Understanding the science of silica milling properly avoids £37m CAPEX
Deep science problem solving – silica sand milling



Private Chemical Company


Increase output to avoid £37m spend on a third mill


•  Output increased by 14.7% to meet additional sales without capital expenditure

•. The proposed location of the third mill would have not worked, due to high temperature and relative humidity


•  Technical problem solving exercise with a small client team

•  Identify that there is high frequency throughput variation by direct observation and installing weigh cells to demonstrate variability of output – cost £15k

•  Understand the relationship between output and atmospheric conditions

•  Forensic investigation showing that the classifier returns agglomerate due to magnetic properties in quartzite crystals

•. Measure and understand the effect of seasonal and diurnal temperature and humidity; install water injection system (with up to 3 kg/hr) to maintain best output on the 3D surface plot above – at a cost of c.£15k