Washing the Fines in Sand, Gravel and Crushed Rock Production

Aggregates Processing

Washing the Fines in Sand, Gravel and Crushed Rock Production

Additional Fines Product together with improved Water Utilisation
A Swedish quarry wanted to improve the quality of its products as well as its economics. Therefore they got their sand and gravel washing plant extended which now utilizes fines in the washed sands and aggregates. The turnkey plant has been specifically designed for both the company’s specific requirements and the climate in Sweden.
(ed. WoMaMarcel - 24/9/2015)
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CDE installed a new sand and gravel washing plant at Bröderna Björklunds Grus’s main quarry in Olofström, Sweden,that has been specifically designed for both the company’s specific requirements and the local climate.

Bröderna Björklunds Grus AB is a rock and gravel/sand quarrying company located in Olofström, Southern Sweden. The company produces rock, gravel and sand products. CDE completed installation of a new sand and gravel washing plant at the company’s main quarry in Olofström in September 2013. The turnkey plant has been specifically designed for both the company’s specific requirements and the climate in Sweden.

Bröderna Björklunds Grus AB was founded in 1922 by the grandfather and great-grandfather of the current owners, Peter and Thomas Björklund. Bröderna Björklunds Grus AB operates three rock and gravel/sand quarry pits in Marieholm, Vånga Krossen and Fjälkinge. The company’s main focus is the production of topsoil, sand, gravel and crushed rock products which have wide reaching uses. The topsoil and natural stone products are used in garden and landscaping projects. Sand, gravel and asphalt are supplied to various concrete factories in Southern Sweden and the crushed rock is used in road construction and various construction projects. The material produced by Bröderna Björklunds Grus is CE certified and meets all requirements for ballast production.

The owners of Bröderna Björklunds Grus, Thomas and Peter Björklund, originally purchased a CDE Evowash in 2007 in order to capture fine sand which was being lost from an existing traditional washing system which incorporated a bucket wheel. Then in 2013 the decision was made to increase their washed sand and aggregate production and CDE was the natural choice to provide the solution. “We had previously purchased a sand washing plant from CDE which was effective at ensuring we did not lose fines material. We are a dynamic and specialised company and wished to increase the flexibility of the types of products we could produce so we decided to upgrade to a new CDE system. We considered several options for their new washing installation, but it was the CDE expertise, their ability to deliver a fully modular solution with the lowest cost per ton of ownership, and fully backed performance guaranteed outputs that separated CDE from other providers.”

The new sand and gravel washing plant of Bröderna Björklund Grus in Olofström.

CDE was presented with a natural sand and gravel feed material which contained high levels of minus 250 µm material. Björklunds Grus required a 200-tph plant that would produce three washed sands and two washed aggregates; a 0-0.25 mm ultra-fine sand, a 0-2 mm fine sand, a 2-8 mm concrete sand, a 8-16 mm aggregate and a +16 mm aggregate.

The customer had several specific requirements for the project. They required an option within the design of the plant for mixing & blending their 0-0.25 mm, 0-2 mm and 2-8 or 2-5 mm sands when required. The plant should also be mobile so they could potentially move the system to any of their other quarries. It was also essential that the plant should integrate with the current CDE Evowash onsite and that it could successfully operate in the extremely cold temperatures experienced in Sweden. These factors, and analysis of the material at the quarry, required that CDE design a bespoke solution for Bröderna Björklunds Grus.

Following a sieve analysis at the Olofström quarry, the equipment specified for this project was a M2500 E4X mobile washing plant with integrated counter flow classification unit (CFCU) due to the high volumes of minus 250 µm sand and an Aquacycle A600 thickener. The Aquacycle was required to ensure the correct amount of water was supplied as water on site is limited and to condense the waste sludge into a high concentration slurry. These products would successfully integrate with the existing Evowash 71 fines recovery system already installed. The existing Evowash enabled the system to output 5 fractions in real time, under computer controlled classification.

lso, due to the project location and specific requirements for mixing the two sands, the plant would have two new and unique features that were being tried for the first time by CDE. This would be the first project that a dual sand conveyor with a diverter system would be used and it would also be the first time a ‘winter pack’ Glycol system would be used to combat frost.

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