equipment ued for quarry operation

quarry management operation is off and running - pit & quarry : pit & quarry

quarry management operation is off and running - pit & quarry : pit & quarry

Caruso saw an opening to get in on the action and start an aggregate operation from the ground up. Ultimately, an opportunity presented itself in a one-time dimensional stone quarry dating back to the 1800s.

The quarry, which had previously earned necessary permits, had been dormant outside the New York City market for years. Caruso and his partners revived the site and began crushing stone that was previously used as tile, flagstone, sills and structural veneer.

Quarry Management, the company Caruso now serves as CEO, brought the old dimensional stone quarry back to life with the support of two key vendors offering the right combination of availability, support and price on processing equipment. The hiring of Pep Hunsicker, an industry veteran who currently runs the day-to-day operation, was also instrumental.

Quarry Managements operation sits on more than 220 acres, 40 of which are permitted for mining. The company mines a high-friction bluestone that meets the needs of New York City and the surrounding tristate area.

Quarry Management had seen an equipment spread, including a CRJ3255 jaw crusher and a pair of CRC380XHLS cone-screen plants at an Emerald Equipment yard. The combination represented a turnkey solution, from systems to setup to support.

We wanted to be a 600-tph plant, he says. We wanted something that was pit portable, something that was a great phase one to our overall operation because were opening up the footprint of the quarry.

Because of the mines tight footprint, Quarry Management sought a compact spread as well as one that was readily available and had the horsepower to deliver the material the company wanted to produce.

Their engineers came to the table with a drawing, Caruso says. We took that and put it against the industry probably the top five guys who have similar equipment. When it came to availability, support and price, it was an unbeatable combination when compared to similar offerings that others brought to the table.

According to Caruso, discussions between Quarry Management, Emerald Equipment and Terex MPS began in December 2018. A deal for the portable spread was struck in February, machines were mobilized in March, and Quarry Management was crushing rock a month later.

Mike said, You guys are looking for this equipment and you have great market penetration. I know a guy who could really tie this whole thing together, Caruso says. Hes got 20-plus years of experience at every level of crushing, and he formerly worked with one of the biggest crushing and mining companies in the state of Pennsylvania.

Hunsicker, who previously oversaw 26 active quarries in addition to asphalt plants and other sites at another producer, estimates he crushed between 14 million and 15 million tpy across his former employers aggregate operations. Hunsickers experience was tremendously appealing to Caruso, who was looking for an industry veteran to manage daily operations.

I have learned that without a great team and people like Pep, theres not much you can do in this business except for burn up lots of capital, Caruso says. The devil is in the detail. Efficiency is critical. Without the right equipment, the right plant and the right vendor support, youre doomed.

When visited in June, Quarry Management was in the process of dialing in its brand-new plant, which was producing about 400 tph at that time. Hunsicker was pleased with the plants performance, and he and Caruso see even greater throughput potential for the spread.

Of course, opening up the floor of the old quarry is a process that will take time. As the operation progresses, Quarry Management gains a better understanding of the rocks characteristics and best practices with its crushing plant.

Were getting started, Hunsicker says. Were still stripping, figuring out the geology of the rock. Were shooting versus ripping, figuring out what we want our patterns to be. Its a lot happening at one time. Were doing it step by step.

Fortunately, Quarry Management has received tremendous support from Emerald Equipment and Terex MPS as production ramps up. For nearly a month, Emerald Equipment regularly made available a team of five or six personnel to ensure a smooth launch at Quarry Management. Likewise, Cedarapids representatives were on hand from day one to offer suggestions to improve the plants efficiency.

In addition to the CRJ3255 jaw plant, pictured in the distance at the far right, the portable spread includes a pair of CRC380XHLS cone-screen plants, a CRS820H 8-ft. x 20-ft. triple-deck finish screen and a CRS620H 6-ft. x 20-ft. triple-deck screen. Photo courtesy of Jamie Harthoorn.

Mike has a great team just like we have a great team, Caruso says. His men are seasoned and trained. He keeps them well-equipped when theres a problem with a part going down. And Cedarapids has been very quick to ship overnight or next morning.

There have been no glitches, no waiting time, Caruso says. Other than a couple of items we had to wait more than 24 hours for, theres been nothing really of consequence that has put us behind. Thats the key element as an aggregate producer. Were crushing rock. Youre [operating] in a brutal environment. This Cedarapids machine is metal. Stone and metal create problems. It doesnt matter what brand it is.

Quarry Managements goal is to see a return on investment within the first phase of its operation. Though still in its infancy, the operation grows every day, Hunsicker says, and he expects new opportunities to present themselves as he opens up the quarry footprint.

He said, Stop thinking too big and narrow it down to the point where you can get it going in 2019, Caruso says. Then, because its portable, we can rearrange the plant and put in some different crushers and bigger surge bins to increase capacity to meet market demand.

It would be silly to spend twice as much money as we have already spent on the plant upfront on the hopes that we could penetrate the market, Caruso adds. Penetrate the market, and then grow into the demand.

equipment you'll find at a typical surface mine - vector solutions

equipment you'll find at a typical surface mine - vector solutions

All of the terms, definitions, and images in this article come from our online MSHA Part 46 Typical Equipment in a Surface Mine training course. Weve included a short sample of that online mining safety course below.

Either track-mounted or tire-mounted, backhoes are a type of excavator equipped with a bucket that faces toward itself. The typical backhoe design incorporates an inward-facing bucket affixed to an articulated arm, or boom. Backhoes are often used for removing and loading overburden as well as scraping down high banks and digging ditches.

Bins and hoppers are containers with open tops for material to enter and an opening at the bottom for material to exit, typically over a conveyor or feeder. They are filled from the top by a loader or conveyor and discharge material at a continuous rate through the opening at the bottom for distribution to other processing and sorting operations.

Feeders transport material a short distance at a consistent rate using conveyor belts or screw conveyors. Feeders may also have an integrated breaker mechanism used to reduce material size as needed for the next processing stage.

Management offices, workshops, storage, refueling, and power generation may all be located on-site. In some cases, a control tower may also be constructed to offer a complete view of processing operations.

Some of the most common types of classifiers are spiral and rake classifiers. Both of these classifiers separate material by dragging the material along the bottom of an inclined surface in a settling chamber from the bottom (inlet) to the top (discharge).

Cone crushers are typically used in downstream crushing operations for medium-sized materials. Like the jaw crusher, the material is fed into the cone crusher from the top and discharged at the bottom. As the material enters the crusher, an eccentrically rotating cone forces the materials against a crushing plate. The shape and movement of the cone progressively reduces the size of material as it moves down through the crushing chamber to the sizing gap above the discharge opening. Resized material may be further sorted and transported to stockpiles or other processing operations.

Draglines, a type of specialized excavation equipment, operate by casting a heavy cable-hung bucket outward from a crane-like boom and dragging the bucket toward itself to remove large amounts of overburden, load ore, and manage stockpiles. Draglines can be equipped with buckets of specific design and weight to match the materials being mined.

Dredges are a type of excavation equipment used to remove material from underwater. They can be land-based or barge-mounted and may employ powerful suction or physical digging methods to bring material to the surface for removal or processing.

Front-end loaders, or simply loaders, are large, typically tire-mounted vehicles with a deep, wide bucket mounted at the front. Loaders are used to load mined material into haul trucks and feeders, push or dump overburden, and manage stockpile or refuse areas. In sand and gravel operations, loaders may also be used for excavation.

Surface mines require the constant operation of heavy equipment consuming large volumes of liquid fuel. Since much of this equipment is not designed to be driven on conventional roadways, refueling must be done on-site making fuel tanks and pumps a necessity. Tanks may be above or below ground and can range in size from 500 to many thousands of gallons.

Active mining operations are often spread across a large area, making walking to distant locations impractical and potentially dangerous. Miners, contractors, and supervisors often need to move quickly between work areas to do their jobs, perform maintenance, and address issues as they arise. A broad range of common passenger vehicles and pickup trucks may share haulage roads to transport people, tools, and small equipment where they are needed.

In-pit belt conveyors are used to move material within a large, active mining pit area or from the pit to loading areas for further distribution within the mine. In-pit conveyors may also move mined material to portable crushing systems that reduce the size of larger rocks or minerals for easier transport.

Jaw crushers are often used early in the production process to prepare material for processing. Raw mined material enters the top of the machine where a moveable jaw opens and closes repeatedly to break the material against a fixed stationary plate. When the material has been reduced to a size small enough to pass through the opening below the jaws, it exits the crusher and may be further sorted for stockpiling or downstream processing.

Most mines will have a maintenance and repair shop onsite to store replacement parts, supplies, tools, and other specialized machinery while providing sufficient space to maintain and repair equipment.

Overland belt conveyors are used on mine sites where there is the need for continuous movement of high volumes of material over long distances, in some cases, several miles. This type of bulk material handling conveyor may be used to transport material from the pit to processing areas or loading areas for rail or barge transport.

Scrapers are a type of earthmoving machine with an open, centrally mounted hopper or bowl with a blade-like leading edge that can be raised or lowered hydraulically to selectively remove and spread overburden over level or relatively level terrain.

Screw conveyors use a rotating, helical screw to move liquid or granular materials through a tube or trough. The screw is commonly referred to as a flighting and may either wrap in a spiral pattern around a central shaft or be shaftless.

Shovels, sometimes called power shovels, are versatile excavation machines, often track-mounted, with a large, outward-facing bucket at the end of a powerful, articulated boom that can rotate 360 degrees. Shovels are used primarily to dig out and remove overburden as well as selectively load material for transport.

Often tire-mounted, skid steers are quick, compact, highly maneuverable, and extremely versatile machines which perform a broad range of vital duties throughout the mine. They may be used in excavation work to carry, spread, and load loose material as well as serve an array of grading, site preparation, construction, demolition, and repair functions.

Track haulage involves the loading and management of specially designed railroad cars to transport enormous volumes of overburden or mined material to other areas of the mine or off-site to distant locations.

Since mining operations exist for the purpose of selling extracted and processed commodities, industrial truck scales are put in place to keep track of transported material volumes. Truck scales are normally situated on drive paths close to where over-the-road trucks exit the mine carrying processed material to customers.

Water reclamation systems remove fine sediments and return a high percentage of the used water back into the mining process. These systems may involve large settling tanks, mud presses, storm water discharge areas, and extensive piping and pumps to reduce runoff, manage environmental impact, and conserve resources.

Weve taken these terms and definitions and have put them together in a multimedia, interactive surface mining equipment glossary. Its cool, and theres even a way for you to download the interactive glossary for free. Go check it out.

Knowing the equipment at a surface mine will help you know whats what and get the job done. Especially if youre a brand new worker or a contractor whos been hired to work at a mine site. So we hope you found some value in this article.

Jeff Dalto, Senior Learning & Performance Improvement Manager Jeff is a learning designer and performance improvement specialist with more than 20 years in learning and development, 15+ of which have been spent working in manufacturing, industrial, and architecture, engineering & construction training. Jeff has worked side-by-side with more than 50 companies as they implemented online training. Jeff is an advocate for using evidence-based training practices and is currently completing a Masters degree in Organizational Performance and Workplace Learning from Boise State University. He writes the Vector Solutions | Convergence Training blog and invites you to connect with him on LinkedIn.

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