions with a series of advanced washing systems

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QUARRY

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www.quarrymagazine.com

CLOSED LOOP WATER SYSTEM DEFIES DROUGHT

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IN THIS ISSUE DECEMBER 2019

VOLUME 27, ISSUE 12

FEATURES 16 MODULAR PLANT OPTIMISES PROFITS A family quarrying and transport business has made a significant investment in a sand washing solution.

27 SMARTER WASHING SOLUTION The persistence of an aggregates producer for a cleaner end product has paid off.

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CLOSING THE LOOP A producer has overcome drought with a series of advanced washing solutions.

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40 SAVINGS THROUGH FINES PROCESSING ULTRA-FINE PARTNERS A partnership of two family companies opens the gate to more sand processing options.

How do you develop a manufactured sand process that maximises output while minimising energy, water?

43 HAS WASHING ENTERED A PARADIGM SHIFT? The first Alliance Low Water Washer has been successfully commissioned in a NSW basalt quarry.

44 SUBMERSIBLE PUMPS PROVE THEIR METTLE Multinational submersible manufacturer Tsurumi has produced a portable, single-phase slurry pump.

46 INNOVATING WITH CUSTOM SOLUTIONS

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ALL-IN-ONE PLANT How the driest of quarries can now benefit from wet processing options.

A producer has overcome dry conditions with a series of advanced washing systems

FIRM BUSINESS CASE Georg Diem and Francis Lacote discuss the merits of crushed sand.

DECEMBER 2019

PARTNERSHIP OPENS DOOR FOR ULTRA-FINE SOLUTIONS

ALL-IN-ONE PLANT ADVANCES M-SAND

A partnership of two family companies will offer sand producers even more scope

How the driest of quarries can now benefit from wet processing options

24

CLOSED LOOP WATER SYSTEM DEFIES DROUGHT

20

14

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

32

A screen media manufacturer has recently commissioned new weaving equipment at its Melbourne facility.

ON THE COVER The AggreSand 206 can produce up to three washed aggregates and two washed sands. It is a modular design with ‘plug and play’ electrical connections for quick set-up. Turn to page 16 or visit: terex.com/washing/ en/australia

EVERY MONTH 04 FROM THE EDITOR

50 IQA NEWS

06 FROM THE PRESIDENT

News from Queensland, South Australia, Tasmania and Western Australia

08 NEWS THIS MONTH 12 PRODUCT FOCUS 48 FROM THE IQA CEO

54 GEOLOGY TALK The elements of surprise

Quarry December 2019 3

EDITORIAL

WHY SAFETY SHOULDN’T BE A LOFTY CHRISTMAS IDEAL

M

aking it to the end of 2019 and spending Christmas with our families and friends ought to be a relief and a joy for everyone. Sadly, at time of writing (in mid-November), Australia has again been beset by bushfires, and it seems likely they will be an ongoing feature of a long, dry summer ahead.

While quarries and mines in the fire-affected regions should remain intact, there are nevertheless dedicated men and women in the extractive industry who will volunteer their time – whether as back-ups to the emergency services, or assisting with their firestricken communities. Some quarrying businesses will also contribute through donations or in-kind supply of water, plant, equipment and other materials.

They should be acknowledged for their selflessness and generosity.

It’s unfortunate then that the unselfish qualities in our quarries and communities are rarely exhibited by our key decision-makers at state and federal levels. Rather than working with each other and emergency services on ways to resolve the crisis, it hasn’t taken much for politicians of all stripes to descend into blaming each other.

The decade-old incendiary debate about climate change particularly gets them going.

Ultimately, what fails to be considered in this “discourse” is that the fires aren’t necessarily about climate, they’re about safety. Did alleged underfunding or under-resourcing of emergency services, or the failure to have sufficient long-term strategies for tackling drought and declining infrastructure in Australia’s regional areas, contribute to the fires? Did our decision makers break a cardinal expectation of the quarrying and extractive industries – that is, to have workable and iron-tight safety and risk management plans for accidents and disasters? Effective

environmental planning is a small part of such strategies.

When a quarry is found wanting on safety and environmental measures, it rightfully has the book thrown at it.

There seems to be no such penalty for governments that overlook safety or long-term planning.

Safety is paramount in everything we do. As parents, we constantly teach our children about safety – for themselves and their peers. Whether you’re a quarry worker, a site manager or even a journalist, you have an obligation to report things that could be hazardous in the workplace and you expect your advice to be taken seriously by your managers. Why then do politicians fail to listen to the very authorities best equipped to handle disasters?

Why don’t we see enough politicians meeting with our volunteers?

To have safe, thriving and reliable industries and services, then governments and regulators must show mature leadership.

Perhaps that’s my Christmas wish or New Year’s resolution – that all stakeholders don’t lose sight of the importance of safety amid asinine squabbles. Indeed, it shouldn’t even be a wish! To happen, though, it requires the unity and good will of governments, regulators and industries – now and long term. Failures and mistakes should be acknowledged but not as part of recriminations.

We can – and should – always strive to be better in everything we do, especially in the planning and practising of health and safety. Yes, it’s a lofty ideal but it’s one that never goes away – and should never be ignored.

Season’s greetings, everyone – and stay safe!

Published by:

TO HAVE SAFE, THRIVING INDUSTRIES, GOVERNMENTS AND REGULATORS MUST SHOW MATURE LEADERSHIP

11-15 Buckhurst Street South Melbourne VIC 3205 T: 03 9690 8766 www.primecreativemedia.com.au Publisher John Murphy john.murphy@primecreative.com.au

Editor Damian Christie damian.christie@primecreative.com.au

Journalist Myles Hume myles.hume@primecreative.com.au

Business Development Manager Les Ilyefalvy les.ilyefalvy@primecreative.com.au

Client Success Manager Ruby Viju ruby.viju@primecreative.com.au

Design Production Manager Michelle Weston michelle.weston@primecreative.com.au

Art Director Blake Storey Design Jo De Bono Subscriptions T: 03 9690 8766 subscriptions@primecreative.com.au The Publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from the advertisers and contributors against damages or liabilities that may arise from material published. © Copyright

DAMIAN CHRISTIE Editor

– No part of this publication may be reproduced, stored in a retrieval system or transmitted in any means electronic, mechanical, photocopying, recording or otherwise without the permission of the publisher.

4 Quarry December 2019

PRESIDENT’S REPORT

IQA MEMBERSHIP VALUE MORE THAN JUST THE EDUCATION ON OFFER The Institute of Quarrying

I

t’s an exciting time for the Institute of Quarrying Australia. I have to thank Clayton Hill for his leadership and passion in overseeing transformational change in the Institute in the past two years. We are now in a better place in terms of governance, structural reform and direction. This includes improved collaboration and progress with the International Presidents as we establish the IQ Connect initiative.

Thanks also to all IQA members and board directors for supporting me and Grant Farquhar with our appointments as President and Deputy President for the next three years.

I am honoured to be given this opportunity to give back to the IQA and the industry that I owe so much. The IQA has been an integral part of my life, helping me grow personally and professionally, including making life-long friends from all parts of the industry. I ask, what other industry offers that level of value and connection, no matter where you work or who you are?

I have been a member since 1989 and Boral, the company for whom I’ve worked throughout this time, has supported my involvement and invested in my professional development by enabling me to attend IQA conferences, technical seminars, workshops and social events. I have heard the question asked: “What value does the IQA offer?”

For me, the answer is not just about the educational offering – that is, growing in terms of its applicability and variety – it also includes the value of networking that you don’t necessarily appreciate until you have to pick up the phone to ask for help, or someone hears that you are in need and reaches out.

I am excited about the years ahead as we strengthen the foundations on which to build a progressive, modern Institute that our stakeholders value. The IQA Board, the CEO and its administration

6 Quarry December 2019

Australia

are united and committed to provide the leadership, direction and support to the branches and sub-branches, so that we can continuously improve value to our members and the industry.

In February 2020, the IQA Board will review the strategic plan that has guided us for the past three years. As things are likely to change, so must we.

Therefore our strategic plan will identify new ways to build on existing strategies that: retain and grow our membership; grow revenue from alternative sources; provide education programs and pathways for high school students and university graduates, and professional development for all the people who work in this great industry; encourage young people to participate; increase gender diversity; and widely promote the quarrying industry so that members and industry partners can progressively inform and encourage stakeholders to support and invest.

The IQA is committed to the future while delivering value today and every day. We need your feedback, support and participation for that to happen. If you have an issue that you would like the Board to consider in the strategic plan review, please contact any of the directors, CEO Kylie Fahey or myself via email: admin@quarry.com.au I look forward to getting around Australia and meeting as many members as possible. Please make yourself known to me, ask questions or provide feedback at any time.

Finally, as 2019 draws to an end, on behalf of the IQA Board, its branches, sub-branches and administration, I wish you and your family a happy, healthy and safe New Year.

SHANE BRADDY President Institute of Quarrying Australia

Educating and connecting our extractive industry

quarry.com.au THE IQA IS COMMITTED TO THE FUTURE WHILE DELIVERING VALUE TODAY AND EVERY DAY.

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 General, membership and financial inquiries should be directed to admin@quarry.com.au or phone 02 9484 0577.

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NEWS

$142M INDUSTRIAL REAL ESTATE DEAL FOR REDEVELOPED QUARRY ‘WE ARE WELL POSITIONED TO DEVELOP PREMIUM LOGISTICS PROPERTIES IN HIGH DEMAND, LOW SUPPLY LOCATIONS.’ PHIL PEARCE, ESR AUSTRALIA CEO

Building products supplier CSR has sold its 21ha redeveloped Horsley Park quarry site in Western Sydney (pictured) to multinational real estate developer ESR.

Asia-Pacific industrial real estate company ESR has purchased a 21ha redeveloped quarry site in Western Sydney from building products supplier CSR. Hong Kong-based ESR announced in November that it had purchased the site within CSR’s Horsley Park industrial development in Burnley Road, 40km west of Sydney, for $142.5 million.

When fully operational, ESR expects to offer up to 110,000m2 of industrial space across as many as six warehouses, strategically located near major transport links. It forms part of the company’s continued expansion

into the Australian industrial and logistics real estate market.

“With the addition of these recent acquisitions to our existing land bank, we are well positioned to deliver on our strategic priority of developing premium logistics properties in high demand, low supply locations for our customers,” ESR Australia CEO Phil Pearce said.

CSR has been undertaking the 50ha Horsley Park redevelopment in three stages, with stage one (10ha) sold to Frasers Property Group for $58m in April 2018. ESR has purchased the second tranche of land, involving development of a former clay quarry.

A CSR spokesperson said the quarry ceased major operations 30 years ago but there had been limited quarrying activity as recently as five years ago for the PGH Bricks plant located adjacent to the site.

The stage two redevelopment of the quarry pit and associated bund walls has required extensive geotechnical works to recompact the site that once reached 26m in depth. It is anticipated CSR will take up to 13 months to complete the geotechnical works before building the necessary road network and services.

CSR has also constructed a substantial bund wall at the rear of the property, which incorporates mature trees, to separate the development from residential properties.

Once developed, the site will be called ESR Horsley Logistics Park.

According to ESR, it is situated within the highly sought after Western Sydney industrial market and near major transport links, including the M4 and M7 motorways and the future Western Sydney Airport.

Since its 2018 entry to the Australian market, ESR has exchanged contracts for several industrial sites in Sydney, Melbourne and Brisbane, accounting for around 70ha of land and 330,000m2 of logistics space. Horsley Park brings ESR’s total development pipeline in Australia to around $1.8 billion. •

GUIDELINES DEVELOPED FOR CONCRETE BATCH PLANTS Cement Concrete & Aggregates Australia (CCAA) has released a new resource to assist concrete batch plant operators comply with environmental obligations.

The Environmental Management Guideline for Concrete Batch Plants aims to facilitate a “fit for purpose” approach to hazard management and drive national consistency.

“This is the first such document that does this on a national level in partnership with all state-based Environment Protection Authorities,” the CCAA’s Victoria/Tasmania state director Brian Hauser told Quarry.

“The guideline takes what can sometimes

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Quarry December 2019

be a diverse range of confusing regulatory requirements across different states and, in a very practical way, allows operators to develop an environmental management system for their own particular plant and needs.”

The guideline was developed under the auspices of the CCAA’s National Premixed Concrete Committee, chaired

by Holcim Australia CEO George Agriogiannis, with senior executives from CCAA member companies.

A working group of six nationally representative experts was convened from the CCAA membership in late

The CCAA’s Environmental Management Guideline for Concrete Batch Plants.

2018 to develop the guideline.

Operators can find the resource on the CCAA’s website: ccaa.com.au •

COUNCIL ROAD LEVY ‘DISADVANTAGES’ QUARRY

COUNCIL LOOKS TO COMMUNITY FOR NEW GRAVEL SOURCE A central Victorian council is seeking alternative locations to source gravel for its 3000km road network after it scrapped a proposed site due to community opposition.

Cr Tony Driscoll.

The owner of Oberon Quarries says his business pays a council levy to maintain local roads but other operators in the region are not.

A New South Wales Central Tablelands quarry operator believes a fee his business pays on a per tonne basis for road maintenance creates a competitive disadvantage.

Neil Hargraves, managing director of Oberon Quarries, 180km west of Sydney, says his is one of the only remaining businesses in the region with haulage vehicles that pays contributions to the Oberon Council for ongoing maintenance of the local road network.

“It would be nice to be on an even playing field with everybody else,” he said. “The road levy was part of the original establishment approval of the quarry, which at the time was reasonable given it was one of largest operations in the area.

“As of now there are larger tonne movers on the local roads which are not subject to the levy. In my view this greatly disadvantages us.”

Oberon Quarries, 5km south-east of Oberon, was established in 1994.

Today it comprises 43 staff and 25 trucks to extract, process and supply basalt for use by councils, asphalt plants, cement plants, RMS projects and the general construction industry.

The business has provided material for projects including Mount Panorama, Mascot Airport, the Sydney Harbour Bridge, RMS roads and the Oberon community, helping lower the council’s operational costs.

During the lifetime of its operations (30 years), Oberon Quarries’ development consent has required it to make Section 7.11 contributions on a per tonne basis to an Oberon Council restricted cash reserve.

The money assists with the ongoing maintenance and/or capital

improvements on the 12km of road network used by the company’s heavy haulage vehicles and use of specific haulage roads.

Hargraves said the quarry contributed about 48 cents per tonne to the council. Historically, this money has paid for a $1.5 million upgrade to Titania Road, which the quarry uses for transportation. On 30 June, 2019, the council’s cash reserve – of which Oberon Quarries is a contributor – had a balance of almost $485,000.

The council recently agreed to transfer $450,000 of those funds for spray re-sealing purposes on roads used by Oberon Quarries’ trucks.

While he understands the reasons for paying contributions and is glad the council is using the money appropriately, Hargraves believes it is unfair that other similar businesses in the region are not contributing to the same level for road maintenance, leaving the council to foot the bill.

“While the levy guarantees roads used by our operation are maintained, we feel council should review its application of this type of levy on other businesses in the area or remove it to even the playing field locally,” he said.

Oberon mayor Kathy Sajowitz said Oberon Quarries was not the only quarry operator in the area required to pay contributions for road use.

“These types of industries, such as quarries, have a significant impact on the local road network through heavy vehicle movements,” she said.

“Council’s contributions plan outlines the requirements for developments of this nature and regulators take these requirements into account when considering applications of this nature.” •

The Northern Grampians Shire Council withdrew an application to establish a new gravel quarry in the Victorian town of Carapooee, 105km west of Bendigo.

Testing had shown the site had a reserve that could have replaced the nearby existing Mine Lane Quarry. However, following consultation with residents in close proximity to the proposed Stuart Mill Quarry, the council decided to no longer pursue the site.

The council now needs to find a location that would minimise impact on residents, while providing enough locally sourced gravel to construct and maintain more than 3000km of local roads and bridges in the shire.“There is still a need to focus on reducing construction and cartage costs so that the community is provided with a road network that provides value for money,” councillor Tony Driscoll told Quarry. “This needs to be done with consideration to local residents living in the vicinity of these quarries.”

The council is undertaking a trial of gravel sourced from a registered quarry in the St Arnaud area up to 20km away, and early results indicate it could be a future source.

Further investigations have also shown “good initial indications” of quality gravel sources in and around the shire’s northern areas.

Driscoll said the council traditionally operated its own quarries to reduce costs, and would look to do so going forward.

Local authorities are also encouraging landowners with a gravel resource who are open to the possibility of it being used as quarry to contact the council. •

Quarry December 2019 9

NEWS

STRONG THIRD QUARTER REVENUES TEMPERED BY WEAKER OUTLOOK Global minerals processing OEMs Terex Materials Processing Systems (Terex MPS) and Metso have reported strong returns for the third quarter of 2019.

Terex MPS, one of two business streams under Terex Corporation, generated $USD339 million ($AUD492m) in sales for the three-month period ending 30 September. This was an increase of eight per cent on the same quarter in 2018 – or 12 per cent, excluding the impact of foreign exchange rates.

The Terex MPS business includes the brands Finlay, Powerscreen, CBI, Ecotec and Fuchs.

According to the company, third quarter revenue was driven by global demand for its crushing and screening products, material handlers, cement mixer trucks and load and haul equipment.

The company reported total backlog sales of $USD264 million ($AUD383m), while bookings in the quarter reached $USD236 million ($AUD342m).

“We had an excellent quarter in materials processing, thanks to strong operational execution across our businesses,” Terex MPS’s president Kieran Hegarty said.

Metso reported a 17 per cent sales increase on the corresponding period, totalling 2.6 billion Euros ($AUD4.2b).

“Activity in our end markets remained healthy and is visible in the strong order intake for services.

Aggregates equipment orders were up slightly despite a seasonally low quarter in the Northern Hemisphere and the Indian market was softer than a year ago,” Metso president and CEO Pekka Vauramo said.

The results follow Metso’s recent acquisition of Canadian mobile screening and crushing equipment manufacturer McCloskey International in June, and the merger of Metso Minerals with rival Finnish equipment manufacturer xxx Outotec in July. •

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Quarry December 2019

OEM UNVEILS ELECTRIC DRIVE LOADER IN AUSTRALIAN MARKET ‘THE CAT XE RANGE WILL BE A POPULAR CHOICE FOR FAST, EFFICIENT OPERATIONS ACROSS ALL SECTORS.’ JARVAS CROOME, WESTRAC CEO

Caterpillar’s large electric drive wheel loader has been put to work at a recent showcase of the OEM’s latest innovations for the construction and extractive sectors in Western Australia.

On 31 October, dealers and key clients attended the 2019 Load and Haul Event at Quarry Farm, 56km south of Perth, where the industrial equipment manufacturer presented its articulated trucks and a range of other machinery.

Caterpillar’s new XE range – including the Cat 988K XE and 972M XE wheel loaders – were the centrepiece of the event. Building on predecessor models, they include additional features for greater productivity, efficiency and all-round performance for construction, earthmoving and smaller mining and quarrying operations.

“The highly versatile Cat XE range is going to be a popular choice for fast, efficient operations across all sectors, not to mention providing improved environmental performance for operators,” said Jarvas Croome, CEO of WesTrac, the WA and New South Wales dealer for Caterpillar.

The 988K XE is Caterpillar’s first large wheel loader with an electric drive system, promising up to 25 per cent greater overall efficiency and up to 10 per cent more productivity in load and haul applications than the equivalent 988K loader.

Its electric drive technology is also said to lower overall maintenance costs, with extended oil change intervals of 2000 hours, requiring 40 per cent less powertrain oil. It offers increased engine life expectancy by up to 3500 hours, extending time between powertrain rebuilds.

The Cat C18 ACERT engine, mechanical dropbox, driveline and axles from the 988K model have been incorporated into the electric drive machine to facilitate consistent, trouble-free operation.

Caterpillar’s showcase event, hosted by WesTrac, also provided the backdrop for the presentation of the 972M XE wheel loader, which uses 25 per cent less fuel on average compared to machines with traditional torque converters.

Caterpillar’s wheel loader range on show at the 2019 Load and Haul Event at Quarry Farm, WA on 31 October.

The 972M XE is suited to the demands of quarrying and mining operations with tighter loading areas and steep gradients. It also excels at truck loading, materials handling, construction, and industrial and waste applications that require high productivity and longer travel distances.

Other key features include a continuous variable transmission that enables smooth shifting, fast acceleration, and speed on grade, while offering fuel economy.

Caterpillar also showcased the 986K wheel loader, the 6015B hydraulic shovel, and the 745 and 740 GC articulated trucks.

Both articulated truck models feature a re-engineered cab design for enhanced comfort and ease of operation. They also include new controls, transmission-protection features, hoist-assist systems, advanced automatic traction control systems, stability-assist machine rollover warning systems, and a fuelsaving ECO mode.

There was a presentation of the Piacentini Panther low loader, which was designed by Bunbury-based contractor Piacentini & Son. It has been developed to improve safety and efficiency for loading and transporting heavy equipment around mine sites.

Croome, of WesTrac, said industry would welcome the further refinement of this range of construction and earthmoving equipment.

“We are delighted to be able to host such an important event on behalf of Caterpillar and welcome the interest and input of industry,” he said. •

RESEARCHERS OFFER ‘COFFEE’ SOLUTION FOR CONCRETE

STONE FERTILISED SOIL FOR EASTER ISLAND INHABITANTS The volcanic rock for Easter Island’s giant moai statues is believed to have contributed to the island’s “horticultural sweet spot”, according to US researchers.

Writing in the Journal of Archaeological Science, they contend that the inhabitants of Easter Island may have survived deforestation and drought for hundreds of years by using labourintensive rock gardens to increase soil fertility.

RMIT researchers say their ‘coffee bricks’ could help overcome environmental challenges.

The construction materials industry could hold the key to reducing tonnes of landfill-destined coffee waste in Australia, according to a group of Melbourne engineering researchers.

The project from the RMIT University’s School of Engineering is investigating ways to develop concrete from coffee grounds that are produced from the 1.3 million cups consumed daily across the nation.

Bachelor of Engineering students Senura Kohombange and Anthony Abiad have worked with senior lecturer Dr Srikanth Venkatesan to test and develop “coffee bricks”, which they believe have potential real world uses.

The work has initially focused on using coffee waste as a sand replacement in materials that could one day be used in homes, driveways or office buildings.

With most concrete mixes containing up to 80 per cent sand, the group found they could replace up to 10 to 15 percent of that with coffee grounds.

“It seems fitting than we’re working on this project in Melbourne, a city known for its great coffee culture,” Kohombange said.

The researchers estimate 2600 cafes in Melbourne alone produce about 156 tonnes of coffee ground waste every month, according to 2017 figures. In addition, sand is the third most used resource behind

water and air, while quarries struggle to keep up with demand.

A frequent coffee drinker, Venkatesan said it was important to find a solution to the waste produced each day. “Countries like Sri Lanka and India have restrictions on dredging and taking of the resource sand, so it is becoming a scarce material. Even if we replace 10 per cent of sand in the concrete mix, we really should be better off,” he said.

The research was built on the premise that coffee grounds blended well with sand in composting and gardening applications. Others had also previously experimented mixing coffee and concrete with limited success.

Venkatesan said the biggest challenge is ensuring the addition of spent coffee grinds does not reduce the concrete’s strength.

Depending on the proportions, the researchers found coffee grounds could weaken the concrete mix by 20 to 50 per cent, meaning the material would initially be used in nonstructural applications. Due to coffee ground being an organic material, the researchers are also testing its durability.

However, Venkatesan said other environmentally friendly products could help bring the material up to full strength. “In addition to the coffee grounds, we can use other recyclable materials like quarry dust and copper slag to take the strength to 100 per cent,” he said. •

According to the study, the weathering of volcanic rock at Easter Island’s major quarry site at Rano Raraku fertilised the surrounding soil with phosphorus and other elements to promote crop growth.

Radiocarbon dating of burned wood and plant material recovered from the quarry’s slopes suggests its inhabitants began to farm there between 1495 and 1585 AD. “Our results confirm a cultivated landscape present on the inner south and east slopes of Rano Raraku [quarry] that included sweet potato and probably bottle gourd along with Polynesian [plant] transfers banana, taro, and paper mulberry from the 14th century AD continuing into the early 19th century AD,” the researchers concluded.

“Rano Raraku [quarry] had – and still has – extremely fertile soils that are the weathering by-product of lapilli tuff sediments generated from the quarrying process.

“This study describes agricultural fertility to hypothesise a rich, multiuse landscape for Rano Raraku inner region that is unparalleled elsewhere on [the island].” •

Easter Island is world famous for its basalt moai statues.

Quarry December 2019 11

PRODUCT FOCUS LARGEST EXCAVATOR FOR TOUGHEST APPLICATIONS The EC950E crawler excavator is built for the toughest applications.

Featuring a wide track gauge, long track length, retractable undercarriage and an optimised counterweight, this 90-tonne machine can be operated in the toughest conditions. Powered by a 446kW D16 engine, a bucket breakout force of 478kN (ISO) and an arm tear-out force of 420kN (ISO), the EC950E offers enhanced digging force and quick cycle times, thanks to an improved hydraulics system, which increases pump power for a fast and smooth operation.

More information: CJD Equipment, cjd.com.au

ENHANCED FRONT-END LOADER The John Deere L-Series wheel loader combines new front-end features that can boost productivity with an all new spacious cab and ergonomic controls. Available in new series models – including the 524L, 544L, and 624L, as well as the 844L (pictured) – its enhancements include near-parallel lift, new bucket and linkage designs, and reimagined electrical and hydraulic routing for performance and reliability. It is suitable for clay, gravel, sand, granite, gypsum, limestone and sandstone applications.

More information: RDO Equipment, rdoequipment.com.au

PORTABLE CRUSHER AND SCREEN COMBO The CRH1111R portable closed circuit impactor/screen plant features the TI4143 impact crusher and a 5m x 1.5m (16’ x 5’) two-deck inclined screen. The crusher is hydraulic clutch-driven direct from a 261kW Scania Diesel engine. All other components are electric-driven from the 150kW generator. With its large capacity screen, wide conveyors, and low maintenance electric driven components, it can be a highly productive, highly portable plant in crushed concrete, asphalt or shot rock applications.

More information: Terex Jaques, terex.com/mps

VERSATILE PUG FOR MIXING APPLICATIONS Made in Australia for Australian conditions, the Scorpion pug has an output of 300 tonnes per hour and can work on any main road requirement. The standard machine is suitable for optimum moisture content roadbase jobs and cement-stabilised applications (with the incorporation of a portable additive bin). The Scorpion’s elevated clamshell design pug head makes cleaning the main belt simpler as the material is carried to the pug head dry. The programmable logic controller system enables operators to select different product mixes at the touch of a button.

More information: Precisionscreen, precisionscreen.com.au

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Quarry December 2019

To submit new product and equipment releases, email: damian.christie@primecreative.com.au

SMART SCALE FOR LOADERS When the pressure is on and customers are waiting, there is a desire to perform faster without compromising accuracy and precision. The L3180 SmartScale adjusts for rough terrain, technique, and movement so new and skilled operators can load with greater accuracy, precision and speed. With built-in Wi-Fi and GPS capabilities, it also consolidates live, operational information to provide real time productivity and performance reports for quarry operators.

More information: Trimble Loadrite, loadritescales.com

VERSATILE, ROBUST LOADER RANGE The Liebherr XPower wheel loader – comprising the L550, the L556 (pictured), the L566, the L576, the L580 and the L586 – offers the quarrying producer more efficiency and output, regardless of long or short distances, or level or uneven ground. This versatility increases productivity in all work cycles for the producer. The Liebherr XPower driveline with Liebherr Power Efficiency achieves a reduction in fuel consumption of up to 30 per cent. The XPower loader’s other components are extremely rugged and low wear. Liebherr wheel loaders can provide maximum performance, even under the toughest, most challenging conditions.

More information: Liebherr Australia, liebherr.com

ROBUST IMPACT BELT SUPPORT SYSTEM Repeated impact from heavy lumps, long drop heights or lumps with sharp edges can potentially cause damage to a conveyor belt’s top cover. The centre of the K-Dynamic impact bed is suspended on anti-vibration mounts that significantly reduce the risk of belt damage. The system features elastic properties that can effectively reduce the full force of the material stream compared to impact idlers or a conventional impact cradle. The modular design is available in all belt widths and includes fixed wings for effective skirting and low friction UHMWPE slider rails.

More information: Kinder Australia, kinder.com.au

MOBILE MULTI-FREQUENCY SCALPER The GT165MF tracked multi-frequency scalping plant can increase productivity and efficiency when screening material of vastly different sizes.

Its bottom deck has six independently controlled exciters that can each apply an additional frequency to the screen media of up to 4200 rpm. For each 760mm of length on the bottom deck media, each exciter is adjustable for frequency, amplitude and stroke. This maximises screening efficiency for the whole screen box and advances incline screening technology from traditionally only having one adjustable operational configuration to seven.

More information: Astec Australia, astecaustralia.com.au

Quarry December 2019 13

SAND PROCESSING

SAND PRODUCER DEFIES DROUGHT WITH CLOSED LOOP WATER SYSTEM With drought in South Australia’s northwest region threatening the viability of a producer’s sand washing operation, a supplier has come to the rescue with a series of advanced water management solutions.

C

linton Sands is a repeat customer for Terex Washing Systems (TWS) Australia. Back in 2017, the company purchased a bespoke Finesmaster Hydro wet classification system for high efficiency separation of fine and coarse sands.

In July 2019, TWS Australia installed a TWS Aquaclear water management system to process the tailings from the Finesmaster Hydro.

The drought conditions experienced on the Yorke Peninsula, South Australia in 2018 brought the issue of water security firmly into focus for the managers of Clinton Sands.

Without water, the business of washing sand would not be possible and on a few occasions, they were close to running out completely.

Clinton Sands director Frank Femia wanted the business to become more efficient in its use of water. Effective water management was suddenly a high priority in order to remain operational. Femia contacted James Murphy of TWS Australia late in 2018 to

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Quarry December 2019

discuss options within the company’s new and expanding range of water management solutions.

TWS launched Aquaclear prior to Hillhead, the UK’s outdoor quarrying plant and equipment expo, in 2017. The various pieces of equipment offered under the Aquaclear banner are designed to remove solids and contaminants from process water or tailings and allow the clarified water to be recycled immediately.

The TWS Aquaclear range includes submersible and vertical shaft pumps, centrifugal pumps, flocculant dosing systems, deep cone thickeners, rake thickeners, filter presses and centrifuges.

Buffer tanks and clarified water storage tanks are also supplied for a closed loop system of water management. Other more specialised equipment such as the patented hydro-flotation system and electro-coagulation system offer advanced technology for the removal of heavy metals and hydrocarbons from process water. This

specialist equipment is more frequently used in wash recycling applications.

MAINTAINING LOW COSTS Clinton Sands’ requirements of a water management system were very clear: produce high density sludge, recycle the maximum amount of water possible, reduce water loss by evaporation and maintain low operational cost.

With this set of guidelines, TWS proposed a system that would tick all the boxes, a solution that offered the highest rates of water recovery on the market and technology and smarts that ensured the operational costs would be much lower than the customers’ expectations.

The entire 290m3 per hour of process water from the TWS Finesmaster Hydro was directed to an in-ground sump tank.

An automated submersible pump with low and high level sensors draws the process water out of the sump and discharges it into a central mixing column within a

150,000-litre deep cone thickener silo.

As the slurry passes through a turbulenceinducing static mixing chamber, a chemical flocculant is injected to encourage rapid settlement of the suspended solids. The TWS FDU2200 (FDU - Flocculant Dosing Unit) is an automated control system that continually measures the settlement rate of the solids and live adjusts the flocculant dose accordingly.

If the solids settlement rate is deemed faster than needed, the system will reduce the volume of chemicals being injected per cubic metre of slurry. In contrast, if the settlement rate is deemed not fast enough, the system will automatically increase the volume of chemicals used. The benefit of using these “smarts” is an overall reduction in the use of flocculant and therefore operational cost.

As the treated slurry enters the mixing column of the deep cone thickener, the process of flocculation is already well in progress. The solid particles become atomically attracted to each other and as they bind together, they mimic larger particles, thus sinking to the bottom of the thickener.

Clarified water, which is now free of silts and clay particles, rises up and overflows the weir at the top of the deep cone thickener. Clinton Sands has chosen to store the clarified water in sealed poly storage tanks to prevent further losses by evaporation.

The small diameter of the TWS Aquaclear deep cone thickener has less than half the surface area exposed to evaporation by the sun, compared to an adequately sized rake thickener. Most operators Australia wide will understand this is a very important factor to consider.

The geometric design of the thickener is such that the sludge is encouraged, without any moving parts, to collect at the base. As the thickener narrows to the base of the cone section, the weight of the water above creates a head pressure that encourages density separation and due to a basic principle of fluid dynamics, additional water is forced upwards. The result is a thickened slurry discharging at 45 per cent solids content.

This high density sludge is the thickest consistency that can be achieved without further dewatering. For example, a rake thickener with its moving parts, high power consumption, high rates of wear and large surface area exposed to the sun will only produce a sludge of a maximum 30 to 35 per cent solids.

There are important benefits of having a

As part of the Aquaclear range, clarified water storage tanks are supplied for a closed loop system of water management.

As slurry passes through a turbulence-inducing mixing chamber, a chemical flocculant is injected to encourage rapid settlement of suspended solids.

thickened sludge with higher solids content.

First, more water is recovered and recycled back into the system. This was an important requirement of the client.

The next benefit is realised downstream.

The thickened sludge would usually be either discharged to evaporation ponds or stored for further dewatering in the likes of a filter press or centrifuge. As the underflow from the Aquaclear deep cone thickener is of higher percentage solids and therefore higher density, its volume in cubic metres per tonne of sand washed will be much lower.

When discharging to evaporation ponds, as is the case at Clinton Sands, the capacity of the ponds is increased when measured in the number of days of sand washing.

FILTER PRESS SELECTION The same principle applies when choosing a suitably sized centrifuge or filter press. The two important criteria for selection are the volume of sludge to be processed and the percentage solids of the sludge.

By having 45 per cent solids upon entering the filter press, we are asking the filter press to remove less water than if we delivered sludge with 30 per cent solids. By reducing

the volume of water needed to pass through the filter cloth, the cycle times are reduced dramatically. Reductions in cycle time of more than 20 minutes are not uncommon when converting from a rake thickener to a deep cone thickener.

With these improvements in performance, the selection of a more compact filter press can save the customer quite a lot in capital expense.

The TWS water management system at Clinton Sands was installed in June 2019 and commissioned in July and the benefits were realised immediately.

The closed loop system recovers 95 per cent of the water used in the system and has reduced the footprint of Clinton Sands’ tailings network allowing the old ponds to be serviced into rejuvenated water storage dams.

In Australia, the distributors of TWS products are Terex Jaques (Queensland, New South Wales, ACT, Victoria, South Australia, Tasmania) and OPS Screening & Crushing Equipment (Western Australia, NT). • Source: Terex Washing Systems Australasia/Terex Jaques

Quarry December 2019 15

SAND PROCESSING

MODULAR SAND PLANT OPTIMISES PROFITS, PERFORMANCE FOR FAMILY BUSINESS A family quarrying and transport business has raised its profitability and phased out inefficiencies in its production process, thanks to its investment in a sand washing solution.

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Quarry December 2019

M

cGuire’s Excavating & Trucking Inc is a family-run business located in Terre Haute, Indiana, USA, that has been operating for more than 33 years. Established in 1986, the company first started washing aggregates in 2007, producing sand and gravel for the expanding local construction and concrete industry.

In early 2019, the company decided to upgrade its washing plant to allow it to offer a higher volume and a wider range of high quality materials to its loyal customer base.

Through the investment in new Terex Washing Systems (TWS) equipment and technology, McGuire’s Excavating & Trucking (McGuire’s) has been able to maximise profits and eliminate inefficiencies in the production process.

“Increasing our production and our saleable material was our reason for looking at a new solution,” Ryan McGuire, McGuire’s vice president, said. “We initially considered a few, different options but the reason we opted for this TWS washing solution was due to the capability to make multiple sands and aggregates at any one time and, in addition, the local dealer support on the ground, which

was crucial not only for the build, but for the life-cycle of the plant thereafter.”

McGuire added that meeting with TWS and his local dealer several times “reassured us in terms of our final decision. We instantly knew this would be the best relationship for us moving forward”.

TWS and its local territory dealer, Powerscreen Crushing and Screening, worked very closely with McGuire’s to provide a solution suited to its needs and desired end products. The solution was specified following several site visits, plant proposals and customer-specific design modifications, as well as samples of the feed material being sent for further testing at TWS’s Headquarters in Dungannon, Northern Ireland.

Ryan McGuire said the support the company received directly from TWS and Powerscreen was “absolutely amazing”.

Whilst TWS is headquartered in Northern Ireland, it has a full facility and team based in Louisville, Kentucky to easily serve its USA customers alongside their dealer network. The service and support from TWS, along with the distributor, is typical of what customers can expect when purchasing

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SHAPING TOMORROW

SAND PROCESSING

McGuire’s has been pleased with the ‘seamless combination’ of the TWS washing solution.

a TWS product. The company’s expertise and highly skilled team of engineers can assist and guide the customer from the initial conception to final installation.

SEAMLESS COMBINATION Designed for the processing of dredged sand and gravel with organics, the TWS washing solution at McGuire’s consists of an AggreSand 206 and the AggreScrub 150, which have now been in the worldwide quarrying market for the past five years.

Both products seamlessly combine to form a washing and scrubbing plant to produce three clean-sized aggregates and one or two sands.

“With this new washing solution, we have so much flexibility,” Ryan McGuire said. “We can produce two sands or one sand, and we can adjust spec by blending more fines into the sand, or less fines, based on what specification of sand our customer needs.

We also have the capability to make three washed aggregates at once, which just makes it a really great plant and meets all of our expectations and more.”

“The McGuire’s installation represents our end to end solution offering,” Barry McMenamin, the global sales director of TWS said. “It demonstrates how our equipment can be seamlessly combined to provide a solution tailored to the customers’ needs, to consistently deliver premium grade sand and aggregates.”

Ryan McGuire further explained that the increased demand for high spec clean aggregates was the major driver in selection of the TWS equipment. Through pre-sale customer visits and gaining an understanding of the required sand production levels, the AggreSand 206 was the obvious choice of sand washing equipment. With its large 6m x 2m (20’ x 6’) bottom deck, sand production could be maximised while offering flexibility to meet 18

Quarry December 2019

The AggreScrub 150 logwasher combines a twin-shaft logwasher, trash screen, sump tank and integrated post-rinsing and sizing on a single chassis.

spec across all products.

Through further feed material sampling it became apparent that, to guarantee the cleanliness of the aggregate, the material would need to be scrubbed. The AggreScrub 150, with its high performance twin-shaft logwasher and integrated post-rinsing and sizing screen met all the needs in one compact chassis.

The pre-wired, pre-plumbed and quickly installed AggreSand concept was intriguing to McGuire’s because it was far removed from its previous wash plant. The material to be processed required extra scrubbing, to ensure the desired product was in spec, therefore the AggreScrub 150 was added as part of this overall solution. It offers increased production capacity and increased levels of access. The seamless combination of the AggreSand 206 and AggreScrub provided the extra required capacity.

RINSING VARIANTS The AggreSand 206 plant consists of a H12 feed system which is fed by a wheel loader.

The feeder is fitted with a 4.2m (14’) wide hydraulic tipping grid, equipped with 101mm (4”) grid bars to scalp off any oversize material in the feed. Both the feeder and grid are powered by the on-board 37kW electric hydraulic power pack. The material transfers from the feeder to the main rinsing screen via a 23m twin-drive feed conveyor with an integrated rubber-lined washbox. Here the material is pre-soaked with a high volume spraybar system which fluidises material, presenting it uniformly onto the 6m x 2m inclined rinsing screen.

The rinsing screen on the AggreSand 206 is available as a twin-deck or triple-deck variant. At McGuire’s, the two-deck version is fitted with polyurethane modular media on

modular media to produce three aggregates: standard pea gravels, specialised pea gravels and oversize (number 8).

The initial section of this screen is fitted with spray bars to rinse off any sand/grit residues produced during the scrubbing process.

A key feature of the AggreScrub 150 is the on-board sump tank and centrifugal pump, where the underflow from the trash screen, and the underflow from the partrinsing screen are captured in the sump tank, then the dirty water is pumped back to the AggreSand 206 sand plant for maximum recovery of sand and efficient use of water. both decks. Each deck utilises 10 individually controlled isolated spray bars to efficiently rinse the aggregate and sand product. From the top deck, a washed “sceptic stone”, +38mm (+1 ½”) aggregate is sent to stockpile for future crushing and processing.

The rinsed material ranging from 6.3mm (¼”) to 38mm on the mid-size deck is fed to the AggreScrub 150 for scrubbing and removal of clay conglomerates.

The two grades of sand are produced through a split bottom deck system, where material is washed through as separate products into a split sump tank, where each grade of sand is then pumped to a dedicated cyclone before finishing on a 4.2m x 2m (14’ x 6’) high frequency dewatering screen making a high quality in spec concrete sand, with the ability to switch to make a variety of sands.

ABRASIVE SCRUBBING ACTION The AggreScrub 150 logwasher combines a high performance twin-shaft logwasher, trash screen, sump tank and integrated postrinsing and sizing on one compact chassis.

It consists of an 8m (26’) hull, housing two rotating shafts fitted with abrasion-resistant blades and paddles. The blades and paddles convey the material from the feed end of the scrub to the discharge end. As the material travels through the hull, the abrasive action of the aggregate colliding and passing through other aggregate (stone on stone) scrubs it clean and breaks up any clay conglomerates which become liberated and then float off through the back of the AggreScrub. The addition of clean water encourages any organics (such as roots) to flow with the suspended fines and clays out of the hull and on for dewatering over the AggreScrub’s 2m x 0.6m (6’ x 2’) trash screen.

Scrubbed aggregate exits the main discharge of the AggreScrub 150 onto a 3.6m x 1.5m (12’ x 5’) two-deck part-rinsing screen. This screen is fitted with polyurethane

CUTTING EDGE CONTROL SYSTEM Using the AggreSand 200 tph two-grade sand plant gives the customer maximum control and flexibility in managing the fine sand fraction in the final C33 product while offering the option to make a dedicated inspec fine sand.

As standard, the AggreSand provides the functionality to blend the fine and coarse sand product at the cyclone discharge point, or at the end of the dewatering screen, at the final product discharge chute. In addition, a third blending opportunity is created via a specially designed rubber-lined catchbox under the rinsing screen which allows individually operated adjustable division plates to blend more fines into the coarse product or alternatively maximise the bottom deck area availability for the fine sand production.

The on-board HMI control system for the AggreSand 206 and the AggreScrub 150 wash plant is another example of the seamless integration possible with these two

plants. Each plant has a dedicated control panel, which is pre-wired and factory-tested.

However, when combined, the entire plant can be operated and monitored from one single HMI. For McGuire’s, the additional feature of having a second HMI located in the plant side operator cabin, allows the operator to monitor plant parameters such as water flow rate and pressure, cyclone pressure and motor running information from one location.

“It has given us a great deal of flexibility in the market,” Ryan McGuire said of the HMI. “We started here with a much smaller washing plant and after looking at the market and the changes, we opted for this solution which has allowed for more flexibility to better serve the market and demands. It’s modular in design, so we can change the modules and we also have the ability to add a larger sand plant if the market changes.

“Moreover, on the back of that, we have built a strong relationship with our local dealer, Powerscreen Crushing and Screening, as well as with TWS. The fantastic thing about the AggreSand is the modular design, allowing us to be flexible and fast in the market and it allows us to react quickly. From start to finish, from the product coming in, the assembly of the build, commissioning, everything has been flawless.”

In Australia, the distributors of TWS products are Terex Jaques (Queensland, New South Wales, ACT, Victoria, South Australia, Tasmania) and OPS Screening & Crushing Equipment (Western Australia, NT). • Source: Terex Washing Systems Australasia/Terex Jaques

McGuire’s AggreSand 206 consists of a H12 feed system, a two-deck 6m x 2m inclined rinsing screen (fitted with polyurethane modular media) and an integrated rubber-lined washbox.

Quarry December 2019 19

The McLanahan UltraWASH MWP 5165 on show at Lincom Group’s HQ in Narangba, Queensland.

SAND PROCESSING

FAMILY ENTERPRISES

COLLABORATE ON ULTRA-FINE SOLUTIONS A partnership between two multinational family companies is expected to give quarrying producers even more scope when making purchasing decisions about sand processing plant and equipment. Damian Christie spoke to Lincom’s Peter Godwin.

I

n the lead-up to biennial European bulk materials handling expo bauma, in Munich, Germany in April this year, a partnership was forged between US-based wet processing solutions manufacturer McLanahan Corporation and the Lincom Group, the Australian supplier and distributor of extensive ranges of screening, crushing and washing plant and equipment for the quarrying, mining and recycling industries.

At the show, McLanahan launched the UltraWASH, a modular wash plant that can be installed in any quarry site almost fully assembled in containerised modules. The UltraWASH can produce up to three clean aggregates and two washed sand fractions.

On 2 April, Lincom announced it was partnering with McLanahan to bring its entire line of sand and aggregates processing solutions, including washing and classifying,

20

Quarry December 2019

tailings and water management, and dewatering equipment, to the Australian and Papua New Guinea (PNG) markets.

Lincom is a family-run company which this year celebrated 25 years of operation – it was established in 1994 by experienced entrepreneur Roy Watterson. Today it has operations throughout Australia, New Zealand, PNG and the Pacific Islands. The company’s head office is in Narangba, about 35km north of Brisbane, while it has other offices in New South Wales, Victoria, Western Australia and North Queensland.

It also has representatives operating in Tasmania, South Australia and the Northern Territory.

McLanahan’s next generation of modular wash plants – including the likes of the UltraWASH, the UltraSAND and the UltraFINES – were always intended to be

the first of its products to be introduced by Lincom to the Australian market. At time of writing, Lincom has received its first working modular plant – the UltraWASH – and has set it up at the Narangba headquarters for inspections by existing and prospective customers in the quarrying and sand mining space.

Peter Godwin, Lincom’s environment and process manager, said senior management at Lincom and McLanahan had been doing business with one another for more than a decade and as successful, family-owned companies, there were many similarities in “their focus on long-term customer relationships, with service and customer support being key to their successes”. He said the timing for the partnership was ideal.

Godwin is himself a former McLanahan employee, having worked for the Australian

arm for five years, before he joined Lincom. He has worked for Lincom for the past two years.

“I’m the common link between the two companies,” Godwin quipped. “McLanahan in the US is a family-structured company; the owner Mike McLanahan is a sixth generation family member [McLanahan was founded in 1835]. Lincom in Australia has been around 25 years; Roy Watterson is the ultimate owner of the whole company. So they’re both family companies and so they’re very similar in their philosophy.”

While Lincom’s focus primarily will be on the new modular equipment range, the company will also handle all of McLanahan’s traditional washing, separation and classification equipment range, including cyclones, dewatering screens, pumps and spares.

Lincom has plenty of experience in distributing other brands of sand washing plant and equipment in the past 25 years.

However, Godwin believes the “combination of Lincom and McLanahan experience in thickening, washing and dewatering equipment in sand, aggregates, construction and demolition wastes, soil washing and water management” will raise the quality of offerings available to the quarrying industry.

“It makes perfect sense to me because McLanahan has so much more than the competitors,” Godwin said. “McLanahan manufactures the widest range of washing equipment including log washers, fine and coarse materials screw washers, blade mills and aggregates conditioners. These are all variations on a theme but they can afford to be more specific about what they’re putting into a circuit; they’ve adapted them for so many different applications for more than 180 years.”

MODULAR FEATURES The UltraWASH is available in three models: the MWP 5124 (with an output of 150 tonnes per hour); the MWP 5165 (250 tph); and the MWP 6206 (400 tph). It is available to producers in a “pre-wash” or double wash configuration, and features single process water feed and effluent discharge points. It comprises the following components: • A heavy-duty dewatering screen with twin counter-rotating vibratory motors and modular polyurethane media.

• Hydrocyclones with abrasion-resistant rubber linings and a high centrifugal separation of product from unwanted minus 63 microns (-63µm).

• The two- or three-deck sizing screen with polyurethane modular screen deck media, fixed isolated spray bars, and a discharge hood for aggregate fraction blending.

• A standard 9m3 feed hopper, with manual tipping grid, variable speed discharge belt and adjustable hopper door, and a 1050mm wide conveyor belt.

• Nine metre-long aggregate conveyors and 12m radial conveyors with a 60- or 120-degree slew.

• Pumps fitted with abrasion-resistant rubber liners and the patent-pending EZE-Riser, which works with the pump service trolley to enable safe, efficient pump maintenance, such as changing impellers or replacing casing liners.

Godwin said all the modular equipment is designed to be robust, with wider walkways and improved maintenance access for quarry personnel. “We have the best laid out equipment, as far as walkways and access to the machine,” he said. “On other sand plants, there is only a walkway on one side, whereas ours has access on both sides. Two people could pass over a walkway side by side, carrying their toolboxes.

“The first comment that everyone makes about the UltraWASH is the space. They can walk around it and see it has access for their

maintenance people. That’s been the most positive feedback and that’s what’s always been intended of the design.”

Godwin said the UltraWASH is designed to Australian standards and therefore comes with regulation guarding features. “On other sand plant brands, you may have to install a whole new set of guarding. With this range, that’s already considered. We don’t need to do anything to it. It turns up with guard rails because we exceed all the walkway distances around the machine.

“There’s other clever features on the UltraWASH that reduce maintenance time and effort,” Godwin elaborated. “The other most commented upon feature from customers is the EZE-Riser or ‘roll out’ centrifugal pump that reduces the amount of time and labour for maintenance.

“To pull the pump out no longer requires two guys, it can be done with just one. A foot pedal lifts the discharge pipe from the pump and utilises a locking mechanism to then hold the pipe aloft. This creates the clearance needed for the pump to roll out on rails about 250 to 300mm from the ground.

When not in use, the rails fold up to former a barrier in front of the pump. So when it’s time for a pump change, those rails come down and then extend out to the side of the machine.”

The UltraSCREEN rinsing and sizing module forms part of the UltraWASH fully integrated modular washing plant and can also be supplied as an independent unit complete with supporting structure.

Quarry December 2019 21

SAND PROCESSING

SAND APPLICATIONS Godwin said the UltraWASH is suitable for natural and manufactured sand applications. “The machine is adaptable to the customer’s needs. As far as the in-feed is concerned, we wash out the clays and the inorganics, and float them off. The rocks we bring down to size through crushing and if someone says they want a 6mm stone and a 20mm stone, we can give them the sizes they want to make into aggregates. With the sands, we can do that too. We can make two different sizes of sands with the UltraSAND component of the UltraWASH.�

The UltraWASH can be relied upon to produce two grades of sand where the feed is clean, or be configured to double wash where the feed is dirty. A functional gate at the back of the dewatering screen can blend the sands to create a ratio of the two. “If you have a split screen, where you have coarse sand on one side and fine sand on the other, it comes down two different chutes,� Godwin said of the gate. “What

this system does is that it has a divider that is movable, so it will take all of one graded sand, and it might take 30 per cent of the next feed chute. So it’s not an accurate blend but it’s as close as we can get and it’s good enough in most instances. So if someone is doing sports sands or concrete sands, for example, the blending system is ideal for them.�

However, the quality of the materials will determine if the UltraWASH – or another of McLanahan’s modular plants – is best suited to the application at hand. “If you have a lot of clays, the UltraWASH is not the machine, you go for the UltraSCRUB, as it’s based around a logwasher as the central component,�

Godwin said. “If you have a site that is just a sand deposit, then the UltraSAND is basically all you need. “The UltraFINES are standalone units for capturing very fine grades of sand, therefore reducing the amount of ultra-fines that would otherwise go to waste,â€? he elaborated. “With an UltraSAND, anything below 75Âľm goes

to waste. The UltraFINES cuts at 32¾m. So it means that fines between 75¾m and 32¾m is no longer wasted, it goes back into the product. It actually recovers more sand and that’s important because it means it’s not filling up your tailings dams. It’s not just about the sand you produce, it’s also about efficient water management.�

The UltraSCREEN and UltraSAND are components of the standard UltraWASH and can be purchased and installed separately as standalone items of equipment. In turn, modules that function independently of the UltraWASH – such as the UltraSCREEN rinser and sizer, the UltraSCRUB, the UltraCRUSH cone crusher and the UltraCLEAR thickener – can be added to the UltraWASH to create a complete wet processing plant.

Godwin said that it is also possible for the modular plant to be added to existing washing circuits. “This happens on occasions, we have a new plant next to an old one. We can add little bits and pieces all

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The Ultrawash MWP 5165 features a heavy-duty dewatering screen, a separate sizing screen, hydrocyclones, a 9m3 feed hopper and aggregate and radial conveyors.

the way through for a customer to change their process and get the desired result.

Lincom has the laboratory testing facilities, plus design and process engineering know-how to size, install and commission the correct equipment to produce the desired results.”

The “beauty” of modular plant is that can be assembled and/or dismantled, and relocated accordingly. The basic UltraWASH is delivered in eight 12m (40’) open containers, and can be assembled within two weeks.

CUSTOMER FEEDBACK Godwin added that ever since the announcement that Lincom was the new Australian dealer for McLanahan equipment, there had been numerous expressions of interest from quarrying operators in the UltraWASH and other McLanahan products.

He is looking forward to growing Lincom’s aftermarket component as Australian interest in McLanahan’s products grows.

As Lincom brings in new plant and equipment into the country, a stock of spares will be kept at the Narangba

HQ. Godwin is also confident that even if demand outstrips supply, there will be the capacity to increase spares coverage to producers through Lincom’s other branches and representatives. Even if replacements have to be sourced out of Brisbane, producers would not have to wait much longer than an overnight delivery.

“My business card and most documents I put out have ‘Anywhere, anytime’ on the bottom,” Godwin said. “That’s because I work on projects all over Australia. We’re very well placed with service people around our centres, and that’s pretty big when you consider some of our competitors have just two or three support people for the whole country! We have a huge service fleet in the business and we send service and maintenance teams to wherever they need to be. It’s all part of the big picture and about looking after your customers, and between the parts and the service, they’re the biggest things we offer.” •

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The CDE Combo all-in-one wet processing plant incorporates feeding, sizing, sand washing, and integrated water management on a compact chassis.

SAND PROCESSING

ALL-IN-ONE WASHING PLANT

ADVANCES CASE FOR MANUFACTURED SAND As manufactured sand grows on the Australian quarrying industry, so does demand for a plant specifically tailored to this application. Damian Christie spoke to Daniel Webber about how modular equipment is providing wet processing options for the driest of quarries.

A

s discussed elsewhere (see page 32), the use of natural sand in construction materials applications around the world is becoming increasingly restricted. Obtaining approvals for sand quarries in Australia is becoming increasingly more difficult, due to bureaucratic concerns about the impact of extraction and processing on the environment.

There is also a scarceness of sand reserves in some parts of Australia, most especially around the Sydney Basin, making sand products more expensive if they are transported from hundreds of kilometres away.

Water management – especially in sand applications, at a time of heavy drought – is extremely expensive for quarrying operations.

Not only are slime ponds costly to maintain (and frowned upon by some regulatory bodies) but there is the extra expense of rehabilitation once the site is depleted.

As a result, the quarrying industry has for several decades explored the replacement of natural sand with manufactured sand. In the NSW southern tablelands region, Boral Peppertree Quarry has been developing manufactured sand from crushed stone as a value add, especially as there is still a strong demand for sand in the Sydney market. In Victoria, Alex Fraser Group, a subsidiary of Hanson Construction Materials, has made significant investments for more than a decade 24

Quarry December 2019

in recycled aggregates technology, developing manufactured sand fines from both recycled concrete and road base materials, and more recently recycled glass. The end products have been successfully employed in road base and concrete applications.

Cement Concrete & Aggregates Australia (CCAA) has also previously published a research paper on the national test methods and specifications of manufactured sand, based on input provided by a working party of representatives from Boral, Hanson, Holcim and Barro, and the CCAA.1 Daniel Webber, CDE’s regional manager for Australasia, told Quarry this report was an example of the “great work” competitive stakeholders do when they pool resources. He said the report helped to “debunk myths about manufactured sand and concrete products”.

The CCAA report also clarified the dual challenges of sand washing plants in developing manufactured sands from crushed rock. “Washing is trying to do two things: reduce the fines content to specified levels, and then eliminate the clays and silts that come into the sand fraction,” Webber explained. “The clays and silts reduce the strength of the concrete and too much fine rock increases water absorption, so there is a trade-off for concrete manufacturers when they do their batching, with cement/water ratios.

If there is too much fine material, more water and cement will need to be added to balance out the mix, so it raises production costs.

“It’s a two-fold problem, and it’s a case of working with concrete manufacturers to get the blending targets right. What we find is that some of the manufactured sands available on the market are simply unwashed crusher fines, which produce uneven results and can significantly reduce the quality of applications such as concrete sands. With cyclone-based washing, crusher fines are turned into high value manufactured sands, proven to be superior in quality to washed natural sands, hitting the specification target in one go and reducing manufacturers’ overall operational costs.”

CDE has also undertaken its own exhaustive research into manufactured sand for its various divisions, eg Primo (sand and aggregates), Reco (construction and demolition waste recycling), Solv (industrial sands) and Meta (mining).2 The company’s focus has been on maximising sand and aggregate resources to create high value materials for a variety of applications, encouraging the circular economy model.

“CDE has taken the lead to prove that manufactured sand can be – and is – as reliable as natural sand products,” Webber said. “Some hard rock resources lend themselves more readily to manufactured sand applications than others; it’s about creating an understanding of the complexity of the process and bringing efficient solutions to operators.

“Notably, each M-Sand has different qualities depending on the original crushed rock it was created from. For example, M-Sand produced

from granite rock helps concrete structures to withstand extreme environmental conditions and prevents corrosion of reinforcement steel.

Size and shape also play an important role in the workability of concrete. With more sand surface area, there is an increased need for cement and water to bond the sand with coarse aggregates. Using CDE M-Sand with less surface area means the concrete can be equally as workable using less water, and consequently less cement. As cement is the most expensive ingredient of concrete mix, representing around 50 to 60 per cent of the cost at less than 20 per cent of the volume, this further emphasises why the consistency of clean, in-specification CDE M-Sands is so important to achieve high strength concrete.”

Webber continued: “The adoption rate of CDE M-Sands technology is growing at a fast pace across the world. For instance, in India, we sell one Combo plant for use by manufactured sand operators every week.

“Manufactured sand complements quarrying businesses. These companies produce aggregates for their greater markets, and by doing so they produce dust, so why not upgrade that dust into a higher end, sellable product? We know of the pressures on different markets to find innovative alternatives to natural reserves, as we’ve seen with the depletion of natural resources around Sydney and Melbourne.

“Rather than looking for natural sand resources further afield, wouldn’t hard rock deposits closer to the cities become more viable as sources of high value construction sand?”

WASHING IN DRY PLACES The challenge for CDE in Australia has been to introduce wet processing systems to hard rock quarrying operations that so far have not considered washing their products.

“When we started,” Webber said, “hard rock quarry operators generally had been running quarries for decades and were very good at crushing and screening. However, the sites weren’t set up for washing. Often, they didn’t have electrical power supplies nor a sophisticated water circuit on site.”

To address the needs of customers in Australia - and indeed around the world - who required efficient alternatives to the depletion of natural resources to ensure the sustainability of their businesses, CDE’s award-winning Research & Development team developed the Combo all-in-one plant. The Combo features patented technology that combines feeding, sizing, sand washing, stockpiling and waste water management on one compact chassis; it allows to run the full feed to the final product

The EvoWash can also assist with the manufactured sand process in a standalone capacity.

process at one touch of a button, with up to two in-spec final materials being produced simultaneously, ready for market straight from the belts. Each Combo modular plant is bespoke to the client’s needs, with a range of options that allows for tonnage flexibility to suit all sizes of operations – and anticipates future needs – from 70 to 500 tonnes per hour.

Webber added: “The Combo is a plug-andplay system that allows for unrivalled control of silt cut points thanks to a highly efficient cyclone-based process; the system also prevents loss of sand in the overflow and loss of valuable fines to ponds. Every grain of valuable product is retained in the system.

“All processing stages of the Combo plant have been conceived with low energy consumption as a must, whilst operators also benefit from exceptionally economical water consumption, with an incorporated water management unit that recycles up to 90 per cent of used water directly into the system.

With all modules working as a closed circuit, materials production is seamless, efficient and in specification every time.

“As valuable fines lost to ponds is a thing of the past, operators can reduce the footprint of their ponds, save on maintenance and therefore on downtime, speeding up production times and return on investment.

“In Australia, the Combo is our response to maximising production on hard rock sites not being set up for washing. Again, it’s a small footprint because often in a hard rock quarry, you have equipment moving around regularly on a hard rock basis.”

The Combo is available worldwide in five models corresponding to various capacities.

Each variation of the washing and water recycling plant is equipped with cyclones (starting at 500mm diameters, with multiple and bespoke sizes on later models), dewatering screens (multiple screens on the 900 and 1500), an AquaCycle thickener (built to CDE’s standard sizes) and a Poly Plant.

COMPACT FOOTPRINT Webber said the Combo series is a perfect fit for the processing of manufactured sand.

“The feed to a manufactured sand plant is often more consistent because it’s coming off

a crusher circuit, so you’re not getting many oversized fractions or variable feed,” he said.

“That stability means we have a much smaller footprint and potentially there is no need for a pre-screen. The on-board process water systems - the thickener and floc station - are incorporated in the single chassis. A Combo can be commissioned in about five days, so it’s readily deployable and easily relocatable to another site. Often these hard rock quarries use contract mining operations, so again this piece of equipment suits that business model.

“The compact footprint means we’re doing less pumping than a traditional plant, and slurry pumps are a big source of power draw,” Webber said of the Combo’s energy efficiency features. “Our thickeners are all very efficient and the Infinity screening technology is one of the most energy-efficient on the market. So CDE offers an efficient response to water and energy consumption.

“When producing manufactured sand, CDE’s wet processing equipment achieves high recovery of water from the sand before stockpiling, so the finished product contains as little as 12 to 15 per cent moisture. The slimes are pumped away, or we can use a filter press to raise the water recovery rate to up to 95 per cent.”

The Infinity dewatering screen operates in a dual pass capacity that delivers fine, coarse or “all-in” sands.

Not only does the Combo already comply with Australian industry standards, but it can be customised to suit a producer’s specifications and be set up alongside another washing plant, where applicable. “The Combo is just another part of CDE’s modular range,” Webber said. “We have already created combinations that include log washers for instance. CDE solutions can be customised to the exact requirement of operators. We’re not trying to make stock equipment the customer’s problem, we’re responding to their process problems.”

SOLO OR TANDEM? The Combo was launched at bauma, Germany, in April 2019 and is still to become a mainstay of the Australian sand processing Quarry December 2019 25

SAND PROCESSING

market, but CDE is far from being new on the market. The company has enjoyed success with its EvoWash modular plant, which has more than 40 installations across Australia.

Like the Combo, the EvoWash – available in four models – is equipped with Infinity screening technology, cyclones arrangements which can be tailored to the customer’s requirements and Warman pumps. As a modular plant, it can be assembled after transportation in 12m (40’) containers.

Webber said the EvoWash can also assist with the manufactured sand process in a standalone capacity if a site has tailings facilities and doesn’t require a thickener. “The size range that the EvoWash operates in – with capacities of up to 250 tonnes per hour – means it is suitable for any size of operation,” he said. “We have seen clients transferring material directly from the wash deck of their crusher plant into the sump of an EvoWash, so it can be ‘plugged and played’ for a relatively small investment.”

He said the EvoWash could operate with non-CDE types of sand washing plant.

“That’s one of the first discussions we have

with a client – does it make business sense to complement the existing equipment or is there a business case to replace all of the equipment with an EvoWash? That’s always going to come back to a commercial discussion, and we let the client drive that.

“Obviously, there are synergies when the EvoWash is installed with another CDE plant, from a process control and interface point of view. However, it can be standalone equipment in a brownfield application.”

Webber said the reception from the domestic market to the EvoWash boded well for the Combo. “We have an EvoWash plant now at its third home in Australia,” he said. “It has moved from Western Australia to the Northern Territory to Melbourne, and that tells you the value that the owner sees in the equipment.

It’s well built, it’s built to last, and it’s a robust piece of equipment, so we’re extremely proud of that.

“We’re equally confident about the Combo, which is built on the same principles as the EvoWash.”

Webber said CDE’s CustomCare programme – which comprises after sales

and support, parts, preventative maintenance, asset care and the suite of CDE CORE smart technology tools – would assist with maintaining the wear and service life of the EvoWash and the Combo, even when dealing with abrasive materials.

“Angular sands or manufactured sands are more aggressive than rounded, alluvial sands but CDE offers a comprehensive, after sales service that guarantees the smooth running of the plant over its lifetime.”

For hard rock producers investigating manufactured sand as added value to their operations, this assurance will certainly be very welcome news, indeed. • REFERENCES & FURTHER READING 1. Cement Concrete & Aggregates Australia.

Research Report: Manufactured Sand - National Test Methods and Specification Values; January 2007. https://www.ccaa.com.au/iMIS_Prod/ CCAA/Public_Content/PUBLICATIONS/Reports/ Manufactured_Sand_National_Test_Methods_And_ Specification_Values.aspx?WebsiteKey=4998d6ce2791-4962-b1e2-6b717f54a8d3 2. CDE. Product and technical brochures. https:// www.cdeglobal.com/brochures

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SAND PROCESSING

AGGREGATES BUSINESS PROFITS FROM SMARTER WASHING SOLUTION Persistence by an aggregates producer in the heart of the US for a modern machine that could produce a cleaner end product from secondary fill has been rewarded accordingly.

T

he large pile of by-product sat in the corner waiting to be sold, though not at a profit. The goal of the aggregates producer was to simply sell the by-product as fill, even though it was not optimistic it would break even on it.

In May 2017, H&H Stone, located in Bolingbrook, Illinois, USA, began using the McCloskey SandStorm 620 3D1S. According to Dave Hamman, the owner of H&H Stone, it has turned the by-product into a “profitable item”.

Hamman has been in the quarrying business since the mid-1970s, and he followed his father into the industry. Over the years, the Hamman family has had a limestone quarry and a sand and gravel operation in Kendall County. The entity known as H&H Stone began in 2013. At that time, Hamman and a partner purchased the limestone quarry in Bolingbrook and a sand and gravel pit in Boone County, Illinois. The purchase was from an old Chicago mining family that was selling off its entities.

The facility in Bolingbrook, which employs up to 12 people, including crushing personnel and drillers, makes a high quality sand product out of a waste by-product by wet screening all of the +4 mesh off the top of the sand product, then using cyclones to wash out the silts and clays from the bottom end of the sand product.

They end up with a spec sand product used in concrete manufacturing. According to Hamman, “Some farmers put it on fields to control the pH level. But in our area, due to the lack of farmland, we wash it and use it for manufacturing.”

H&H Stone’s industry is very much tied to the economy, particularly real estate.

28

Hamman says the mobility of the equipment gives H&H Stone the option to one day move it to another site.

When the US economy tanked in 2007-08, the Bolingbrook facility was shut down.

Hamman and his team reopened the quarry in September 2014. The materials from the Bolingbrook plant are sold to either readymix companies or pre-cast companies. The readymix companies use it for foundations in homes and driveways while the pre-cast companies use it to manufacture pre-cast panels for distribution centres and other precast buildings.

With the American economy humming along, business has improved for H&H Stone.

Challenges, however, remain. Hamman cites two challenges in particular that he and H&H Stone face. “The Illinois economy has not recovered fully – it’s way behind the rest of the nation,” he said.

In addition, the material the quarry produces is relatively low priced, so there’s a limit on how far it can be shipped. Also, margins are low and like every other business/industry, there is competition.

So, how does H&H Stone rise above the challenges? It’s about cleanliness.

AFFORDABLE, CLEAN PRODUCT “I went to customers and told them ‘I have a good clean product that is affordable,’” Hamman said. “The product that H&H

Stone produces is cleaner than that of his competition. They [the competition] are trying to do the same thing we do but with older technology, so they end up with material that is usable but not for all applications.”

Over the years, Hamman has rented, but never owned, various pieces of McCloskey equipment, including crushers and dry screening plants. That all changed when McCloskey representative Craig Rautiola met with Hamman at the end of 2016. “I gave him samples of my raw materials and told him the cleanliness level I needed on the finished product,” Hamman said. “He guaranteed he could produce materials as clean as I requested.”

That guarantee is what ultimately convinced Hamman to buy the SandStorm 620 3D1S plant. Prior to being delivered to H&H, the SandStorm 620 was on display at CONEXPO in Las Vegas in March of 2017. From there, it was moved to H&H Stone’s quarry in Bolingbrook.

“Building a traditional wash plant onsite takes longer and is more expensive,” Hamman said. “This plant was built in a factory and therefore was easy to get up and running. They hauled it in on trucks and set it up in less than a week.”

The delivery was in May 2017, and the

Quarry December 2019

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SAND PROCESSING

equipment has been up and running since.

The SandStorm 620 has delivered on Rautiola’s promise. Hamman said, “I’m very satisfied. It’s doing an excellent job, better than any type of equipment I’ve used in the past.”

MOBILITY, SPEED Billed as a modular, mobile wash plant, the SandStorm 620 is 45m in length, 34m in width and eight metres in height, according to the specs. Hamman appreciates the size: “It’s relatively small.” The mobility of the equipment — which he explained is part of the reason H&H Stone bought it — gives the company the option to move it. Hamman said they might consider doing that some day.

One crucial component of the equipment is its speed. “It’s about tonnes per hour, and we are very satisfied with its production,” Hamman said. “The Sandstorm 620 can produce up to four wash products at once.

It’s powerful and durable and offers a variable speed belt feeder and an adjustable hopper door for consistent material feed and has dual and single sand options for up to 400 tonnes per hour.”

According to Hamman, the SandStorm 620 is also operator-friendly. He points to the fact

The Sandstorm 620 moved to H&H Stone’s quarry in 2017 after initially being on show at CONEXPO.

that it is touchscreen-operated as proof of this. The fully automated machine is radiocontrolled and has an advanced automated control system. This makes it easy to use.

Hamman appreciates that the machine is a “very quiet, clean plant with very little spillage.”

When making a major purchase, such as the one for the SandStorm, relationships come into play. After all, challenges are bound to occur and it’s then that people want to work with others whom they are comfortable with and respect. “They [McCloskey] have addressed all of our issues and have been there when we needed them,” Hamman said.

In addition to simply being there, Hamman remarked the McCloskey people are “cordial,

easy to work with and nice people to do business with”. Business does not end at 5.00pm either. “The McCloskey rep who oversaw the set-up gave me his home number,” Hamman said. But Hamman has never had to use Rautiola’s home number.

“He always answers his cell phone.”

These days the pile of by-product is being sold instead of piled. After all, it’s now a money-maker and helps H&H Stone and the Hamman family continue to prosper in the business of quarrying.

In Australia, sales inquiries about the McCloskey Sandstorm 620 can be directed to the national distributor 888 Crushing & Screening Equipment, headquartered in Perth, WA. • Source: McCloskey Washing Systems

SMARTER WASHING SOLUTION 888 Crushing & Screening Equipment (888CSE) has taken delivery of another Sandstorm 620 sand and aggregate washing system from McCloskey Washing Systems (MWS).

With the MWS Sandstorm, MWS Compact Washing Systems and MWS Tracked Mobile Rinser Screens in stock in Australia, 888CSE offers nationwide coverage for one of the industry’s most comprehensive sand and aggregate washing portfolios.

There are already several MWS Smarter Washing System units successfully operating in Australia.

The Sandstorm was assembled in a centrally located site in New South Wales for viewing by any potential customer.

The whole plant can be loaded and delivered to site within days. Commissioning of the plant can therefore take place within a couple of weeks of an order being placed, once both water and electrical supply are connected.

Polyurethane screen decks are selected

30

and fitted to suit the exact site specifications required.

The Sandstorm has been developed with leading features for optimised production, easier maintenance access and reduced servicing intervals. The plant is fully electricpowered for efficiency with the control panel designed and built to meet Australian Standards.

This MWS Sandstorm modular washing solution can typically handle up to 450 tonnes per hour* (tph) of mixed sand/ aggregate, with 150 to 200 tph of sand production. A large 6m x 2m (20’ x 6’) tripledeck screen with five conveyors allows the

production of up to three aggregate sizes as well as one or two sand products.

With the option to provide a split sand product, the MWS Sandstorm can make a coarse and fine sand product if the feed material is suitable. Alternatively, the plant can be set up to provide high capacities of a single-sized sand. Smaller Sandstorm plants are also available with lower capacities.

A complete water treatment package with a thickener tank, an automated floc dosing system and freshwater storage can be added to the Sandstorm, if required.

With the addition of a filter press, water requirements can be reduced by up to 90 per cent in some cases. *The capacity of the Sandstorm 620 varies depending on feed material and required product sizes. 888CSE personnel can assist in the selection of equipment depending on performance requirements. • Source: 888 Crushing & Screening Equipment

Quarry December 2019

21067

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TRAILBLAZING SAND WASHING

• In-specification sand every time • 50-500tph capacity • Up to 90% of the process water recycled

CDE is committed to reducing waste and turning every ounce of saleable material into a high-value product.

CDE’s patented Combo™ modular technology is set to revolutionise the wet processing industry, delivering five processes on one compact chassis with exceptional return on investment. We have created a solution that can process both natural sand and crushed rock reserves into high value products, with up to 90% of the process water recycled.

This is the shape of things to come.

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SAND PROCESSING

IS THERE A BUSINESS

CASE FOR CRUSHED SAND? With access to natural sand limited either by natural attrition or legislative design, the quarrying industry worldwide is having to experiment with manufactured sand from conventional aggregate sources. Georg Diem and Francis Lacote explain why the answer is crushed sand.

T

he demand for economical, efficient ways to produce crushed sand is growing, as natural sand deposits located near growth centres are depleted and environmental regulations get stricter.

What makes the change even more significant is the rapid pace of urbanisation.

According to the United Nations, the number of people living in cities could double by 2050 to 6.5 billion. To accommodate growing populations, more houses, parks, roads, and underground utilities, among others, sand is required in one form or another as a basic building component.

Many aggregates producers are now studying the possibility of producing crushed sand, and at the same time looking at how to address the growing piles of quarrying waste, which may contain a fair proportion of fine aggregates that could be used in construction projects.

Is there a solution that would benefit all parties involved? Georg Diem, a senior process expert on the use of crushed sand in concrete production, and Francis Lacote, a sales support manager at Metso, delve into the topic.

A NATURAL SAND REPLACEMENT? Sand – whether extracted from natural gravel or sand deposits or made by crushing

bedrock – is used in many applications because of its mineral and physical qualities.

The most typical application for sand is concrete, where it accounts for about 30 to 40 per cent of the material volume.

“Concrete is the most common manmade material,” Lacote said. “You can find it everywhere. It is an essential element in the construction of infrastructure and in the building industry. Most of the interstate road network in the US is made of durable concrete, which can withstand heavy traffic and changing weather conditions.

Dams – like the Three Gorges Dam in China, where Metso’s crushing equipment has been used to produce aggregates – are the biggest structures made of concrete.

“Asphalt, which is common in road and highway construction, is the second most important application.

There are also the ‘functional’ aggregates, which are used, for example, for water purification in water treatment plants, golf courses and bunkers, children’s playgrounds, and horse-riding arenas, as well as on roads and pavements in icy climates to prevent sliding and slipping. In all of these applications, it is possible to replace natural sand with crushed sand, and even improve the properties of the end product.”

A DIMINISHING RESOURCE The use of natural sand is regulated by law in many places and totally forbidden in some places, like Japan. Some countries, including Sweden, have called for crushed sand to be used in place of natural sand whenever possible. In Australia, the constraints relating to obtaining approvals are increasing, too.

Illegal sand mining has become an issue in some developing countries where demand is unbridled and the regulatory consequences are minimal. Selling sand is considered a quick way to make money with very little investment; all that is needed is a truck, a driver and a place from which to extract the sand. This is one of the reasons why India, among others, has established a sand policy to encourage the creation of new manufactured sand units by favouring them in the permit process for new quarries (see the success of Robo-Silicon, on page 38).

“I would say there are three categories of countries,” Diem said. “Take Sweden, where you have a special natural gravel tax to regulate sand mining. Some other European countries restrict the opening of new pits by other means. Then there are countries, like India, Singapore, and Malaysia, that have huge problems with non-existent or quickly diminishing natural sand resources. In these countries, sand is mined from open pits, Quarry December 2019 33

SAND PROCESSING

beaches, and in-land dunes, and dredged from ocean and riverbeds. Legislation is not always in place or is just not effective [if it is].”

CRUSHED SAND IN CONCRETE Diem has a clear view of why crushed sand works well in concrete production.

“Concrete producers must meet certain minimum safety margins for the compressive strength of their products,” he said. “The higher the variability of the raw materials, the higher the cement content needed to maintain a certain level of margins. Thus, at the end of the day, the cost of raw materials of a lower quality and lower variability is comparable to the cost of better quality materials, but of a variable quality.

“With crushed sand produced in a controlled, engineered process, it is possible to achieve stable quality. It is much more difficult to control the variability of natural sand, especially if the sand is not washed,” he explained.

Washing, however, is not always feasible due to problems like lack of space, availability of water resources, environmental issues from dewatering ponds, and operational problems in places that experience freezing temperatures, eg in the Nordic countries.

“There are also other direct technical benefits from the use of the crushed sand,” Diem said.

“For example, natural sand grains are rounded as a result of weathering, whereas crushed sand particles are typically angular and have a rougher surface texture, enabling better bonding with the cement paste in concrete, and thus providing improved strength properties at the same cement consumption (a constant water to cement ratio).”

When you are developing a concrete product with natural sand, opportunities for improvement are scarce. However, with crushed sand, Diem said, there are more opportunities and a wider range, and you can find the best fit for different types of concrete.

A totally different hurdle is the acceptance of the use of crushed sand in the mix design.

Queensland still requires 40 per cent of the fine aggregate used in a concrete mix design to be made up of natural sand. This will need to change in the future to reflect the declining resource availability and the improved availability of high quality crushed sand products.

A BUSINESS CASE? Legislation and availability of natural sand dictate the price of sand – and thus profitability. There are also costs associated

with obtaining the approvals, which can result in it not being economically viable to extract the resource.

“Transportation costs from sand quarries contribute significantly to the overall cost of the product to the end user,” Lacote explained.

“If the end product is of higher value, like silica sand for glass manufacturing, higher transportation costs can be allowed. Higher volume sand products with lower margins are a different case. The sand production site needs to be close to the location where it will be used.

“It’s a lot about the economies of scale. If you have a good sandpit near the place of use, you just screen the sand to the right size.

With crushed sand, you need to consider many other aspects. When crushing bedrock, production costs are higher and there are additional costs involved. Between 30 per cent and 40 per cent – and sometimes as much as 50 per cent – of the crushed rock may end up in the quarry waste pile,” Lacote clarified. “The smaller the particle size and the softer the material quarried, the more waste is generated. To improve profitability, you either need to reduce the amount of waste, or figure out new uses for the fines.

“Particles less than 4mm are often considered waste, that is, not good enough for any purpose. The material is often piled and, increasingly, producers have to pay waste fees for their piles. It would benefit all parties if the fines could be used and sold for other purposes. In Finland, this type of quarry waste can partly be used for surfacing driveways and yards.”

According to Lacote, making a business

case is largely dependent on how the industry can develop and tailor the technical properties of crushed sand for different applications.

It also requires educating and convincing stakeholders about the good qualities of crushed sand so that it becomes acceptable and widely adopted. Naturally, pricing needs to be competitive.

“It is possible to use most of the rock for concrete production. A certain level of rock hardness is needed,” Lacote said. “One of the biggest enemies is too much mica, which is difficult and expensive to remove. The question is: what does the market look like? Is there a lot of competition? In other words, is there a lot of sand available at a reasonable price?

“The quality of natural sand varies more than that of sand produced in an industrial process.

Consistent quality is a typical feature of crushed sand. Concrete manufacturers benefit from the use of sand that is of a stable quality, because it allows them to use less cement, typically between five per cent and 20 per cent less cement. The decreased use of cement also benefits the environment through reduced carbon dioxide emissions,” Lacote continued.

Diem approached the question with an illustrative case example. “Let’s take a case from Norway,” he said. “In this case, the transportation distance is short, less than 40km for both manufactured and natural sand. The price for high quality natural sand is NOK80 to 85 ($AUD12.77 to $AUD13.62) per tonne, and the price for incomparable crushed sand as a by-product from coarse aggregate production is NOK30 to 35 ($4.79 to $5.59).

There is room to spend money on improving the quality.

Robo-Silicon’s Metso Barmac crushing plant in Hyderabad, India. The Barmac’s high velocity impact crushing can produce a quality that is very close to natural sand.

“To add VSI crushing, you’d have to add NOK10 ($1.60) to the production costs – and for fines classification, another NOK10. This would allow for a product with a higher profit margin. However, it’s not so straightforward, as you also have to be able to invest considerable resources in the development of the whole process. The producer needs to work together with the customer and understand their needs – and do technical sales on a totally new level that is not typical of the aggregate market in general. It’s both a challenge and an opportunity.”

CHOOSING THE RIGHT TECHNOLOGY “Producing crushed sand is usually a much more complex process than simply extracting natural sand,” Diem explained. “Standalone crushed sand plants are rare, and production is usually integrated with the production of coarse crushed aggregate.

“The exact layout of a crushing plant can vary. The production process usually involves several size reduction stages, which

Manufactured sand – made by crushing bedrock – is used in many applications because of its mineral and physical qualities.

include crushing, transport, size control and classification equipment.”

“In terms of the equipment, all the necessary technology is already there,” Lacote added.

“Metso has lots of knowledge in this area and can provide valuable insight for customers considering the manufacturing of crushed sand.

“Further development is always underway.

The biggest gap is in the material technology for concrete. Until now, all textbooks have been written with the default assumption of using natural sand. Practical concrete

technologists don’t understand the new crushed material or how to optimise its use. A lot of research has been done during recent years, but it hasn’t been applied much.”

“If you want to develop a crushed sand product at a quarry, you have to have a good understanding of the end material, that is, concrete,” Diem said. “You cannot just give a sample to your end customers – they will test it with current knowledge and, in many instances, fail. Instead, a much more direct technical sales approach is needed, educating customers in the possibilities of the new

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SAND PROCESSING

material and conducting lab trials together – pretty much in the same way that concrete admixtures, for example, are typically sold.”

MEETING THE CHALLENGE Metso has years of know-how in different solutions for sand processing and a good portfolio of related equipment.

Shape is a major issue. This is where the role of crushing equipment is critical to ensure an acceptable shape and size.

Cone crushers like the Metso MX, Metso Nordberg HP Series and GP Series enable the production of finer products, together with coarser aggregates. They also lower the initial capital investment and save energy, due to having fewer crushing stages.

Metso’s HRC high pressure grinding roll technology lends itself particularly well to the production of sand. The inter-particle comminution method makes the cubical/ angular product shape under the correct operating conditions.

“Studies show that the best end product

strength. Good, workable fresh concrete is for various purposes can be achieved with easy to lay on a floor or cast in a form without high velocity impact crushing,” Lacote too much physical effort. And the fresh said. “The Metso Barmac VSI vertical concrete mass needs to stay uniform, without shaft autogenous impactor improves the aggregate segregation or water bleeding. For soundness and shape of the material and asphalt and functional aggregates, there are produces a quality that is very close to natural grading specifications that must be met.” sand. Most other VSI crushers use metallic Fulfilling these demands requires the crusher parts to crush rock but the Barmac VSI uses product to be screened/classified. The sand a rock-on-rock crushing method. The better top size, normally 2mm to 4mm, is screened the grain shape of the end product, the better with vibrating screens. Rock dust/filler can be its performance in concrete, asphalt and classified best by wet processing or with air base mixtures. The rock-on-rock crushing and classifiers. Air classification is suitable for both grinding action also provides the lowest cost concrete and asphalt production. In asphalt per tonne of any impact crushing method.” production, dry asphalt sand produced with Classifiers are then used to remove the air classification is an economical solution; needed amount of fine particles and dust. it eliminates the need to evaporate water, Metso’s static air classifiers, which are which is an energy-intensive process in a environmentally friendly and economical to hot mix asphalt plant. Concrete sand can be use, produce consistent sand quality. tailored using two-stage air classification and “For concrete, there are two important TELESTACK TS-36-140 AGGSTACK mixing the classified filler back into the sand, requirements,” Lacote said. “First, fresh if needed.

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SAND PROCESSING

SUBCONTINENT PRODUCER PUSHES ENVELOPE WITH MANUFACTURED SAND

R

iver sand is a depleting resource across the globe and mining from the riverbed has been banned in many places. As an important raw material used in construction, so there has been a dire need for an alternative to this ever-growing demand. As a result, Vijay Kosaraju, the managing director of Robo Silicon Pvt Ltd (RSPL), started producing manufactured sand in 2001 to feed the growing demand for sand and aggregates in t Hyderabad, in the southwest of India.

RSPL’s pilot project initially produced 55 tonnes per hour (tph) of manufactured sand, as the acceptability was still an issue. The company’s focus was to sell sand to readymix concrete manufacturers in the region.

“I am thankful for the Cement & Building

Materials Laboratory, which certified the results showing that manufactured sand is much stronger than river sand,” Kosaraju said. “Other reports on manufactured sand and published by different bodies promoted its use, as it had good particle shape, perfect gradation, enhanced the performance of high strength concrete, and was readily available, compared to natural sand. The industry players ultimately moved to manufactured sand, and RSPL started selling manufactured sand to some of its prime customers.

“Our end customers were the big infrastructure and readymix concrete (RMC) companies,” Kosaraju said. “Initially, they were hesitant, but eventually accepted the product after witnessing the benefits – like a reduction

in the overall cost of operations, cubical shape, high compressive strength, ecofriendliness, and availability at half the cost of river sand.”

After gaining industry acceptance, RSPL opened another 200 tph Metso plant, comprising jaw, cone and Barmac VSI crushers, at Bangalore to meet the demand of the RMC companies. RSPL quickly expanded and today has 14 operational plants across India, all supplied by Metso. Moreover, RSPL received large-scale orders for the supply of aggregates from Reliance refinery at Jam Nagar and GMR for airport work at Hyderabad and Delhi. At this time, the company was producing 300,000 tonnes of aggregates commercially with Metso equipment.

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POSSIBILITIES WITH NICHE PRODUCTS “Metso is a reputable brand that has been delivering quality equipment and services to us since the very beginning,” Kosaraju said. “We have been buying equipment from Metso for the past 17 years. The first crusher we bought in 2001 is still in operation.

“A Metso plant may be costly initially, but ultimately one saves more, as production is higher and maintenance costs are low. The sale of a local plant may save some money initially, but given the overall production, maintenance and breakdown analysis, Metso is superior and that is why our 14 sites run Metso plants. Also, we only use Metso original spare parts. This offers better availability.”

RSPL continues to create a niche for itself in the region with its Robo Sand, Rotek Sand, Rotek Aggregates and Rotek Plaster Sand – all produced with Metso equipment. Rotek Plaster Sand is the latest offering from Robotek, the flagship company of RSPL. “Rotek Plaster Sand (minus 2.36mm) is produced with Metso’s triple-slope screen,

The crushing, screening and washing circuit at Robo Silicon’s Hyderabad quarry.

which filters the desired product, and Metso’s air classifier, which helps derive plaster sand after the removal of micro-fines from the fines using gravitational, inertial, centrifugal and aerodynamic forces, to efficiently classify materials at cut points ranging from 300 to 75 microns,” Kosaraju said.

“At one of our sites, we installed our first four-stage plant comprising Metso’s jaw, cone, Barmac VSI, Premier TS screen and air classifier to produce 10 different products to accommodate the varied demands of our customers. Our target with this plant is to produce 25,000 tonnes of plaster sand per month; the plant currently is not running at full

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capacity, and we are producing 10,000 tonnes of plaster sand and 40,000 to 45,000 tonnes of aggregates (0–20mm) per month.”

Kosaraju said an increasing push on infrastructure is paving the way for cutting edge technology and trailblazing innovation.

By investing in technologically advanced equipment and finding unique ways to fulfil rising demand, RSPL has been able to make a unique selling proposition for itself. “Investing in the latest technology is a cost-effective and futuristic way of moving infrastructure forward for the nation,” Kosaraju said. • Source: Metso

An Alliance low water washer consists of an agitator and dewatering screen.

Depending on the application, water is introduced through a series of spray bars.

SAND PROCESSING

ACHIEVING SAVINGS THROUGH FINES PROCESSING IN THE CRUSHING CIRCUIT As the quarrying industry experiments more with manufactured sand, so the focus falls on how to develop a process that maximises output while minimising energy and water consumption costs.

40

Quarry December 2019

D

emand for manufactured sand is increasing at a rapid pace as natural sand reserves deplete, environmental constraints tighten, and permit processes lag. As aggregate producers work to keep up with more stringent product specifications, the need for efficient crusher fines management is key to running a costeffective operation.

Typical solutions for washing crusher fines include sand screws and cyclones, which require high water use. A standard sand screw needs about 12.5m3 per hour of water for every tonne of minus 75 microns (µm). Even if an operation only produces 90 tonnes per hour (tph) and their -75µm is 15 per cent – that equals 15 tonnes of fines requiring 187m3 per hour to lift the silt over the screw.

The water requirement for a 220 tph capacity cyclone dewatering plant will run between 450 and 600m3 per hour).

The cost of using that much water, along with imposed environmental restraints, makes using a sand screw or cyclone plant prohibitive for many crushing operations.

In addition, washing crusher fines with a sand screw or cyclone typically requires operators to transfer the material

from their crushing circuit to a separate washing circuit.

The rehandling process calls for an additional wheel loader, driver and generator — all added costs. The extra time it takes to haul this material slows down an operator’s ability to get product to market.

To provide a solution for this unaddressed problem, Superior Industries designed and built the Alliance Low Water Washer. The unit allows operators to wash crusher dust within their crushing circuit, eliminating the cost of handling and hauling these fines to a separate washing site. Designed with a small footprint, the machinery is easily incorporated into an existing plant. Current customers have experienced 80 per cent less water consumption when washing straight off a dry feed in place of their previous solution.

The Alliance Low Water Washer’s agitator mixes a dry feed with water, producing a thick slurry that discharges onto an attached dewatering screen. The agitator is equipped with a spray bar along its entire length for thorough cleaning and to keep material from building up along the sides.

The blades are constructed of 25mm abrasion-resistant cast iron.

Using a sand screw requires a large volume of water to lift the silt over the weirs of the screw. Alternatively, the low water washer pushes material down through the screen, a process that requires much less water.

After the agitator, material is discharged to an integrated dewatering screen, which reduces moisture content to as low as eight per cent. Its deep bed design removes moisture more effectively and retains the highest possible percentage of saleable product. Urethane sidewalls are lined with screen openings, creating a larger surface area for drainage.

Compared to cyclone plants or sand screws, the Alliance Low Water Washer requires less power. A 220 tph cyclone plant typically runs at 93kW while a low water washer processing 181 tph runs at only 28kW. A 220 tph sand screw requires two 11kW motors to operate.

Designed with a small footprint, the Alliance Low Water Washer is easily incorporated into an existing plant.

SAND PROCESSING

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CASE STUDY: PRODUCER ACHIEVES LARGE THROUGHPUT Rilite Aggregates, based in Reno, Nevada, USA, faced a water management challenge. The company had been washing its concrete sand with a 1371mm twin screw that required a whopping 500m3 per hour of water.

“We had to fill a holding pond and utilise a large pump. With that, we could wash material for only three hours per day,” Michael Rudolph, a long-term crushing subcontractor who has worked with Rilite for nearly 20 years, said.

The water management situation reached a “crisis” mode when a specification change in utility bedding sand required the company to wash that product as well, lowering the minus 75µm from 15 per cent to seven per cent or less.

Rudolph said that Rilite needed an aggressive washing system that could run off available water. “With a drastic change in sand specifications, we were forced to add washing capacities, so we wanted a lower cost, lower maintenance solution that would limit water use. We have our own well but it only pumps 220 gallons per minute [50m3 per hour],” he said.

The local Superior Industries dealer, Kimball Equipment, referred Rudolph to John Bennington, Superior’s director of washing and classifying. It wasn’t long before Rudolph flew to a Michigan quarry to see the prototype of the Alliance Low Water Washer in action.

According to Bennington, the operation in Michigan processes 90 to 108 tph of feed through the low water washer, and generally runs from 45m3 to 57m3 per hour) The raw feed averages about 22 per cent of -75µm. At that rate, the conventional sand screw would require 250m3 per hour. “After washing, the operation is achieving under a six per cent -75µm, with a target of four per cent after further refinements,” he said.

At the Michigan site, Rudolph ran pre- and post-wash samples through the washer and found that the unit would meet Rilite’s specification requirements. This led to the installation of the Alliance Low Water Washer at Rilite Aggregates in February of 2017.

“I had the site ready to go, so it was a matter of unloading the truck, plus one day of hook-up, and we were in business washing bedding sand at 158 to 181 tph,” Rudolph said. “It handles that capacity in such a small footprint, allowing us to install the washer without making any modifications to the existing plant.”

He added that he placed a belt stacker in front of the washer that can swing to feed the washer or swing away to by-pass the washer when needed.

Rudolph said the low water washer averages about 68m3 per hour, which is fed from a large freshwater pond that acts as a surge system for the well.

“Versus the previous use of twin sand screws at 500m3 per hour, I now vary my flow rate to the low water washer between 45m3 and 90m3 per hour. This has dramatically lowered our washing costs.

We can conserve water, and manage its use without jeopardising our need for water trucks for dust control,” he stressed.

Importantly, Rudolph pointed to the moisture content of the material after washing. “It’s between 11 and 13 per cent. With that, we can sell the product within one day. With our previous set-up, we had 22 per cent moisture content after washing and had to let the material sit and dry for about a week,” he said, summing up the biggest advantage of “low water use and large throughput”. • Source: Superior Industries

SAND PROCESSING

The Alliance Low Water Washer at a NSW basalt operation.

After ‘wetting’ the crusher fines with agitation, the Alliance Low Water Washer builds a deep bed of material on the deck of a dewatering screen.

HAS THE EVOLUTION OF WASHING ENTERED A PARADIGM SHIFT?

I

n the field of sand washing, major developments are few and far between.

Some types of equipment actively used today were developed over a century ago, and many items are 50 years old.

There have been improvements over time, of course - in quality, tolerances, efficiencies, motors, bearings, wear parts, etc - but few transformative leaps in the actual washing process.

However, we may now be approaching a paradigm shift in the processing of crusher fines or dust – thanks to results produced by the Superior Industries Alliance Low Water Washer at a basalt operation in southern New South Wales.

Crusher dust has been washed for decades with cyclones and sand screws. Both techniques have been finetuned to carry out this process, and with sufficient power and sufficient water, each application can achieve an outcome. The Alliance Low Water Washer, using minimal water and limited power, conditions or “wets” the crusher fines with agitation, then builds a deep bed of material on the deck of a dewatering screen. The dewatering screen has spray bars to inject water into the product bed, releasing finer size particles through the deck’s apertures.

In this issue, Superior Industries covers the development and technical aspects of the

Alliance Low Water Washer (see page 40).

It made its international debut at Bauma earlier this year.

At almost the same time, the first unit arrived in Australia. This was delivered and installed at a basalt operation, south of Sydney, virtually going straight to work.

The quarry has previously washed crusher fines with a sand screw and used an air separator. Its owners were interested in controlling their particle separation and using as little water as possible. Once the Alliance Low Water Washer was commissioned and operational, the quarry operators finetuned it to their satisfaction.

At this site, there are typical averages of 17 per cent passing 75 microns (µm) in their crusher fines (the -5mm material). The aim was to achieve an average of nine per cent -75µm. The operation has now been producing manufactured sand at its preferred grading for more than six months. The operators have complete control and can readily adjust any changes in the feed. They have been able to get the product stockpile down to six per cent moisture.

Different crushers and different rock types produce a range of gradings, particularly in the -75µm percentages. The initial challenges in manufactured sand were focused on removing excess -75µm material.

Paradigm shift. (n) 1. A complete change of the framework within which an idea is expounded, a situation viewed, etc.

2. Any major change.

Macquarie Concise Dictionary

The industry has reached a stage where individual sites are attempting to make their manufactured sand suit individual batch plants, as well as the broader market.

Achieving five per cent -75µm is possible with certain rock types and feed gradings.

All of this is carried out with similar power usage to a sand screw, and less than a third of the power used to pump to a cyclone, with a fraction of the amount of water used in either of those processes.

Superior Industries continues to develop a broad range of experience in rock types, as the use of the Alliance Low Water Washer continues to grow. Locally, discussions have been held with a number of other producers with differing issues, gradings and rock types. The evolution of producing manufactured sand appears to have reached a paradigm shift. • Jim Hankins is the principal of Rivergum Industries.

Quarry December 2019 43

PUMPS

P

t

SUBMERSIBLE PUMPS PROVE THEIR METTLE

IN ARDUOUS CONDITIONS

A

simple pump failure in a quarry can be costly, as production is stopped while a replacement is organised. However, there is now a low-cost back-up solution that can be deployed fast in an emergency.

Multinational submersible manufacturer Tsurumi has produced a portable singlephase slurry pump that is inexpensive and easy to install.

“These tough, portable submersibles can be set up quickly to clear flood water or as extra support for existing pumps,” said Albie Bester, product manager for Tsurumi’s Australian distributor Aussie Pumps. “They’re slurry pumps with built-in agitators and are designed to handle abrasive water.”

Tsurumi’s model HSD2.55S has a 50mm (2”) discharge port. The pump produces up to a 220 litres per minute (lpm) flow and has a maximum head of 13.2 metres. The motor is a single-phase squirrel-caged submersible design, drawing 7.2 amps at full load.

The heart of the pump is a semi-vortex high chrome iron impeller designed to pass sand- and silt-laden water easily through the pump chamber.

The shaft-mounted agitator prevents “air lock” and stirs the mixture liquidising the sediment so it can be passed. The agitator is also made of high chrome iron for long wear life in demanding applications.

Other key features include an anti-wicking 44

Quarry December 2019

block at cable entry. That block prevents the incursion of water due to capillary wicking in the event that the power cable is damaged or the end submerged. This unique feature prevents one of the major failures of motors in submersible pumps.

“We’ve had a lot of these pumps bought by batch plants for use in wedge pits as well as emergency back-up general dewatering submersibles,” said Bester. “They are also available as an auto version with a robust float system,” he said.

Like all Tsurumi pumps sold by Australian Pumps, the HSD pump is covered by an exclusive three-year warranty.

Australian Pumps’ partnership with Tsurumi allows the company to augment its “Mine Boss” pump range with submersible pumps that handle corrosive liquids.

Australia’s rapid expansion in copper production means the demand for 316 Stainless steel submersible pumps is increasing. Tsurumi SFQ series pumps are also used in quarries around Australia.

Tsurumi’s SFQ series 316 stainless steel pumps have been readily accepted in gold and copper mines where cast iron pumps simply don’t last.

“We heard reports of cast iron submersible pumps failing in only a matter of days, not even weeks,” said Aussie Pumps’ chief engineer John Hales.

With a power range of up to 11kW, Tsurumi’s corrosive resistant, heavy-duty pumps feature two-pole motors with high grade bearings. An especially high carbon grade of 316 SS is used that allows the pump to be fully cast with no welds to corrode.

Tsurumi’s LH series high head pumps are also popular across Australia. This unique design with its centre-mounted outlet makes it convenient to install. The slim line of the product provides the ability to fit in 610mm (24”) diameter bores. That is even true of the 110kW version.

The pumps are fitted with abrasionresistant, high chrome, closed impellers, providing heads of up to 200 metres and flows as high as 6500 lpm.

The pumps range is available from the 316 SS all the way up to the big 200mm (8”) model LH8110. That 110kW pump produces flows of 3000 lpm at heads of up to 100m.

Pumps will be wound in 415 volt and 1000 volt configurations, as well as optional 690 volt versions.

To learn more about Aussie Pumps’ complete corrosive liquid pump package, a free copy of its quarrying and mining capability document Mining & Quarry Solutions is available at aussiepumps.com.au • Source: Australian Pumps

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SCREEN MEDIA

SCREEN MEDIA MANUFACTURER INNOVATES WITH CUSTOM SOLUTIONS

A

supplier of woven wire screens, poly and wire ripple screens, poly modular systems, rubber screens and modular systems, along with associated accessories, Locker has recently commissioned new weaving equipment at its Dandenong, Victoria facility. The state of the art crimper and loom machinery will allow the fast and efficient production of made to order screens for the Australian market.

Locker has been a major supplier to the extractive market for more than 40 years and continues to innovate in terms of both products and services. This is to help producers improve operational efficiency at both the screening and procurement ends of the process.

The company originally introduced the slab stock process (holding flat wire screens locally) that could be cut and hooked to the required screen sizes in three days, removing the need to weave to order. The market followed with imported screens purchased from a variety of suppliers, whereas Locker manufactures its own at its Indian plant, where quality control, safety and efficiency are maintained, and there are further supports for local crimping and weaving for made to order requirements.

In 2019, Locker installed and commissioned two state of the art wire weaving lines at its Dandenong, Victoria facility. These two lines produce the widest range of screening media products in Australia and New Zealand and

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can crimp and weave wire from 1.2mm to 12.5mm in an aperture range from 2mm to 100mm. These are the first new looms to be installed anywhere in Australia in the past decade and the company is very proud to continue to invest in Australian manufacturing.

To complement the wire segment, Locker has invested in a new rubber punching process that seeks to improve the current quality in the market, making small aperture cross-tension screening a cost-effective alternative to other options.

According to the company, its customers continue to help drive its innovative approach to the extractive market. Locker has completed the acquisition of the Polyscreen assets which have been integrated into its supply chain and

With 20 years experience in the heavy industries, we have established our supplier network, who are making parts as per OEM approval process world-widely.

A web-based platform is set up to receive online enquiry for the spare, wear parts and screen media used in the mining, quarrying and recycling fields.

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Quarry December 2019

further enhance the portfolio of products it offers to help improve quarrying producers’ process efficiencies, occupational health and safety outcomes and quality.

These local manufacturing capabilities are supported by Locker’s Indian facility, based in Mumbai, which has also seen large investment in capital equipment with new weaving lines, a Polyripple manufacturing cell and a rubber cross-tension mat processing line that started in 2018 and will be completed this year. This facility supports Locker’s Indian, Middle East and South East Asian customer base while providing slab stock for Australian and New Zealand customers.

By the end of 2019, Locker will also have commissioned its Tufflex fabrication and hooking cell, which can potentially improve lead times by 60 per cent and provide more support to the market. With producers experiencing up to 12 times more life than imported equivalent screens, reduced operational noise, reduced risk to staff during installation and change-out and the ability to change screens in minutes (not hours), Tufflex

The loom can crimp and weave wire from 1.2mm to 12.5mm in an aperture range from 2mm to 100mm.

In 2019, Locker Group installed and commissioned two state of the art wire weaving lines at its Dandenong, Victoria facility.

is an important tool for quarry operators to reduce cost and risk.

To support its customers in both major centres and remote areas, Locker will introduce VERA Connect, a Con-Stock app that will let producers holding consignment stock manage stock usage and simplify the

procurement process from a smart mobile device.

Locker is a proud Australian manufacturer, supported by a growing supply chain provided by parent company Valmont. • Source: Locker, a Valmont company

ERIEZ

CrossFlow Classifier Cuts Coarser than Cyclones and Finer than Screens

Feed material (2 mm x 0) cut at 400 micron.

Weight split roughly 50:50.

CrossFlow Advantages: • High Volume • Low Water Consumption • Sharp Cuts • No Power Requirement • Small Footprint

Contact Eriez Magnetics Pty Ltd / Eriez Flotation Division 61 3 8401 7400 or visit Eriez.com.au / EriezFlotation.com

Quarry December 2019 47

The Institute of Quarrying Australia

FROM THE CEO

THINKING ABOUT OUR WORKFORCE’S

FUTURE SKILLS, PROFESSIONAL DEVELOPMENT Geelong was a wonderful host for the IQA’s 62nd annual conference in October.

The city itself showcased a progressive region that supports infrastructure growth, tourism, agriculture and light industry. The theme – The Future of Quarrying – was apt for the region as we had the privilege of visiting Barro Point Wilson and Boral Deer Park Quarries. These are two examples of the extractive industry working closely with a range of stakeholders for the advancement of the region.

I would again like to thank our platinum sponsors Hitachi Construction Machinery, Komatsu and Caterpillar, and the official partner program sponsor Orica Australia.

The support of our platinum sponsors enabled us to provide a very different social program that supported networking and captured the essence of Geelong.

The conference provided many opportunities for us to reflect and think about the future. A key theme that many speakers touched on was that of the workforce and the future skills of the workforce.

Community expectations, technology, data, increased safety standards, automation and competition for talent from other sectors all mean that we have to think about our workforces today and into the future.

We have to work to encourage people into the sector and look at improved ways to embrace diversity.

Diversity in our teams will help build an innovative culture and is proven to improve business outcomes.

The IQA will continue to work with industry on what is needed to truly address diversity.

The Young Members and Women in Quarrying networks will be supported to encourage participation in the sector.

A number of events and conferences will be held in 2020 and I encourage you

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Quarry December 2019

to support people from all parts of the industry to be involved.

Whenever I participate in industry events, I certainly make my passion for workforce development known. Having previously worked in health, the concept of mandatory professional development is one I am very used to. We are seeing the dialogue around professional development become more paramount in the industry with various state legislation requiring competence and maintenance of competence.

New South Wales is currently the only state with mandatory CPD (for quarry managers holding a NSW Practicing Certificate – without conditions).

While not mandatory in other states, the IQA has always held a strong position on the importance of ongoing education. Effective from November 2019, the IQA relaunched its Quarry Manager Certification System (QMCS) which has been implemented to grant

professional recognition to quarry industry professionals. QMCS is overseen by the IQA’s CP Committee.

The CP Committee may accredit a person as a: • Certified Practicing Quarry Manager (CPQM).

• Certified Practicing Quarry Supervisor (CPQS).

For more information about the QMCS, email education@quarry.com.au I would like to congratulate all IQA Award winners for 2019. This year we saw innovation and leadership in all the submissions. The winners will be profiled in future issues in 2020.

I wish you all a very safe and happy Christmas and I look forward to what 2020 brings.

KYLIE FAHEY Chief Executive Officer Institute of Quarrying Australia

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IQA NEWS Speakers from the Mines Inspectorate provided updates on legislation and competencies. Inspector of Mines Greg Manthey provided information on the Inspectorate’s Respirable Dust Initiative, and Neel Balgovind, the RTO manager for Simtars, updated attendees on safe drill and blasting, legislation and associated competencies.

Breakfast MC Anita Waihi with (l-r) Mark Provost, of Barro Group, and Matt Smith and Ross Poynton of Rossco Site Servicing personnel.

The Institute of Quarrying Australia

branch could not deliver relevant, informative and effective meetings.

Thanks also to North Queensland branch members and industry colleagues for support in 2019! The branch is looking forward to seeing you all in 2020!

By Jennifer Milward

Carly Clifford, the health and safety lead for Sibelco Australia, provided an interesting presentation on managing the risks of falls from mobile plants.

Evolution Mining sponsored the network drinks following the seminar.

By Jennifer Milward

NORTH QUEENSLAND BRANCH NEWS More than 50 delegates attended the annual safety seminar on 23 October in Rockhampton.

QUEENSLAND BRANCH NEWS The Queensland branch hosted its annual breakfast meeting in September, sponsored

by Rossco’s Site Servicing. One of the guest speakers was Daniel Hall, from Hitech Electrical Automation, an industry specialist in electrical contracting within the quarrying industry. Daniel reported on new technology available to the Australian market which is “revolutionising” the belt scale industry.

Software scales are installed only in the MCC motor starter of the conveyor, with no field electrical components, providing a costeffective, no-maintenance alternative for final stacker belts.

The Queensland branch was pleased to launch the first in its “Leadership Series” of talks, with guest speakers sharing their career highlights and providing industry insights. The first speaker in this series was Peter Ambrose, Holcim Australia’s Queensland general manager of aggregates.

Breakfast MC Anita Waihi, the deputy chair of the Queensland branch, presented a certificate to new member Mark Provost from the Barro Group.

Site tour of Fulton Hogan facility, Townsville Members of the North Queensland branch were hosted by Fulton Hogan at its asphalt plant in Townsville on 8 October. More than 40 members and guests thoroughly enjoyed a detailed tour of the plant and associated facilities including the bitumen works, gaining a detailed understanding of the end use of aggregates in road construction and the technical challenges and opportunities being incorporated into modern processes.

Brad Hamilton, the divisional manager for Fulton Hogan (as well as the North Queensland branch’s treasurer/secretary) led the tour, giving insights into RAP use and production, speciality products and modified bitumen, as well as testing, transport and further manufacturing options. Many questions were asked and a rewarding evening was had by all.

Thanks are in order to the evening sponsors VCV and Holcim and, as always, the branch premium sponsors in Impact Drill & Blast, Komatsu, Hastings Deering, Markwell and Ritchie Brothers for their ongoing support throughout the year. Without their support, the

Safety & Health Seminar, Rockhampton The Central Queensland sub-branch and the Department of Natural Resources, Mining and Energy partnered on 23 October to present the Annual Mining and Quarrying Safety and Health Seminar in Rockhampton. There were more than 50 delegates for the half-day program.

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Quarry December 2019

More than 40 IQA members and guests toured Fulton Hogan’s asphalt plant in Townsville on 8 October.

Guest speakers Michael Close (left) and Chris Kummerow (right), with SA branch chairman Andrew Wilson.

SOUTH AUSTRALIAN BRANCH NEWS The last SA branch dinner for the year was held at the Pullman Adelaide on 8 November and was a roaring success, with the largest number of attendees to a branch function for many years. The draw card was obviously the quality of the three guest speakers for the evening.

The first speaker was Michael Close, of Adelaide Brighton, who recaptured the highlights from his trip to the Metso factories in Macon, France and Tampere, Finland to celebrate the production of Metso’s 10,000th crusher. Michael also gave an insightful overview of his visits to quarries in France and Finland.

Appreciation was extended to Metso for providing a C150 jaw crusher model as a door prize, which was first won by one of the guest presenters who kindly donated it back! Mark Bevan (Boral) was the eventual lucky recipient.

Second up presenting was Frank Pedretti (Boral), the recent winner of the IQA’s 2019 Quarry Manager of the Year Award. Frank gave a thoughtful, amusing overview of his background in the industry, the history of the many quarry sites he had worked on, and especially acknowledged the support of his wife and the many colleagues he has worked with over the years.

The final guest speaker was Chris Kummerow, the National Heavy Vehicle Regulator’s (NHVR) director of prosecutions, presenting on the Chain of Responsibility regular update. Chris’s talk focused on

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The Institute of Quarrying Australia

the extremely high level of importance the industry needs to place on all aspects of heavy vehicle management, movement, loading, unloading and maintenance. The subject matter was very relevant to the industry today.

The SA branch again thanks its sponsors for their continued support which goes a long way to ensuring that the branch remains relevant, vibrant and effective for its members.

The SA branch committee wishes all of its members, sponsors and colleagues a safe and merry Christmas and a happy new year.

By Marie Cunningham

TASMANIAN BRANCH NEWS Branch AGM On 8 October, the Tasmanian branch convened at the Ole Tudor Motor Inn for its annual general meeting. The following officebearers were proposed and endorsed: • Ben Palmer (Chair).

• Chris Terry (Secretary).

• Doug Fulton (Treasurer).

Thanks were extended to the previous chair Nic Palmer and the former secretary Erin Duggan for their support.

CCAA Safety Seminar, Hobart

The view from the top of the downhill conveyor, overlooking the Hanson Flagstaff Gully Quarry, and Hobart in the far distance.

prepared by CCAA in response to safety issues related to tipping loads at worksites and within facilities.

The seminar was officially opened by The Honourable Elise Archer MP, the Attorney-General, Minister for Justice and Minister for Building and Construction in the Tasmanian Government. The other session presenters were: Consultant Dr Kirsty McCullough – on the principles of fatigue management and its application in the workplace and the concrete and aggregates industry.

Robin Murcott, Hanson Australia’s compliance and fleet manager – on the principles of Chain of Responsibility and safety during tipping loads at worksites and within facilities.

The seminar was followed by lunch and in the afternoon delegates split into two groups to view the downhill conveyor overlooking Flagstaff Gully Quarry and Downer’s new asphalt plant co-located at the site.

By John Stanton

The Tasmanian branch of the CCAA hosted a half-day safety seminar at Hanson’s Flagstaff Gully Quarry, in Lindisfarne, near Hobart.

The CCAA Safety Seminar is held each year in conjunction with Work Safe Tasmania’s October Safety Month. This year the seminar theme focused on transport logistics and safety in quarries.

Hanson did a great job prepping the quarry site generally for visitors and built a marquee for the 50 delegates in attendance.

The CCAA’s Victoria/Tasmania state director Brian Hauser was the MC. He launched the recently published Tipper Guidelines

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Quarry December 2019

Associate Associate Associate Associate Associate Member Associate Associate Associate Associate T/Member Fellow Member

Daniel Webber Sarah Grixti Wayne Grech Ralph Barling Michael Vayro Lachlan McRae Lorraine Anderson Robert Davies Kendal Masterton Leanne Muir Stephen Sandiford Stephen Wilson David Salim

For more information about events or any of the WA branch’s activities, contact Celia Pavri, tel 0417 027 928 or email wa-admin@ quarry.com.au

ACT NSW

Peter Hewson: 0429 001 476 Gemma Thursfield: 0402 431 090

Northern Gemma Thursfield: 0402 431 090

IQA NEW MEMBERS NAME

The branch thanked Mark for sharing his expertise and enthusiasm.

IQA BRANCH CONTACTS

The WA branch held a breakfast function on 22 October which was proudly sponsored by CJD Equipment.

GRADE

The guest speaker was Mark Nickerson, the Tunneling & Forrestfield Station Project manager from WA’s Public Transport Authority. Mark’s enthusiasm for his job and passion for tunneling was evident as he described the tunnel boring machines “Grace” and “Sandy” from early concept, commissioning, launch, ongoing operations and their progress along the 8km journey underground from Forrestfield to Bayswater. The mind-boggling complexity of the tunneling aspect of the project, the challenges of the nature of the geology along the tunnel’s course and the precision and attention to detail required made for one of the most interesting topics presented at the branch’s breakfast functions.

By Celia Pavri

WESTERN AUSTRALIAN BRANCH NEWS

Brian Hauser was the MC for the CCAA’s Safety Seminar on 23 October.

Tunnel one facing towards TBM Grace in October 2018.

Hunter BRANCH QLD NSW NSW QLD QLD VIC WA WA WA WA WA QLD NSW

Illawarra

Gemma Thursfield: 0402 431 090 Dylan Treadwell: 0418 632 057

Central West Mitchell Bland: 0428 462 987 NT

Darren McKenna: 08 8988 4520

QLD

Jennifer Milward: 0419 782 688

Gladstone Jennifer Milward: 0419 782 688 Townsville Jennifer Milward: 0419 782 688 Cairns SA Tasmania Victoria

Chris Wilson: 0438 134 752 Marie Cunningham: 08 8243 2505 Nicholas Palmer: 0418 126 253 Eli Carbone: 03 8637 4723

Vic Sub-branch Craig Staggard: 0407 509 424

WA

Celia Pavri: 0417 027 928

GEOLOGY TALK

THE ELEMENTS OF SURPRISE

Antimony is most commonly found in the mineral stibnite (also known as antimonite). This sample is on display in the Carnegie Museum of Natural History, in Pittsburgh, Pennsylvania, USA.

As we close out the year, Bill Langer acknowledges some of the elements on the Periodic Table, which was first formulated 150 years ago …

Y

ou may have noticed that over the past few months that I have discussed some of the elements on the Periodic Table, which this year is 150 years old.

This article describes some special elements with properties or their uses that might surprise you: • Sulfur (or sulphur, S – Atomic Number 16), infamous for a smell comparable to rotten eggs, is actually a tasteless, odourless non-metal. The smell associated with sulfur is actually characteristic of hydrogen sulfide (H2S). While sulfur may not seem odd to most people, it has a curious property – it changes colour. In its native form sulfur is a yellow crystalline solid. But if you melt sulfur, it becomes a blood red liquid, and if you burn sulfur, a neon blue flame is produced. You might say it is the “chameleon” of the elements.

• Gallium (Ga – Atomic Number 31) is a soft metal that doesn’t occur in pure form

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Quarry December 2019

in nature but can readily be smelted from minerals. It is used in semi-conductor production, mainly for light-emitting diodes (LEDs), laser diodes, and solar panels. It is also used to create brilliant mirrors. What’s amazing is that gallium does something that metals aren’t supposed to do – it melts in a human hand, then re-solidifies once it cools down below its 29oC (or 85oF) melting point. That property made it the basis for chemist pranks involving gallium utensils at meals.

• Antimony (Sb – Atomic number 51) is a rare element occasionally found in its pure form but mostly in the mineral stibnite.

Antimony has a number of industrial uses, but perhaps its most notorious property is that, along with arsenic and mercury, it is among the deadliest elements on the Periodic Table. However, that didn’t stop people from ingesting it. In the 18th century, pills of antimony were popular as a laxative. It worked so well that

some people would root through their excrement to retrieve the pill and reuse it later. About that same time, tartar emetic, an efflorescent crystalline salt with a sweetish metallic taste, was a popular hangover cure. Wolfgang Amadeus Mozart, a heavy drinker, was known to overindulge in the cure. Unfortunately, tarter emeric contains antimony, which some speculate led to his death.

• Iridium (Ir – Atomic number 77) is the most corrosive-resistant element and can’t be affected by water, chemicals or acids. Iridium also is the second most dense element. Consequently, it is rare on earth because it sank into the centre of the planet as the planet was formed. But iridium can be found in large concentrations in asteroids and likely comprised part of the meteorite that wiped out the dinosaurs 65 million years ago. Scientists have found that geologic rocks at the Cretaceous Tertiary boundary, which marks the extinction of the dinosaurs, contain more than 100 times the quantities of iridium than normally expected.

• Bismuth (Bi – Atomic Number 83) – Bismuth is the heaviest non-radioactive metal, which lends its name and pink colour to a famous over the counter medicine in the US – Pepto-Bismol (known as peptosyl in Australia). But its most curious property is that it is diamagnetic. That means if you place a magnet between two pieces of bismuth, it will levitate indefinitely.

The Periodic Table is one of the most important, influential scientific achievements. It reflects the essence not only of chemistry, but also of physics, biology, geology, and other basic sciences disciplines. So, on its 150th anniversary, I say … •

Bill Langer is a consultant geologist.

QUARRIES FOR SALE GROMAC CENTRAL DIVISION

• SARINA • HATFIELD • BLUE MOUNTAIN, QLD OFFERS INVITED FOR THE SALE OF QUARRY SITES AT SARINA, HATFIELD AND BLUE MOUNTAIN, CENTRAL QUEENSLAND

SARINA

HATFIELD

BLUE MOUNTAIN

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Located on the Bruce Highway, approximately 5kms south of Sarina, Queensland.

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Located on Bolingbroke Road, Koumala, approximately 35km from Sarina, Queensland.

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Located approximately 40kms south west of Mackay, QLD and is accessed via the Peak Downs Highway.

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Owned under freehold title

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Operated under a licence agreement

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Owned free hold

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Development approval 5000t – 100,000t

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Weighbridge including computer and software

Development approval for 100,000t – 1,000,000t

Development approval for 100,000t – 1,000,000t

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Licence renegotiation March 2022

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Access via a road easement

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Office building with fixed desks and cupboards

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Weighbridge including computer and software

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Workshop building

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Two water tanks adjacent to office with pressure pump

Office building with fixed desks and cupboards

Sale of a parcel of freehold land encompassing the quarry or licence agreement

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Weighbridge including computer and software

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Demountable office building

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Shipping container adjoined to office building used as store room

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Bore pump and water lines Pugmill with Genset

Workers camp consisting of four demountable buildings, cement tank, pressure pump, roof structure

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Bore pump and water lines

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Two access grids

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Underground fuel tank

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Jaques Jaw crusher

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Shipping container containing fuel pump

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Pugmill with Genset

High quality mineral resources across all quarry sites, capable of meeting market demand across all quarry products. n n n n n n n

Ballast Precoated Aggregate Road Base Armour Rock Flood Rock Crusher Dust Cement treated base “Pugged”

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Concrete Aggregate

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Aggregate

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Gabion Rock

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Drainage Rock

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Mattress Rock

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Shot Rock/Blast Rock

Note: All sites are capable of producing the full range of quarry products

All quarries benefit from close proximity to the Hay Point Port, one of the largest coal ports globally, the Goonyella rail system and the growing central Queensland city of Mackay. There are no operational constraints at the sites, with the exception of development and environmental restrictions.

NOW ACCEPTING OFFERS Contact Ray Gross for further details Mobile 0407 595 253 | Email: ray@gromac.com.au

DECEMBER 2019

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