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QUARRY ACADEMY CAN MAKE OPERATION MORE EFFICIENT
Quarry academy article by Harold Hough

For decades the quarry business was a quiet one. Quarry owners were able to make a decent profit by providing a good product for local construction companies. But that has changed. Specifications for aggregate, sand, and other quarry materials are now more exacting and small traditional quarries that haven’t kept up with the times will be facing difficult challenges in the next few years, especially since energy costs have a significant impact on quarrying.

This is where the Quarry Academy comes in. The Academy is a partnership between Sandvik, Dyno Nobel, and the Colorado School of Mines, that combines the experience of all three and puts it into a format where quarry owners and operators can learn how to make their operations more efficient. The focus this year was on better integrating “chemical crushing” (the drilling and blasting process) into the crushing-sizing process. General sessions were held in the auditorium and breakouts were held in smaller rooms.

This was the third Quarry Academy held. The previous ones held in 2005 and 2007 were so successful that they decided to offer an expanded program in November of 2008. “Now, more than ever, anytime you can increase efficiency, you need to do it,” said John Remakis, North America marketing manager for Sandvik. The classes were held to 70 attendees so the setting remained intimate and interactive.
The focus of the course is on the whole operation, not just specific parts. “You have a value chain,” says John Watson, general manager of drilling for Dyno Nobel. “You don’t look at each process separately, but the total package.”

As new construction begins to contract, heavy equipment operators become harder to find, and energy prices remain volatile; quarries need to review current practices. There’s also public and regulatory expectations and increased market competition which will force the industry to go beyond traditional methods. The quarry that hopes to grow in future years will have to change their practices and find new ways to work with their employees, customers, and the public.

One way to improve operations in a quarry or mining operation is to focus on the drilling and blasting program. Blasts that are designed for specific crushing and sizing setups can lower cost per ton, while improving productivity. The instructors looked at a case study where a quarry worked with Sandvik and Dyno Nobel to apply new drilling and blasting techniques to get the right particle size for their processing. The result was higher blasting costs, but a lower cost per ton and improved production. In fact, according to Watson, subsequent quarrying projects that would normally take three months only took two with the new design techniques. They showed that good blasting and drilling practices could save money downstream. “There was a clear improvement,” noted Watson.

Good drilling and blasting practices also have other benefits. Since drilling is hard on equipment, good drilling practices can reduce wear and tear on your equipment, which reduces maintenance costs and down time. And, well planned blasting will reduce fines, which can’t be used, can pose maintenance problems for your equipment, and are an air pollution problem.

In addition to drilling and blasting experts, the Quarry Academy also invited the well-known futurist David Houle to speak on trends. He is regarded as one of the thought shapers in the arena of alternative energy. He has met with some of the greatest energy and space scientists in the country and has discussed the future of energy and Space Solar Power in particular with them. His first book, “The Shift Age” was published earlier this year.

The good response to the Quarry Academy has organizers looking at holding another event in 2009. Remakis admitted that a time hasn’t been picked yet, but any new information will be posted on their website www.quarryacademy.com. As economic conditions continue to change dramatically, this will be one way to maintain the productivity and cost edge necessary to remain on top.