Productivity increase with high-tech screening technology

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. Centered on the previously explored Redkinsky mixed sand and gravel deposit, the quarry has been under development since the spring of 2015. Faced with a sharp decline in the availability of mineral aggregates in the 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 per 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 to 12 years. The quarried materials require full-cycle processing and therefore, besides two-stage crushing, the production process includes washing and screening to obtain finished products in the form of crushed stone and gravel grades 5-20, 20-40 and 40-100 mm, 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 Bogayevsky Karyer decided to purchase high-performance equipment with the maximum possible operating life and throughput capability. This approach was vital as the quarrying program was developed with a view to minimizing loading and handling costs. Excavators operate over the full length of the quarry face which extends to nearly two kilometers, with tipper trucks, with a capacity up to 55 t, being used to transport the processed materials. Additionally a separate excavator is provided to work waterlogged areas. However the process is overseen by engineers with an extensive track record in the quarrying industry who have thoroughly planned the entire process. 

In terms of ensuring final product quality, the backbone of Bogaevsky Karyer’s operation is two powerful Sandvik QA451 triple deck screens. The mobile QA451 screening plant of Sandvik Construction (Fig.) combines high throughput with high screening accuracy. A single QA451 unit is capable of grading up to 140 m3 of material per hour and up to 1500 m3 per shift. Each machine is operated by an appropriately trained two-man team.

The QA451 triple-deck screen features numerous innovations developed to improve throughput as well as facilitate servicing and maintenance, making it the idea screen for Bogaevsky Karyer’s ambitious requirements. For example, the machine possesses a control panel with color-coded pushbuttons and sequential start-up capability. Additionally a hydraulic screen tilt adjustment makes the process of replacing the screen media much quicker, whilst the remote control panel and onboard electrical equipment have been upgraded to further enhance operator safety and control. Furthermore the drop-down ­walkways now have new coverings with improved non-slip properties. 

The previously mentioned patented unique Doublescreen system has two independent screen boxes with a total area of 6 m x 1.5 m that possess operating flexibility with the ability to produce large volumes of high specification products. A large volume hopper with remote control hydraulic grid allows ample material feed whilst massive stockpiling capability is delivered through integrated hydraulic conveyors to further facilitate plant efficiencies.


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