The big challenge in quarrying is to boost profitability through lowering the cost per tonne of finished product.
Gaining a competitive edge demands a thorough knowledge of the entire quarrying process, as well as the right choice of equipment, service, support and consumables, and optimal settings.
Conditions are tough, and the demands vary considerably depending on the material being quarried. New environmental regulations are becoming increasingly stringent as to safety, noise, dust and landscaping.
Quarrying techniques: Hole surveys
Bench drilling is used in production of aggregates such as crushed rock, gravel and ballast material for the construction industry.
The right pattern ensures the highest possible yield from each blast. A square pattern is commonly used as it aids accuracy. It is simple to spot where the holes should be drilled.
Quarrying techniques: Hole drilling
Quality holes can make a big difference both from a technical and economical point of view.
Quality holes are drilled:
- In the correct position
- At the right angle
- To required depth
Rig set up and collaring technique are critical operations for successful quality hole drilling. A stable rig set-up and good drilling practices are critical to securing a quality outcome. Selecting the right drill bit can also make a major contribution to avoiding hole deviation.
Inaccurate drilling can result in issues such shot rock fragmentation, which in turn affects throughput time and cost for secondary breaking, loading, hauling, crushing and screening.
Quarrying techniques: Secondary breaking
When blasted rock is too big for the feeder or crusher, secondary breaking is needed to get the boulders down to size. The type of rock dictates the effectiveness of the process, with brittle rock giving the best performance.
Hydraulic breakers are the most common solution, as they minimize disruption to the production process. They can be mounted to a vehicle such as an excavator for a mobile solution, or attached to a crusher.
Quarrying techniques: Crushing
Crushing is used for mechanical size reduction of feed material. A number of different crusher types may be used. The first considerations for selection are at what point in the process the crusher will be used, the type of material, and the output required.
Quarrying techniques: Screening
Screening is used to size and separate material prior to crushing or final product stockpiling. Screening efficiency can have a big impact on crusher efficiency, so it's essential to get the setup right.
The key is to achieve a balance between throughput and efficiency. This can demand a great deal of fine tuning as there are many variables. Getting it right can have a significant impact on overall efficiency and economy.
Optimal screening ensures the best crusher performance and reduces recirculating load, thereby reducing energy consumption and wear and tear on other equipment.
Quarrying expertise: How we deliver
As one of the world's leading quarry equipment manufacturers, we understand how equipment in different parts of the process needs to work in harmony to ensure the best possible output and maximum overall profitability. Whether you're working with limestone aggregate, hard rock and aggregate, or sand and gravel, we ensure that you will get the right fractions at the desired level of production.
Choosing quarry equipment from Sandvik Construction gives you a head start. Having spent time on construction sites and quarries to get a better understanding of what you need, we understand the daily challenges that you face when using quarry equipment. We are continually developing and improving our products and services through in-depth research and development, in order to solve the challenges of quarries and to ensure that you get the best performance from your equipment. Recent developments that we have made to our equipment include reductions in noise and dust emissions, and additional safety measures.
We continuously develop or products and services to solve the challenges of quarries. Recent developments include reductions in noise and dust emissions, and additional safety measures.
In addition to equipment, we provide professional training through the Sandvik Quarry Academy. We also offer advanced simulation programs based on input data derived from job sites all over the world.
Contact us for advice on product selection or other technical support.