Boral has implemented an innovative in-pit crushing solution at its new Peppertree Quarry in Marulan South, in the NSW Southern Tablelands, around 180 kilometers southwest of Sydney. The new quarry, due to become fully operational in 2014, will supply the Sydney metropolitan area and greater NSW building and construction industries with up to 3.5 million tons of aggregate products per annum.
Construction of the new facilities at Peppertree started in July 2011 after more than a decade of planning. A risk assessment of the crushing process led to the selection of in-pit crushing as the safest and most efficient option for the new plant. Boral Site Manager Steve Parsons says that the use of in-pit crushing for quarry applications has been a trend in Europe for some time but is relatively new in Australia.
Boral is now looking to optimize its quarrying process and get away from the traditional load and haul operations, where you have a large number of trucks and people moving between the blast site and the fixed crushing plant.
One is the safety aspect it reduces our mobile fleet, so weve got less traffic movement on the site, which is much safer, she explains. From an environmental perspective, it reduces fuel consumption and the environmental impact of dust emissions. From a health, safety and environmental perspective, its a really great solution; but, most importantly, from an operational perspective, it does everything we need it to do.
Rigorous research into finding a crusher that could handle the planned production volume at the Peppertree plant led Boral to select Metsos Lokotrack LT160 together with the companys patented Lokolink mobile conveyor system.
Weighing in at an amazing 285 tons and measuring 12 meters high by 25 meters in length, the Lokotrack LT160 at Peppertree is the largest mobile crusher in the Southern Hemisphere. Extensive design consultation between Borals technical staff and Metsos design team prior to design finalization and manufacture has produced the most sophisticated machine of its kind, with a number of innovations never before seen on a mobile machine.
From the outset, Boral was determined to ensure its new facilities incorporated the worlds best standards in safety, sustainability and efficiency. One of the major challenges was to customize the LT160 to meet Borals strict safety requirements, which are even more stringent than Australian and European standards. To achieve this, Boral put together a team of designers, engineers, operators and OHS personnel to review the LT160 design and to identify any potential hazards and improvements before accepting the final design.
Some of the solutions, such as guarding and using stairs rather than ladders for maintenance access, are requirements of Australian standards whereas others are unique requirements that arose during the design consultation phase. These solutions include shrouds around the crusher to reduce both dust and noise, rubber wear liners on the hopper to reduce noise, a service crane installed for jaw liner changes to eliminate the need for a mobile crane, as well as walkways that extend the full length of the Lokolink conveyors on both sides.
Ensuring that the machine fully met Australian standards and Borals requirements before delivery brought the company significant cost savings by eliminating the need for site re-work and retrofits along with the associated loss of production.
In a conventional crushing plant, a drill and blast team blasts the shot and develops a muck pile. A front-end loader at the muck pile loads haul trucks that transport the rock to a fixed primary crusher. With the in-put crushing solution at Peppertree, an excavator located on the muck pile loads material directly into the Lokotrack crushers hopper. The rock moves along a grizzly feeder that passes undersized rock directly onto the machines outbound conveyor. Only the large rock that needs to be crushed passes through the jaw crusher, which is capable of processing rocks up to one meter in size. In this way, energy isnt wasted on passing small material through the crusher.
Crushed rock is then transported to the fixed, in-pit belt conveyor via two mobile Lokolink conveyors. The fixed conveyor carries crushed rock from the Lokotrack to the fixed plant for further processing. A patented swivel mechanism on the Lokolink conveyors ensures crushed material flows freely at all conveyor angles.
The Lokotrack LT160 can crush 1150 tons of rock per hour and needs to be relocated every few hours a process that can be done in minutes by an operator via a remote console worn around the operators waist. The Lokotrack is moved to the next loading position and the unique technology of the Lokolink conveyors allows them to simply follow.
When blasting is performed, the Lokotrack and Lokolink conveyors move to a safe distance around 70 meters away. After the blast, a wheel loader cleans the quarry floor and the Lokotrack moves to the new muck pile. Operation resumes with minimal production downtime.
When its time to move to a different pit location, the Lokolink conveyors are disconnected from the field hopper using hydraulic actuators. The Lokotrack and Lokolink conveyors can also move from one level to another along a normal ramp.
After the machine was delivered to the Peppertree site in late 2012, the LT160 went through a three-stage commissioning process (static, dry and wet) and achieved practical completion in mid-August 2013.
One of Borals key lessons from this project is that when importing a plant and equipment there are a number of opportunities to adjust the design and capability of the equipment. These opportunities are rarely taken up by Australian industry. Weve found that the need to partner with offshore suppliers is critical and its achievable.
When Soda is applied, surfaces such as, aluminium, stainless steel, brick, stone, glass, fibreglass, wood, plastics, bearings, seals, hydraulic cylinders and many more can be cleaned, stripped and prepared safely with no-abrasion or harm to the surface substrate.
Soda blasting also breaks down hydrocarbons through a process called, saponification which makes it highly suitable for cleaning equipment covered in fatty foods or engine parts and when your finished just rinse off and the water-soluble soda disappears.
The non-flammable properties of sodium bicarbonate allow it to be used for cleaning in the petroleum industry where other methods cannot be used. Likewise, its non-toxic properties mean that it can be used in food-processing and similar areas.
Sodablasting can be used for cleaning timber, wood, oak beams, oak floors, doors, stairs & bannisters, cars, boat hulls, masonry, and food processing equipment. Sodablasting can also be used to removegraffitiand to cleanstructural steel. Soda blasting is very effective for the removal of mould and will deodorize and clean fire and smoke damaged areas.
Usually attached to a 40 ton excavator and moved around the quarry crushing rock directly into the dump trucks. This unit was cleaned of grease, dirt and corrosion in preparation for a service and re-paint. Non of the hydraulic pipes, bearings or belts had to be removed which saved the client many hours of dismantling costs. dismantling costs.
Vintage and Classic vehicle restoration This is a Rover SD1 being prepared for restoration the full shell is on the rotisserie having the paint and underseal removed with super fine media leaving the tin work ready for immediate priming and painting. Vehicles can be brought to our fully equipped workshop for dismantling if required.
Vintage and Classic vehicle restoration this is a mark 2 Ford Cortina being prepared for restoration the full shell is on the rotisserie having the paint and underseal removed with super fine media leaving the tin work ready for immediate priming and painting. Vehicles can be brought to our fully equipped workshop for dismantling if required.
Larry Mirabelli, senior manager at Buckley Powder Co., teamed with Bill Hissem, senior mining engineer at Sandvik Construction, to deliver a presentation on drilling and blasting at the 2015 Quarry Academy hosted by Dyno Nobel and Sandvik.
Mirabelli, who has more than 40 years of experience in explosives technology between Buckley Powder and Dyno Nobel discussed a concept with Hissem called chemical crushing, which the two describe as making drilling and blasting a symbiotic process to achieve better results. Pit & Quarry recently connected with Mirabelli to discuss this concept further, as well as best blasting practices.
Mirabelli: I feel the biggest mistake is separating drilling from blasting. The traditional method of drilling and blasting is to treat the two items as separate processes. A driller comes in to drill a hole; a blasting company puts explosives in the hole and blasts it. If you keep these two items separate, you cannot always achieve the best results.
Its not chemical crushing, as [Hissem] and I call it. We really think quarries should manage these two activities as one. When these two are managed separately, you are likely to get non-uniform rock fragmentation. If you combine the processes, you can achieve a more uniform gradationthat will make the crushing process easier down the production line.
Mirabelli: Some are embracing it. When we present this topic at Quarry Academy events, many of those attendees take this information back to their companies and have been successful at integrating it. They have told us they see rewards. We did a chemical crushing case study in 2009 at Capital Quarries in JeffersonCity, Mo., to show the importance of tying drilling and blasting together for better results in the blast and reduced overall operating costs.
Mirabelli: Another big shortfall I see a lot is implementation of the blast pattern to the bench. Often, quarries will adjust their blast design to the bench condition. For consistency in results, it should really be the other way so that a straighter quarry face results after each blast.So instead of that approach, design and prepare the bench to accommodate your blast design. This will help maintain a straight face and improve the overall consistency of the blast pattern.
Mirabelli:They should set quality standards that both the drilling and blasting contractors are expected to meet. If they are doing their own drilling or blasting, these quality standards should be met one in the same. Drill holes need to be placed at their proper position on the bench top and bottom of the hole to proper depth in an overall condition that will allow explosives to be loaded into them, and with all details documented in a drill log for communication to the blasting contractor. Blasting contractors should lay out the drill pattern based on a surveyed profile of the face. At a minimum, a profile survey should be done after drilling and before loading so that the proper explosive load can be determined for each blast hole based on the survey and drill log. A best practice would be to profile both before and after drilling. The post drilling survey will indicate how well the blast design was implemented. Measurement before and after each blast will lead to improved blast performance.
Unless youve visited or toured a quarry, chances are you dont know much about what goes on inside one. In the simplest terms, a rock quarry is a place where little rocks are made from big rocks. Although the basic process is the same, each quarry is different and some of the things in Quarry Story may not apply to all operations. Geography, geology and the type of stone mined, how close a quarry is to neighbors, the size of the operation and the main transportation method used to get the stone products to customers all have an impact on how each quarry is designed and operated.
At Vulcan Materials Company, our primary business is quarry mining. We take big rocks out of quarries and make smaller rocks and sand by crushing them. We sell the crushed rock and sand to builders and contractors who use them to build roads, highways, bridges, houses, shopping malls, schools, churches and other buildings and structures.
Before we can start operating a quarry many preparations must be made. First, our geologists must find a place where there is a large supply of rocks beneath the earths surface. We mine igneous, metamorphic, and sedimentary rocks to be used for construction. A quarry is frequently located near a community where our products are needed because if it isnt, it will cost our customers too much to haul the crushed stone, which is very heavy, over long distances.
After we find a good place to put a quarry, our geologists survey the land, and we develop a design that will make our quarry safe and efficient. Then, we have to get a variety of operating permits from local, state and federal governments. For instance, to obtain the environmental permits, it is necessary to provide a plan that shows we can and will obey all environmental rules of the state and federal governments. Once we obtain the proper permits, equipment is purchased, roads are built to the facility and we begin building the processing plant.
It is very important to us that we operate as a good neighbor in the communities where we build quarries. For example, at many sites we create buffer zones around the quarry so noise is kept to a minimum. We landscape the entrance to the quarry so that it blends with the surrounding area. We install special water systems so we can recycle the water we use in processing, and we put in many other features to protect the health and safety of our employees and our neighbors.
Great care is also taken to protect the environment and the animals that live on our quarry lands. A quarry site might be as big as 600 or more acres, but, only a small part of that land is actually used for the quarry and processing plant. We often establish wildlife habitats in the buffer zones to attract and protect animals that might live around our quarries. At some locations we have also built parks, nature trails and ball fields in buffer zones. Our quarries are full of so many interesting things that they are often seen as huge outdoor classrooms where students can come to see what we do and learn about earth science and nature. Once we decide where to put a quarry, we prepare the site for quarrying.
In order to get to the rock beneath the surface of the earth, we have to clear the land we are going to mine. Once we have the land prepared we are ready to begin mining rock. At many sites, the material that is removed is used to begin construction of berms and other buffer areas, or donated for landscaping or construction projects in the community.
Drilling and blasting is a very important part of how we get rocks out of the earth. We design this process around how much rock we want to break apart, the type of rock we are working with and the size pieces we want to break off. We hire experts to help with drilling and blasting because they know exactly how to work with explosives to make sure this part of the process is handled safely, efficiently and as quietly as possible.
First, holes are drilled in the earth and explosives are placed inside. The explosives are detonated to provide the smallest release of energy for the most efficient blast. The entire blasting process occurs in just a few seconds. Larger quarries may blast once a day and smaller quarries may blast once or twice a week. Blasting is monitored with a special machine to record sound and vibrations so that the community around our quarry remains protected and safe.
The area that begins to form out of the earth when we blast away big pieces of rock becomes the quarry or pit. We use very large haul trucks to load and move the rocks out of the pit and to the processing plant where they are crushed and divided into different sizes. Trucks move back and forth between the pit and the processing plant.
When trucks deliver the big pieces of rock to the processing plant, the rocks are put into a primary crusher that will break them into smaller pieces. The primary crusher can crush between 300 and 2,000 tons per hour. Depending on what size we want to make the rocks, they may be put through different kinds and smaller sizes of crushers one or two more times. As the rocks pass through the crushers, they are moved around the processing plant on conveyor belts.
After crushing, comes screening. As the rocks are broken down to smaller sizes, we use screens to separate them into piles that are the same size. Some screens are larger and they allow the bigger rocks to pass through. The smaller screens let only the small rocks through. Rocks may be crushed and screened many times before they are put in a stockpile with other rocks the same size.
During the entire quarrying process, we make sure that we protect the health and safety of our employees and neighbors.quarry-story--truck Mining rocks and moving rocks around a processing plant can create fine particles of dust. We control dust by using water sprays on the rocks as they are processed, and by using spraying equipment to wet quarry roads.
To protect the environment, we use water that we recycle in our own closed loop water system that collects rainwater and water that we use during processing. Water is stored in a recycling pond where the sediment is allowed to accumulate. If we have to discharge water from a recycling pond, we test the water to make sure that it is safe and that it meets environmental water quality regulations.
Stockpiles are huge piles of rock, sand, gravel and other materials, and we do mean huge. Some of our stockpiles are as much as 30 feet high and 800 feet around. They are so big that we have to keep them outside. Because they are exposed to the weather, they have to be carefully maintained so heavy rain doesn't wash them away. We also have to be careful not to let other materials get mixed in with them. We use bulldozers and front end loaders to keep the stockpiles in place. When customers come to our facility for a load of crushed stone, they go to the stockpile. We use a shipping loader to fill their trucks with the rocks and other aggregates from the stockpile.
Our rocks are sold by the ton. Before we can bill a customer for the materials they buy from us, we have to know the weight of each load. When trucks come to our facility, they are weighed before loading. Once they are loaded they are weighed again. Then, we subtract the weight of the empty truck from the weight of the full truck and we know how much the load weighs. This is the way we calculate how much the company has to pay for the load. Weighing is also important because it helps make sure that the trucks leaving our quarry are not too heavy for the roads they will travel on. Each state has laws that say how much weight a truck can legally carry. If a truck weighs too much, some of the material is taken off of it and then it is weighed again before it leaves the quarry.
Most of the time customers come to our facilities and we load the materials they need onto their trucks for transport to where they need to use them. Sometimes though, the materials have to be moved over greater distances. If materials need to be moved a long way, we might use boats, trains or barges to move them.
As you can see, making little rocks out of big rocks isnt as easy as it sounds. At Vulcan Materials Company, we work very hard to be our nations best and most environmentally friendly producer of construction materials. We are committed to doing things right, every day, through every step in the process of making rocks. We take important steps to make sure that our employees and neighbors are safe and the environment is protected. We hope you enjoyed learning about how a quarry operates. If you have any questions, please contact us at [email protected]
Vulcan Materials Company Corporate Office 1200 Urban Center Drive Birmingham, AL 35242 Tel: (205) 298-3000 Questions about our site? Contact Us To report Business Conduct concerns,click here To purchase or inquire about products visit our Product Sales page
AtQPS Engineeringwe pride ourselves on providing cost effective service with a high level of quality, and a strong focus on safety. Since 2006QPS Engineeringhas gradually expanded and now operates from a 4000m2 workshop, yard and office facility located on Brisbane's northern suburb of Narangba.
Our committment to providing experienced and fully resourced personnel has seen our activities steadily grow. This success has allowed us to expand operations to include plant design and full turnkey project works.