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Stent higher grade recycling

First publishedin Aggregates Business Europe on www.AggBusiness.com
2012 July August
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Terex Finlay J-1175 jaw crusher
The Terex Finlay J-1175 jaw crusher at work in Gunheath Quarry

Material left over from County Cornwall’s china clay quarrying is being recycled into useful material

High performance plant supplied by Finlay Plant SW to Kendall Plant is enabling large volumes of high grade, recycled material to be processed, in the heartlands of Cornwall’s china clay quarrying industry.

Machinery including the Terex Finlay J-1175 jaw crusher, C-1540 RS cone crusher and Supertrak 694+ tracked mobile screen is being used by Kendall Plant in the ‘White Mountains’ region of the south-west England county to process stent, the material left over from the extraction of china clay.

Keith Kendall, who has a background in agricultural contracting, is the owner and director of Kendall Plant, making his first venture into crushing 14 months ago.

He has been contracted by Brookland Sand and Aggregates at Gunheath Quarry, near St Austell (County Cornwall), to process the stent, millions of tonnes of which are on the site, along with regular deliveries from china clay quarries in the locality.

To cut through the volume, plant was needed with high outputs, and Kendall has worked closely with Gareth Johnson, managing director of Finlay Plant SW to introduce high performance machinery that delivers maximum value from the processed material, producing a clean and valuable end product.

The process starts with a Terex Finlay J-1175 jaw crusher, which has the capacity to take in half-tonne rocks through to dust.
With an independent pre-screen fitted, fines in the stent can be removed at an early stage in the process thus eliminating the need for a reclaimer or any other type of screener to scalp off -45mm.

This function is particularly valuable as the stent material comprises up to 50% fines in with the granite rock.
Fines fall through the mesh and -45mm is scalped off to make Type 1 803  material, while +45mm goes through the jaw to produce crusher run, of which 75mm is the largest size. 

This then goes into the Terex Finlay C-1540 RS cone crusher, which provides the versatility of a crushing and screening plant in one machine.

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Kendall Plant’s Terex Finlay Supertrak 694+ tracked mobile screen
Kendall Plant's Terex Finlay Supertrak 694+ tracked mobile screen and C-1540 RS cone crusher process stent
Featuring an onboard recirculating system and detachable sizing screen, the machine at Gunheath processes 45mm material through the mesh, with +45mm re-circulating and then going into the four-way Terex Finlay 694+ at -45mm.
The 694+ offers a triple-deck screen configuration, providing three full-sized 6.1m x 1.525m screens, and a hydraulically folded fourth conveyor.

It produces an end single size product of 40mm clean chippings, 20mm clean chippings and 10mm clean chippings, used as decorative material, as well as for ready-mixed concrete and drainage and pipefill material. The 6mm to dust end product is delivered to a nearby manufacturer for concrete blocks.

The machinery currently outputs 2,000tonnes a day and there is no waste from the processing activity with all the end product material used, making it a highly-effective recycling process.

Keith Kendall said: “We’ve worked with Finlay Plant SW because they offer exceptional service and great back-up for us on site.
“We are in a remote area, but we can always ensure a prompt service in terms of fitting and commissioning, parts and spares and advice on the specification of machinery.

“All the machinery is working really well, and the pre-screen on the J-1175 delivers major economic benefits as it means we don’t need a reclaimer to scalp off fines.

“We are benefitting from exceptional performance, reliability and volume of product, with the ability to increase capacity as required.” 

Gareth Johnson, managing director of Finlay Plant SW, which is part of the Finlay Group of companies, said: “The plant has been selected to all join up for maximum productivity.

“As well as this ‘train’ effect, it can also work independently, with flexible configurations, ease of maintenance and mobility assured.”

Finlay Plant SW is part of the Finlay Group, which comprises of 11 stand-alone companies offering a modern and diverse range of material processing equipment available in the marketplace today.

Companies in this article

Finlay Group
Terex Finlay

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