QMS replaces giant primary crusher at UK’s largest cement plant

Breedon's Hope cement plant contributes heavily to the UK's cement industry and is integral to Breedon's manufacturing capabilities. To sustain the processing of quarried limestone required for cement manufacturing, the Group recently replaced its 1940's era crusher with a new 1,250tph primary gyratory crusher, supplied by FLSmidth. To install the primary crusher, Quarry Manufacturing and Supplies Ltd. (QMS) led the months-long project.

The Hope cement manufacturing process begins at the quarry where two types of limestone are sourced: high-silica limestone and low-silica limestone. The quarry's upper beds have more of the high-silica limestone due to the high chert content. Further down in the quarry, lower-silica limestone is located. Shale is also used from an adjacent quarry on the site; both limestone and shale quarrying operations are integral to the cement manufacturing plant. 

Updating quarrying operations

To sustain operations, Breedon installed a new gyratory primary crusher in September 2024. Due to advancements in primary crusher technology, and a desire by the business to improve the maintainability of the crusher, plans for the replacement of the original crusher were put in place in 2022. 

The project involved the installation of a single, new primary crusher and associated equipment which was installed on the limestone crushing line. The limestone crushing line further consists of a twin line secondary and tertiary crushing stage, consisting of QMS B6 cone crushers. The task of pre-assembling the new FLSmidth crusher, demolishing, and removing the old crusher, and finally installing the new FLSmidth crusher, was given to QMS who worked in close partnership with the Breedon team at Hope, their contract partners, and equipment suppliers FLSmidth.

Multi-stage teamwork

George Close, UK sales director at QMS, explains: "Working closely with FLSmidth, we had to first build up the new gyratory crusher. This was a time-consuming and exacting process, as we were working with tight deadlines and the crusher had to be assembled on site. This site assembly was the first time all the crusher parts had been together, as the components were delivered by FLSmidth from all over the world. This took approximately five weeks. This utilized QMS' expertise and experience gained working with gyratory crushers throughout the world. This took two weeks, working 24/7, and was finally completed in mid-August (2024)."

"The third and final stage of the project was the actual installation of the new crusher, this again further necessitated working round the clock, night and day, taking over five weeks to complete. In addition, the new crusher has a QMS-manufactured, bespoke stainless steel lubrication system, which is now integral to the crusher's operation. We further assisted through the commissioning of the crusher, alongside the Breedon and FLSmidth teams, thereby ensuring that it was fully operational."

With a project of this scope and importance, QMS was not the only contractor involved. "Our task not only involved work at our end but also working with the Projects Team at Hope, including FortunumPM, which acted as client representative, as well as the other contractors whose work was essential to the success of the project. Other contractors on the installation included PCS UK Ltd, that handled all the electrical work, Tideswell Welding Services, that handled all the ancillary fabrication and welding (not involving the crusher itself), and Access Drilling Services Ltd, that handled all the significant concrete removal work. All the contractors on the project were unfailingly first class and a pleasure to work with," added George. 

David Boole, project engineer at Hope and Breedon's representative for the installation, said of the work undertaken by QMS and the other contractors: "We have been working with Jonathan and the team from QMS for many years now. They maintain the site's Sandvik cone crushers (as well as the new QMS B6 cone crushers) and help to ensure Hope Works operates at optimized efficiency. The work undertaken on the installation of the FLSmidth gyratory crusher is a credit to QMS and the other contractors."