{"id":1644,"date":"2016-07-04T23:08:11","date_gmt":"2016-07-04T23:08:11","guid":{"rendered":"http:\/\/yinghuiinternational.com\/?p=1644"},"modified":"2016-07-11T23:11:15","modified_gmt":"2016-07-11T23:11:15","slug":"peppertree-quarry-a-generational-investment","status":"publish","type":"post","link":"https:\/\/yinghuiinternational.com\/index.php\/2016\/07\/04\/peppertree-quarry-a-generational-investment\/","title":{"rendered":"PEPPERTREE QUARRY A \u2018GENERATIONAL INVESTMENT\u2019"},"content":{"rendered":"
\"Eight<\/p>\n
Eight storage silos for the base materials are fed by a complex 3D maze of conveyors<\/a> from multiple crushing and screening plants.<\/span><\/div>\n<\/div>\n
\n

PEPPERTREE QUARRY A \u2018GENERATIONAL INVESTMENT\u2019<\/span><\/h1>\n<\/div>\n
Posted July 04, 2016<\/span> |<\/span><\/div>\n
In 2014 Boral commissioned an advanced processing plant for Peppertree Quarry, south of Sydney. This facility \u2013 featuring crushers<\/a>, screens, conveyors and processing systems \u2013 has set new benchmarks in environmental management, safety, production and quality.<\/span><\/div>\n

As you approach Boral\u2019s Peppertree Quarry, a two-hour drive from Sydney, it\u2019s immediately obvious this is no ordinary quarry operation.<\/p>\n

There are no stockpiles of different products, no loaders and dump trucks moving material around, no lines of tip trucks collecting material for delivery to building and construction<\/a> sites back in Sydney \u2013 and very little noise.<\/p>\n

Instead, eight gleaming stainless steel towers soar into the sky \u2013 storage silos for the base materials that combine to make up the numerous different product mixes the site can produce.<\/p>\n

These silos are fed by a complex 3D maze of conveyors from the multiple crushing and screening plants housed in an array of structures \u2013 which in turn are fed from a single, massive stockpile bringing in the raw crushed material from the quarry pit itself.<\/p>\n

The quarry\u2019s entire output leaves the site by train \u2013 four trainloads a day, every day \u2013 with multiple product mixes in every trainload. Not a single kilogram of product leaves the site by road.<\/p>\n

And yet a single person can control this entire processing operation.<\/p>\n

The whole site has just 30 people running it across a 24\/7 operation; compare this with equivalent output conventional quarry operations, which typically require more personnel than that, along with multiple items of mobile equipment.<\/p>\n

\u2018Generational investment\u2019<\/h6>\n

So what was behind Boral\u2019s decision to go far beyond anything that had been done in Australia previously and build a world\u2019s best practice operation?<\/p>\n

A unique combination of history, geography, geology and environment \u2013 along with some equally unique challenges \u2013 has resulted in the company\u2019s new Peppertree processing plant.<\/p>\n

David Bolton, Boral Construction Materials\u2019 general manager of quarries for New South Wales and the Australian Capital Territory, said for many years the company had known it would need to replace its Penrith Lakes Scheme quarry, on the western outskirts of Sydney.<\/p>\n

\u201cPenrith Lakes supplied Sydney with construction materials for over 100 years but was exhausted by 2015,\u201d he said.<\/p>\n

Quarrying at Penrith Lakes officially ceased in July 2016 after almost 130 years of extraction.<\/p>\n

Boral needed a replacement quarry close enough to Sydney to economically transport product to the metropolitan region and to the demanding standards of its customers \u2013 from homeowners, small tradespeople and builders to multinational civil and building contractors<\/a> and their clients.<\/p>\n

<\/p>\n
\"While<\/p>\n
While 30 personnel run the whole site, a single person can control the entire processing operation.<\/div>\n<\/div>\n

<\/center><\/div>\n

\u201cWe identified a large deposit of granodiorite adjacent to our existing limestone<\/a> quarry near Marulan, south of Sydney,\u201d Bolton said.<\/p>\n

Granodiorite is a very hard and durable rock, making it ideal for concrete and asphalt applications.<\/p>\n

\u201cOur Peppertree Quarry is a generational investment, and will secure Boral and the Sydney construction materials market for many, many years to come,\u201d Bolton said.<\/p>\n

\u201cWe were granted consent to extract and process 3.5 million tonnes a year. This consent is for an initial period of 30 years, but the resource at Peppertree will last significantly longer than that.\u201d<\/p>\n

One issue Boral faced in the move from Penrith Lakes to Peppertree was the fact the new site had no sand resources.<\/p>\n

Accordingly, the company decided to develop its own manufactured sand products, combining granodiorite from the new Peppertree Quarry mixed with product from its adjacent limestone quarry.<\/p>\n

In fact, 40 per cent of the output from Peppertree is manufactured sand \u2013 and it has proven to be a product of such outstanding characteristics that demand for it is growing.<\/p>\n

Transport by rail<\/h6>\n

Bolton said another major challenge for Boral was getting its product to Australia\u2019s largest city, almost 200km away. The quarry\u2019s target output would have meant a steady stream of trucks travelling up and down the Hume Highway, and into an already very congested city road network.<\/p>\n

\u201cThe need to ensure that all aggregates were railed from the site rather than truck presented a number of challenges to Boral and to Sandvik in developing the systems and infrastructure to accommodate such large volumes of diverse products by rail,\u201d he said. \u201cThe rail loading infrastructure that was developed by Boral and Sandvik for this project, I believe, is one of a kind in this industry.<\/p>\n

\u201cIt combines the ability to load multiple products, doing this at high capacity, similar to large scale mining operations.<\/p>\n

\u201cHowever, in large scale mining operations you are dealing with just a single product that\u2019s going onto a train, whereas the system we have developed in conjunction with Sandvik allows us to deal with multiple products at very high rates, thus maximising our rail utilisation.\u201d<\/p>\n

To maximise the plant\u2019s efficiency and productivity, minimise ongoing operating costs and ensure a high degree<\/a>of flexibility to meet changing market demands well into the future, Boral adapted the principles of \u201clean manufacturing\u201d at its Peppertree operations.<\/p>\n

\"The<\/p>\n
The exterior of one of the crushing stations at Peppertree Quarry.<\/div>\n<\/div>\n
\"Boral<\/p>\n
Boral project manager Kai Kane (left) with Sandvik Construction\u2019s Glenn Cooper.<\/div>\n<\/div>\n

\u201cThe entire design of Peppertree incorporates a number of lean manufacturing initiatives to reduce material transport requirements and material movements, as well as excess stocks of materials on-site,\u201d Bolton said. \u201cProducts from Peppertree and the way that these products were delivered to our markets drove us to design a plant based on what our customers truly valued.\u201cFrom these customer requirements, the original project specification was developed, and Sandvik and Boral then designed and built the plant and equipment to meet those needs.\u201d<\/p>\n

Fully integrated plant<\/h6>\n

From the earliest specification and design stage, Boral worked closely with Sandvik Construction to develop a fully integrated processing plant that met the highest standards of production reliability, product quality and safety.<\/p>\n

Once the raw quarried material leaves the pit, Sandvik-supplied conveyors, crushers, screens, air classifiers and surge bins, along with sophisticated control and quality monitoring systems, manage every aspect of production until the final product is loaded<\/a> onto the train.<\/p>\n

A key element of this process has been to ensure products out of Peppertree meet specifications, and achieve market acceptance.<\/p>\n

According to Peppertree Quarry manager Angus Shedden, the quality of Peppertree products has exceeded all expectations.<\/p>\n

\u201cThe feedback from our customers has been exceptional, far better than we expected,\u201d he said. \u201cOur secondary crushers, the Sandvik cone crushers, are really delivering fantastic shape.\u201d<\/p>\n

Shedden said this shape straight off the cone crushers was of such high quality the operation had been able to reduce the feed going through its quaternary vertical shaft impactor (VSI) crushers.<\/p>\n

\u201cWe are also getting excellent consistency of our aggregate,\u201d he said. \u201cWe are able to produce the same product consistently, first time, all the time. The biggest success here, from my point of view, has been the quality of the aggregates. The quality has just been exceptional.<\/p>\n

\u201cSince production out of Peppertree started, we have supplied a number of high profile infrastructure projects in Sydney \u2013 including Barangaroo \u2013 with customers very happy with the high quality aggregates that we are producing.\u201d<\/p>\n

Shedden is proud of the high degree of automation at Peppertree, and the benefits it has in terms of safety and efficiency.<\/p>\n

\u201cBecause of the automation in the plant, not only can we operate the plant with one person, but it also means that we don\u2019t have lots of vehicles, and we don\u2019t have huge numbers of people on site,\u201d he said.<\/p>\n

\u201cOur standard operating team per production shift is four people \u2013 and I defy anywhere else to have those sorts of numbers to produce the output we are achieving.<\/p>\n

\u201cFor us, from an occupational health and safety (OHS) point of view, that has huge implications. A lot fewer people around and a lot fewer vehicles takes away a huge amount of risk. And, from an operational cost, we don\u2019t have all that maintenance to carry out on mobile plant and equipment.<\/p>\n

\"There<\/p>\n
There are very few tipper trucks that visit the Peppertree Quarry site.<\/div>\n<\/div>\n

\u201cAs well, not having a lot of vehicles moving around the site really helps with our environmental controls.\u201d<\/p>\n

EHS solutions<\/h6>\n

Boral has taken the opportunity in developing a greenfield operation to introduce highly innovative environmental and OHS solutions, as Sharon Makin, stakeholder and environmental manager at Peppertree, explained.<\/p>\n

\u201cI had the privilege of actually starting here back when work on the site began in July 2011, and have stayed on to do health, safety and environment through operations,\u201d Makin said.<\/p>\n

An important element of the Peppertree site from the start was the \u201csafety and design\u201d concept.<\/p>\n

\u201cWhat that has meant in terms of operation is an OHS management system which ties in with all the physical, mechanical safeguards that we have put in place here,\u201d Makin said.<\/p>\n

\u201cSome examples of what came out of this safety and design process is that everything is guarded \u2013 and all guarding is bright yellow in colour, so you can pick when something might be missing.<\/p>\n

\u201cThere are no underground conveyors or underground tunnels; everything is above ground. Access is down the side of each conveyor and confined spaces, as much as possible, have been removed. Ladders have been almost eliminated from the operation, and wherever we can, access is by stairs.\u201d<\/p>\n

From an environmental point of view, Makin described the plant as \u201ca dry process\u201d.<\/p>\n

\u201cThe site doesn\u2019t have a water supply \u2013 apart from what falls out of the sky \u2013 so Boral and Sandvik also looked at what we needed to do in regard to environmental performance,\u201d she said.<\/p>\n

\u201cSo, for example, all conveyors are covered, all operations are within buildings, and we have minimal water usage to control dust.\u201d<\/p>\n

Because of the restricted water supply at Peppertree, Boral and Sandvik worked closely from the earliest stages of the design process to eliminate all haul trucks from the operation.<\/p>\n

\u201cMaterial comes out of the pit by conveyor, it goes through all the processing operations via conveyor,\u201d Makin said.<\/p>\n

\u201cWe are also the first quarry in Australia to put our product into silos, so we don\u2019t have on-ground stockpiles that need to be watered and, again, we don\u2019t need the trucks to haul them off-site.<\/p>\n

\"A<\/p>\n
A glimpse inside the main screening building.<\/div>\n<\/div>\n
\"High<\/p>\n
High speed camera monitors ensure the product passing through the stations meets specifications.<\/div>\n<\/div>\n

\u201cAnd as Peppertree has 100 per cent of its dispatch by rail, the silos feed the conveyor direct into the wagons, and so we minimise the need for water through that process as well.\u201d<\/p>\n

\u2018Extensive benchmarking\u2019<\/h6>\n

One of the key people in helping Boral develop its vision of a highly automated, extremely safe site with the highest environmental standards has been Kai Kane, the project manager for Boral\u2019s Sydney Aggregates Project, which covers the Peppertree Quarry, its adjacent limestone manufactured sand plant, rail infrastructure and the Maldon rail terminal that services the site.<\/p>\n

\u201cThe criterion that we used in developing our concepts for Peppertree was extensive benchmarking of leading international sites,\u201d Kane said. \u201cWe spent several months benchmarking various sites by Sandvik, in particular Perrier TP\u2019s Mions Quarry in France, which became the reference point for this particular project.<\/p>\n

\u201cThese reference plans were then used to consolidate our designs and use them for benchmarking to get world\u2019s best practice in our design process, and then develop our safety and design requirements, as well as Australianising all those European designs.<\/p>\n

\u201cThe safety and design process between the Boral and Sandvik teams was very iterative and collaborative. Our processes included extensive risk assessments, going through each of the existing designs and then through our new design to make sure that we captured the earnings from the ones that we benchmarked.<\/p>\n

\u201cThe plant we now have is world standard in terms of safety and quality, and has produced an exceptionally ergonomic and maintainable operation.\u201d<\/p>\n

Kane highlighted Peppertree\u2019s train loading system and its \u201creject stockpile\u201d concept as particularly innovative solutions to significant challenges.<\/p>\n

\u201cOur train loader, which was a collaboration between Boral and Sandvik, has resulted in a world class rail loading system, which operates at 2000 tonnes per hour,\u201d Kane said. \u201cIt is the most efficient loading system that Boral currently operates.<\/p>\n

\u201cIt is unique in that it is capable of loading multiple products \u2013 in our case, multiple different products and recipes \u2013 something that is unique in the quarrying industry.\u201d<\/p>\n

The site\u2019s reject stockpile system is what Kane calls an \u201celegant solution\u201d to the challenge of dealing with out-of-spec products coming from the silos to the train loader.<\/p>\n

Product comes out of the silos at 2000tph, and before going to the train loader goes through a sampling station, where a high speed camera monitors to ensure the product passing through the stations meets specifications.<\/p>\n

\u201cAny out-of-spec materials are picked up within five seconds as they go past the camera detection systems, then the chute changes direction and diverts the material to a radial stacker and our reject stockpile,\u201d Kane said.<\/p>\n

\u201cThese materials that come out of our radial stacker are then recirculated by a front-end loader, back into our screening and crushing plants for recovery.<\/p>\n

\"Peppertree<\/p>\n
Peppertree Quarry\u2019s entire output leaves the site by train, with multiple product mixes in every trainload.<\/div>\n<\/div>\n

\u201cComparing it with the plants we benchmarked when designing and specifying Peppertree, this is now in a superior state to all of those, particularly from an automation perspective.\u201d<\/p>\n

David Bolton said customer acceptance of Boral\u2019s product out of Peppertree, in both concrete and asphalt operations, was even better than the company had hoped. He reiterated the development of Peppertree as \u201ca generational investment\u201d for Boral.<\/p>\n

\u201cIt\u2019s been a once in a lifetime opportunity to be involved in something of this scale,\u201d he said. \u201cIt\u2019s also been a pleasure to work with a great team at Boral Peppertree and a great team at Sandvik.<\/p>\n

\u201cWhat these two teams have been able to achieve working together has really opened our eyes to opportunities for improving our existing operations, as well as learnings we can apply to future greenfield and brownfield developments.\u201d<\/p>\n

Source: Sandvik Construction<\/em><\/p>\n","protected":false},"excerpt":{"rendered":"

Eight storage silos for the base materials are fed by a complex 3D maze of conveyors from multiple crushing and screening plants. PEPPERTREE QUARRY A \u2018GENERATIONAL INVESTMENT\u2019 Posted July 04, 2016 | In 2014 Boral commissioned an advanced processing plant for Peppertree Quarry, south of Sydney. This facility \u2013 featuring crushers, screens, conveyors and processing … Continue reading “PEPPERTREE QUARRY A \u2018GENERATIONAL INVESTMENT\u2019”<\/span><\/a><\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"jetpack_post_was_ever_published":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_publicize_message":"","jetpack_publicize_feature_enabled":true,"jetpack_social_post_already_shared":false,"jetpack_social_options":{"image_generator_settings":{"template":"highway","default_image_id":0,"font":"","enabled":false},"version":2}},"categories":[6],"tags":[],"class_list":["post-1644","post","type-post","status-publish","format-standard","hentry","category-mines-and-quarry"],"jetpack_publicize_connections":[],"jetpack_featured_media_url":"","jetpack_shortlink":"https:\/\/wp.me\/p83F9T-qw","jetpack-related-posts":[{"id":8787,"url":"https:\/\/yinghuiinternational.com\/index.php\/2024\/07\/17\/new-victorian-sand-quarry-approval-keeps-sector-booming\/","url_meta":{"origin":1644,"position":0},"title":"New Victorian sand quarry approval keeps sector \u2018booming\u2019","author":"yinghui","date":"July 17, 2024","format":false,"excerpt":"ADAM DAUNT A new sand quarry has been approved in Melbourne. 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Approvals for expansions to two quarries, the Tinda Creek Sand Quarry near the Wollemi National Park, and the Gunlake quarry near Goulburn, will create an additional 18 jobs for each operation, including\u2026","rel":"","context":"In "Mines and Quarry"","block_context":{"text":"Mines and Quarry","link":"https:\/\/yinghuiinternational.com\/index.php\/category\/mines-and-quarry\/"},"img":{"alt_text":"","src":"","width":0,"height":0},"classes":[]},{"id":995,"url":"https:\/\/yinghuiinternational.com\/index.php\/2015\/09\/25\/buyer-sought-for-quarry-ahead-of-redevelopment\/","url_meta":{"origin":1644,"position":2},"title":"BUYER SOUGHT FOR QUARRY AHEAD OF REDEVELOPMENT","author":"yinghui","date":"September 25, 2015","format":false,"excerpt":"A quarry operator is seeking a buyer for its limestone operation ahead of the site\u2019s proposed redevelopment into a residential hub. 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High temperatures, freezing cold, heavy material and constant use can put extreme pressure on components.\u00a0 This is why\u00a0Oli Vibrators Australia is fully stocked and on standby to assist Australian quarries.\u00a0 Many quarries are also located in remote areas, operating\u2026","rel":"","context":"In "Mines and Quarry"","block_context":{"text":"Mines and Quarry","link":"https:\/\/yinghuiinternational.com\/index.php\/category\/mines-and-quarry\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/www.quarrymagazine.com\/wp-content\/uploads\/2023\/08\/To-Think-Dewatering-1024x768.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/www.quarrymagazine.com\/wp-content\/uploads\/2023\/08\/To-Think-Dewatering-1024x768.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/www.quarrymagazine.com\/wp-content\/uploads\/2023\/08\/To-Think-Dewatering-1024x768.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/www.quarrymagazine.com\/wp-content\/uploads\/2023\/08\/To-Think-Dewatering-1024x768.jpg?resize=700%2C400&ssl=1 2x"},"classes":[]}],"jetpack_sharing_enabled":true,"_links":{"self":[{"href":"https:\/\/yinghuiinternational.com\/index.php\/wp-json\/wp\/v2\/posts\/1644","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/yinghuiinternational.com\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/yinghuiinternational.com\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/yinghuiinternational.com\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/yinghuiinternational.com\/index.php\/wp-json\/wp\/v2\/comments?post=1644"}],"version-history":[{"count":1,"href":"https:\/\/yinghuiinternational.com\/index.php\/wp-json\/wp\/v2\/posts\/1644\/revisions"}],"predecessor-version":[{"id":1645,"href":"https:\/\/yinghuiinternational.com\/index.php\/wp-json\/wp\/v2\/posts\/1644\/revisions\/1645"}],"wp:attachment":[{"href":"https:\/\/yinghuiinternational.com\/index.php\/wp-json\/wp\/v2\/media?parent=1644"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/yinghuiinternational.com\/index.php\/wp-json\/wp\/v2\/categories?post=1644"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/yinghuiinternational.com\/index.php\/wp-json\/wp\/v2\/tags?post=1644"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}