An old quarry can always look for ways to enhance its production methods. The German quarry Terratec Basalt GmbH, is looking for savings in production by changing its processing method from stationary to mobile. Metso’s new Lokotrack LT220D “two-in-one” plant (Figure 1) helps the company to achieve the targeted goals.
“We estimate to get 25 to 30 % savings resulting in 1,0 to 1,5 €/t less costs by changing our quarry gradually from stationary to mobile. This is really providing significant savings for us,” comments Karl-Werner Bierbrauer, Managing director and owner of Terratec Basalt GmbH. “Our savings are based on cutting half the transportation of blasted rock to processing. Instead of bringing rocks to top-on-the-hill old stationary plant, we only need to transport the materials to the nearby Lokotrack mobile process,” he adds.
Started in 1962, A. Caspar Basaltwerk in Ettringen, a Bavarian city wets from Munich, has been known for its high-quality aggregates, produced of basalt and volcanic lava. The family company was bought early 2017 by Terratec Basalt.
Today, Bierbrauer & Sohn GmbH is known of their biggest, single Lokotrack fleet in Germany. The company leases today a fleet of twelve Lokotracks.
The mobile process now already started, will include three track-mounted units from Metso Inc., Tampere/Finland, a Lokotrack LT106 jaw plant, ST2.4. mobile screen and a LT220D cone plant with a screen. The LT220D is the first one being used in Germany.
Blasted basalt and lava is fed first to the LT106 primary jaw plant, which feeds the materials to ST2.4 screen. The screen separates 80 to 120 mm oversized from 0 to 80 mm sizes that are taken to LT220D cone-screen plant. The main end products from LT220D are 0 to 2 mm, 3 to 8 mm and 8 to 16 mm.
The end products are used in various applications in the region, e. g. street works, isolation and base materials in construction sites.
Terratec Basalt will lower the present 300,000 t/a production in the future down to some 150,000 t. The hourly capacity with the mobile Lokotrack process will be 150 to 250 t.