AIB 012

Manufactured sand from aggregate waste in the Barmac VSI

Aggregate producers more often than not generate a certain amount of waste for every the of saleable material. This material may simply be the wrong shape or size, and the aggregate producer is left with a stockpile of material which he cant sell. In many aggregate production plants, the rock is crushed by compression, resulting in elongated, flaky particles. As specifications become tighter, producers are finding that they are making even more of this waste material. Historically, a large percentage of sand has been produced from alluvial deposits. However, we are now experiencing a global shortage of natural sand, and environmental pressures, costs and a shortage of this type of deposit has necessitated the manufacture of sand from quarried material. Case Study A Malaysian aggregate producer has 700,000 tonnes of waste material. This minus 8mm aggregate is product from a cone crusher, which is too flaky and elongated to meet specifications. The Solution Extensive test work was carried out in the Barmac Application Laboratory in New Zealand and also using a Barmac on a mobile unit at the companys own premises. Subsequently, Metso Minerals proposed to install a Barmac VSI crusher to crush the unsaleable cone crusher fines to improve the particle shape and size distribution, and to produce Barmac sand. The Barmac was installed in open circuit to crush the minus 8mm material. Other Benefits and Advantages The Barmac VSI has given the operator the ability to vary parameters such as rotor type, rotor speed, cascade feed setting and choice of crushing chamber profile, allowing increased flexibility and precise control over the sand specification produced. Conclusion The product obtained from the Barmac is a well graded, equidimensionally shaped manufactured sand, which falls well within specification. In fact, full scale concrete testing, carried out by the customer, has shown that the Barmac sand performs in concrete at least as well as the local natural sands normally used, if not better.

1-Deck Screen Cutting at 8mm

Barmac B9000 VSI 300kW [400 hp]

Barmac Model Selected B9000 Barmac Duopactor 300kW [400 hp] Material: Granite Feed: 8mm Product: Sand

Major Benefits To The Concrete Industry Manufactured, or Barmac Sand is being successfully used in the production of high quality concrete and asphalt around the world. Its superior equidimensional shape puts it well within specifications imposed on sand for use in concrete production. Natural sand is a product of many thousands of years of erosion. However, the Barmac VSI simulates the particle size reduction and shaping that occurs in nature, using a unique rock-on-rock crushing action. The Barmac grinds and mills the feed material to produce a fine product with no contamination from wear parts. As the material fed into the Barmac grinds and impacts against itself, the typical wear cost per tonne of material processed is very low.

100 90 80 70 Cum % Passing 60 50 40 30 20 10 0 0.01 Barmac Feed Barmac Product

0.1

1 Sieve Size (mm.)

10

100

Barmac VSI crushers are also used in the industrial minerals, mining, recycling and general quarrying industries. A wide range of materials are processed through Barmac crushers worldwide. For more information on this or any other Barmac application, please contact your nearest Barmac representative.

Metso Minerals (Matamata) Limited Mangawhero Road, Private Bag 4071, Matamata, New Zealand Tel. +64 7 881 9060, fax +64 7 888 5244 minerals.info@metso.com

AIB 012 1 4/99