Quarry Fines Minimisation:

Process Optimisation Case Study 1

1 2
Clive Mitchell & Adam Benn
1 British Geological Survey, Nicker Hill, Keyworth, Nottingham, Nottinghamshire, NG12 5GG
2 Metso Minerals (UK) Ltd, Parkfield Road, Rugby, Warwickshire, CV21 1QJ

Kingsley Dunham Centre, Keyworth, Nottingham NG12 5GG, Tel 0115 936 3100 © NERC All rights reserved
 Quarry Fines Minimisation

• Production of quarry fines (material < 4mm) is a consequence of

extraction & processing in a quarry.
• The amount produced depends on the rock type, amount of
fragmentation by blasting & type of crushing used.
• Optimisation of process circuits may help to reduce the amount
of fines produced.
• This case study presents a process audit & modelling of process
changes using Metso Minerals optimisation software, Bruno.
• This work was carried out for the ‘Quarry Fines Minimisation’
project funded by the Aggregate Levy Sustainability Fund
(ALSF) MIST programme (www.mi-st.org.uk)
• Further information: www.goodquarry.com
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 Case Study 1: Sandstone Quarry
• Operation: Sandstone quarry, Mid Wales
• Geology: Strinds Formation, Wentnor Group, Precambrian
• Products : High PSV road stone aggregate (coated &
uncoated), crushed rock aggregate
• Process plant: A three stage crushing circuit, including a
primary Jaw crusher, secondary Impact crusher and 2 tertiary
Cone crushers.
• Process optimisation: Process audit was carried out to
determine the ‘mass balance’ of the existing circuit. Process
changes were then carried out to reduce fines production.

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 Case Study 1: Process change

• Current operation: A three stage crushing circuit using an

Horizontal Shaft Impact (HSI) crusher in the secondary stage.
• Process Change: The HSI crusher was replaced by a Cone
crusher, with minimal reconfiguration of the process circuit.
• Result: The yield of the product (0/20 aggregate) is more
consistent and the product quality has been maintained. The
particle shape of the product has not been significantly affected.
The proportion of fines has been reduced.

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 Feed
700mm medium Screen 105mm
Sandstone Feed 400 tph
Undersize
Process Flowsheet
174tph Original process circuit
Jaw Crusher
Feed 226 tph
Setting 125mm
Aggregate product

0/20 250tph 100%

Horizontal Shaft Impact crusher

Feed / output 250 tph
Tip speed 45 m/s
35mm setting Screens 40 / 20 mm
Feed / output 329 tph
Output
12 tph +40mm
67 tph +20mm
250 tph -20mm

Cone Crushers
Feed / output 79 tph
Setting 14 mm
0/20 Aggregate

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 Feed
700mm medium Gritstone Screen 105mm
Feed 400 tph
Undersize Process Flowsheet
174tph
Modified process circuit
Jaw Crusher
Feed 226 tph
Setting 125mm
Aggregate product

0/20 300tph 100%

Cone Crusher
Feed / output 300 tph
35mm setting
Screens 40 / 20 mm
Feed / output 467 tph
Output
11
45 tph +40mm
122 tph +20mm
300 tph -20mm

Cone Crushers
Setting 14 mm
Feed / output 167 tph
0/20 Aggregate

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 Product (0/20 aggregate) grading

Product Original Process Modified Process

Grading, mm % passing % passing

20mm 100 100

14mm 78 69
10mm 60 51
6mm 44 35
4mm 38 30
0.075mm 4 2

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 Case Study 1: Conclusions

• Process change: Replacement of an HSI crusher with a cone

crusher
• Product: The amount of 0/20mm aggregate has been increased
from 250 to 300tph from the same feed rate; this represents a
20% increase in production
• Fines: The proportion of fines present in the product has been
decreased from 38 to 30%; this represents a 21% decrease in
fines production

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