Page 41 - HUB-4 Magazine Issue 97

Aggregate Washing & Screening
Quarry Dust Washing
– An Investment for
Sustainable Growth
Bruce Cyclone Sand Plant
For each of the three booster pumps from DXB that incorporated a
Cornell 12x10 end-suction centrifugal pump driven by a Brooks
Crompton 400kW IEC4 motor, DXB designed large, sound-
attenuated, fully bunded canopies that allowed for easy
maintenance and protected the equipment from the local harsh
environment.
A fully automated pipe manifold system was designed and installed,
which enabled all the pumps to operate independently or in parallel
with each other, giving a final pumpstation performance in excess of
1000l/sec or 3600m3 per hour, well beyond the design
specifications.
The whole dewatering electrical system was upgraded, with the
existing MCC control room moved down to the new lower level,
along with the submersible pumps, and the new control centre,
including a new substation, was installed beside the new pump
station, three levels up.
Software and control systems were written by in-house expert
Richard Marsh with the assistance of DXB enabling all the pumps
and valves to be automatically controlled and work together to
optimise the system and ensure each of the pumps in the sumps
worked in series with the new booster pumps.
Commissioned over a three-day period, DXB worked closely with the
Torr team to firstly commission the new washplant pumps that
increased flows up to 70 l/sec giving the quarry the ability to fill
multiple tanks on site at the same time, something they had not
been able to undertake before.
The booster pumpsets were first commissioned individually then in
parallel to ensure that they individually worked to specification at
the 442l/sec flowrates then together to maximise the flows with two
pumps at over 1000l/sec through the common suction and discharge
manifolds. The previous highest flows were under 700l/sec.
All pumps were tested and then run hard to ensure the system
integrity and operating philosophy worked well, allowing DXB to
leave the site with the fully commissioned high-performing new
dewatering system.
Bruce Materials Processing Solutions
have been supplying a range of intelligent
washing solutions to wash quarry dust,
tailored to suit specific site and project
requirements.
The quarrying and crushing of aggregates inevitably
generate large quantities of quarry dust (also known
as CRF / Crusher Rock Fines). Traditionally, this fine
material has been treated as a waste byproduct -
stockpiled, dumped, or sold at very low value -
creating environmental and operational challenges for
quarry operators.
A key advantage of quarry dust washing is it’s
relatively low capital investment compared to
installing a full-scale wash plant. By integrating
modular washing equipment, such as the Bruce range
of BWS Cyclone Sand Plants, often within an existing
processing line - quarry operators can benefit from the
production of an additional revenue creating washed
sand.
Crusher fines washing is a practical, high-impact
solution for modern quarrying. It addresses waste
management challenges, creates additional revenue,
and supports sustainable construction practices.
For quarry owners and aggregate producers looking to
future-proof their operations, quarry dust washing is
not just an optional upgrade - it is a smart step
toward a circular, profitable and practical quarrying
operation.
“Quarry dust washing is emerging as a relatively low-
investment and environmentally aligned solution.
Quarry owners are able to convert what was
previously deemed a waste byproduct from their
crushing & screening processes, into a usable
resource. Additionally, reducing reliance on virgin
materials, enhancing sustainability, and promoting a
circular economy are at the heart of decisions in the
modern materials processing industry.”, comments
Thomas Haughey, Dealer Manager for Bruce.
www.hub-4.com March/April - Issue 97
| p41 |