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Russian quarry ramps-up production through hi-tech Sandvik screening

First publishedin Aggregates Business Europe
2015 November December
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Sandvik QA451 triple-deck screens
One of the two Sandvik QA451 triple-deck screens in use at Bogaevsky Karyer
Bogaevsky Karyer is a relatively new aggregates production and quarrying company with operations located not far from Oreshki village in the Ruzsky district of Moscow province, Russia.

Centred on the previously explored Redkinsky mixed sand and gravel deposit, the company’s quarry has been under development since early in 2015.

Faced with a sharp decline in the availability of mineral aggregates in Moscow province, the decision was taken to develop full-scale production of high quality crushed stone as well as sand and gravel as quickly as possible. In order to achieve this an ambitious, yet achievable, annual production target of not less than 2–3 million m³ metres/year was set.

The deposits at the quarry are estimated to be in the region of 48 million m³, and according to engineers this should be sufficient to support production operations, including plans for expansion, for around 10–12 years.

The quarried materials require full-cycle processing, and therefore as well as two-stage crushing the production process includes washing and screening to obtain finished products in the form of crushed stone and gravel grades 5–20mm, 20–40mm and 40–100mm, plus quartz sand classes I and II.

To keep a firm grip on production costs and lay solid foundations for sustainable development of the business, the company decided to adopt a focused approach at one of earliest key stages of the project: the procurement of plant and equipment.

With this in mind, the company’s guiding principle was the commitment to buy high-performance equipment with the maximum possible operating life and throughput capability.

This approach was vital as the quarrying programme was developed with a view to minimising loading and handling costs. Excavators operate the full length of the near-2km quarry face while up to 55tonne capacity tipper trucks are used to transport the processed materials. A separate excavator is also provided to work waterlogged areas.

The process is overseen by experienced engineers with an extensive track record in the quarrying industry.

In terms of ensuring final product quality, the backbone of the operation is two powerful Sandvik QA451 triple-deck screens supplied by Sandvik Construction’s authorised distributor Quarry-Service.

The QA451 is the largest and “most impressive” model in the Sandvik Construction range of mobile screens, which combines high throughput with high screening accuracy. A single QA451 unit is capable of grading up to 140m³ of material/hour and up to 1,500m³/shift. Each machine is operated by a two-man team, with all operations staff having received advanced training in how to operate and service the units. This was undertaken during the machine commissioning which was carried out by expert Quarry-Service personnel.

One of the key advantages of the QA451 is said to be the patented Doublescreen system, developed in 1999. Its operating principle is based on the use of two 6m x 1.5m screen boxes working independently of each other. The first screen box can be tilted through a wide range of angles compared with the second box, which considerably increases screening accuracy. The equipment can be put into service in a very short time.

“Our decision to choose the Sandvik QA451 was influenced by two factors: firstly we needed a screen capable of providing the maximum possible throughput in line with our future plans to increase production volumes. At the same time the equipment has to be rugged and reliable in order to withstand the heavy workloads: in our case the screens are running more or less round the clock,” says Alexander Shkuratov, Bogaevsky Karyer’s managing director.

“Secondly we wanted to be sure of getting high quality and prompt after-sales support. The Quarry-Service specialists always arrive on time and there are no problems with consumables and parts availability, which means minimal equipment downtime.”

The QA451 triple-deck screen features many innovations developed to improve throughput as well as facilitate servicing and maintenance. It offers a control panel with colour-coded push-buttons and sequential start-up capability along with a hydraulic screen tilt adjustment, making the replacement of screen media much quicker, while the remote control panel and onboard electrical equipment have been upgraded to further enhance operator safety and control.

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