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Race to Success

Blackley Quarry lies approximately 8 miles north of Chelmsford on the A131 at Great Leighs. The green field site was originally purchased from Aggregate Industries in March 2001 by Frank Lyons Plant Services who recognised that the quarry had a ready made market on its doorstep with the proposed development of the first new horse racecourse in England at the Essex Showground.

The site has a permitted annual output of 200,000/250,000 tonnes; last autumn a brand new high specification Powerscreen Washing plant was installed. This has provided the company with the ability to process more difficult and dirtier material, which in the past would have been a problem. The result is a more profitable operation through a major reduction both in the moisture content of the material and in saleable material discharging to lagoons; this in itself has reduced lagoon maintenance and saved money.

The plant comprises a Commander 1400 feed hopper, an 80 ft transfer feed conveyor, a static 16 x 5 twin-deck full rinsing screen capable of handling up to 320 tonnes per hour (with full walkway access and rolling chutes for ease of maintenance) which feeds a Fines master 120 operating at a typical high capacity of 120 tonnes per hr supplying 2 T5032 stockpile conveyors with 3mm and 5mm material.

The twin-deck rinsing screen also feeds a stockpile conveyor with 40mm material, a static logwasher capable of handling 175 tonnes per hr linked to a T6532 transfer conveyor which feeds a static secondary 16 x 5 part-rinser twin-deck screen (with full walkway access and rolling chutes for ease of maintenance) supplying three further T5032 stockpile conveyors with 10mm, 20mm and 40mm material. Fresh water is supplied from an adjacent lagoon, and process water gravity flows to a second lagoon.