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New modular Sandvik crushing/screening plant for Russia’s Sinarsky Quarry

First publishedin Aggregates Business Europe
2015 September October
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Sandvik Construction crushing and screening plant
The Sinarsky Quarry has invested heavily in a new modular Sandvik Construction crushing and screening plant
Sandvik Construction in Russia has recently supplied the Sinarsky Quarry with a new modular crushing and screening plant.

The plant is being used to expand the company’s aggregates production, aiming to double its capacity to an impressive 1.2–1.8 million tonnes of accurately sized aggregates/year.

The Sinarsky Quarry is located in the Kurgan Region (Urals) of Russia, and it has recently celebrated the new plant becoming fully operational.

Having invested over €2 million on the plant, the plan to double aggregates production is required in order to meet the doubling of demand for aggregates to be used on local authority road construction and infrastructure development projects.

Aggregates from the Sinarsky Quarry are in high demand as they are famous for high resistance and density, which is due to the special geological qualities of the local touchstone and liparite.

However, these attributes come at a price: the rock is also very demanding on crushing and screening equipment efficiency. This meant that when the management of the quarry sought to improve production it decided to source equipment from a reliable European supplier, which would be able to provide the ideal equipment solution in order to satisfy the increased demand.

After contacting Sandvik Construction in Russia, it confirmed it was able to supply the equipment and also develop a crushing and screening process which maximises production while ensuring accurately sized products.

Following discussions between Sandvik and quarry management it was agreed that the best solution for improving production was to supply an assortment of stationary equipment, comprising three crushers, two screens, three feeders and one grizzly feeder.

The first stage of the process sees the rock being fed to a ST1263 grizzly feeder. Here around 9% of fines (0–20mm) are separated. The material then proceeds to a CJ411 jaw crusher for primary crushing.

Following this the secondary crushing is performed by a CH440 cone crusher with an EC chamber which produces 0–5 mm, 20-40 and 40–70mm fractions. After screening by a CS108, the oversize material is then recycled. The 5–20mm, 20–40mm and 40–70mm fractions are then fed into a CH440 cone crusher with an F chamber for tertiary crushing.

The quarry was initially aiming to produce 5–20mm aggregates with 10% flakiness, but the first laboratory tests showed the flakiness index to be below 5%. Thus, after tertiary crushing the material is fed into a CS126 triple-deck screen which produces 0–5mm and 5–20mm final fractions.

At first the share of the 5–20mm fraction was 36%, but thanks to the flexibility of the new plant, the quarry is now able to automatically change the volume ratio of desired fractions, thereby anticipating fluctuations in market demand.  

In order to ensure that production requirements are being met, a six-month trial period has been scheduled, during which operators will be able to undertake any required enhancements and find the best parameters for more efficient crushing.

However, the management of the Sinarsky quarry foresees just a few shutdowns being required, as all the constituent crushing and screening parts have been primarily selected and configured in accordance with the results of geological tests performed by Sandvik specialists. This means that the equipment is focused on providing the best possible performance under the exacting current quarrying conditions.

Sandvik Construction says the Sinarsky Quarry operation is proving to be a great success, and while this is not the only plant that Sandvik Construction has installed, it is the first of its kind.

“Today we have more than 40 similar plants operating in Russia, but this one is the first modular plant. It incorporates the latest Sandvik technologies and design. Our vast experience in this field has made it possible to offer the most efficient solution for the Sinarsky Quarry, which will help the company to produce sufficient volumes of desired fractions,” says Cristian Rusu, sales manager Crushing and Screening North Europe, Region East, Sandvik Construction.

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