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Bespoke wash plant boosts new quarry operation

 

A new extractive operation in England’s East Midlands has seamlessly taken over the duties of a neighbouring exhausted pit operation, thanks in part to a custom-designed sand washing plant.

A new quarry at West Deeping, Lincolnshire, UK has begun supplying high quality sand and gravel into the local market, including to CEMEX UK concrete and asphalt plants within an 80km  radius, and will also stock a new on-site bagging plant.

The new site at West Deeping, which has replaced the now exhausted Manor Pit operation, has reserves which will secure the site for several years. It features a new Terex Washing Systems (TWS) plant which has been supplied by DUO (Europe), the English and Welsh dealer for TWS.

West Deeping is now one of three large processing operations within the CEMEX UK central area, with the others being Rugeley and Swinderby. The Manor Pit operation, which is about 6km away, had an operating life of 20 years and is now being restored.

“The old plant at Manor Pit was very large, with a totally different computerised blending system to the new plant that DUO have installed, so it’s a complete ‘sea change’ for our operating team,” said Philip McComb, West Deeping’s quarry manager. “Although we are still in the commissioning stage, after one month we are achieving the optimum tonnes per day. Early indications suggest the new plant will be more efficient and reliable.”

The FM 200C features a centrifugal slurry pump, a 4m x 2m dewatering screen (rear) and twin hydrocyclones (foreground) that produce two-in-specification sands.

A BLANK SHEET

The Manor Pit site contained a significant amount of ironstone. The deposit at West Deeping is very similar but cleaner with a mixed deposit in bands with clay seams in the gravel, which is efficiently dealt with by the new processing plant.

 “We have been very lucky that we started with a blank piece of paper and benefitted from previous experience with other plants supplied from various manufacturers,” McComb said. “We are very fortunate to have a plant that has been through a design process and eliminated issues we have experienced in the past. “Working with the CEMEX engineering department we arrived at what was required on-site and after various consultation and site visits DUO designed us a plant based on the TWS Fines Master FM200C, which was accepted, and they were subsequently awarded the order.”

The Fines Master FM200 can operate at up to 220 tonnes per hour (tph). The plant consists of a bespoke feed system fed by a wheel loader, via a feed hopper which incorporates a remote control tipping grid. Material is then fed up the inclined feed conveyor onto the 6m x 2m three-deck rinsing screen which utilises individually controlled spray bars on each deck, which are fitted with polyurethane modular media.

Acting as a protection deck, the top deck removes any rejects up to +90mm and clay to stockpile and any +40mm oversize is sent to a further stockpile. The bottom deck provides the feed to the Fines Master 200C to produce the required sands.

Built as a static sand recovery unit on one chassis, the FM 200C features a centrifugal slurry pump, a 4m x 2m dewatering screen and twin hydrocyclones that produce two-in-specification sands.

A specially designed rubber-lined underflow box allows blending to take place so that an acceptable coarse and fine sand ratio can be achieved. These sands are then delivered to separate radial conveyors and stockpiled.

“Originally the radial arc was going to be two equal runs, but as we produce more sharp sand naturally, we decided to install a split arc with most of the arc utilised by the sharp sand conveyor to allow us a larger stockpile,” McComb explained.

SECONDARY PROCESSING

Any remaining gravels off the first screen are then fed onto a second inclined transfer conveyor which feeds onto a triple-deck part rinser which takes out and provides feed to 6mm, 10mm, 14mm and 20mm stockpiles.

“This second split also features the option of redirecting the feed to the -6mm conveyor only, through a set of flaps,” McComb added. “This is an event we schedule every couple of weeks to produce a 04/20mm for our concrete plants. This is, along with sharp sand, our main seller, although currently 4/10mm is in demand and as our material is very clean, the 2/6 and 4/10mm also have added value as they can be potentially sold as decorative gravel.

“The final specification included lattice conveyors with a full walk around for complete access and all bearings were specified by SKF. Overall, we are very happy with the plant to date, it’s producing in-specification material and providing us with much more control and flexibility over our production, enabling us to efficiently satisfy the demand.”

TWS provides cohesive solutions for all material and mineral washing needs through its English and Welsh dealer in DUO. Focusing solely on providing solutions to the quarrying, aggregate, mining and C&D recycling industries, TWS is dedicated to providing reliable, high quality and very productive equipment with ease of transport and fast on-site installation.

This is achieved through a broad product portfolio which offers modular, mobile and static wash plants with the ability to work in many applications. Meeting individual materials and mineral washing needs to achieve today’s stringent specifications of clean material is at the top of the agenda.

In Australia, TWS is distributed through Terex Jaques in the eastern states. OPS Screening & Crushing Equipment is the
TWS distributor for WA and NT.

The bespoke feed system is fed by a wheel loader, via a feed hopper that incorporates a remote
control tipping grid.

Source: Terex Washing Systems

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