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<p>As the aggregates industry faces increasing regulatory and environmental pressures, sustainable water management and the mitigation of subsurface operational risks have become critical priorities. This paper presents a comprehensive case study of the integrated water recycling and fines recovery system implemented at Vulcan Materials Company’s Franklin Quarry in Tennessee. Historically, the facility faced dual challenges: extreme municipal water expenditures during drought cycles, exceeding $100k per month during peak season, and the “walking leak” phenomenon caused by injecting slurry into abandoned underground workings, which threatened active mining faces. To address these issues, a $5M+ closed-loop circuit was engineered, featuring a high-rate thickener and a belt filter press. The system was founded on a repurposed 25-ft deep wash-out pond utilizing specialized shot rock structural fill. Results from the 2024 operating year demonstrate a 98.9% reduction in municipal water costs and the successful recovery of fines produced annually. Furthermore, the transition to mechanical dewatering has eliminated subsurface slurry migration, enhancing mine safety and structural integrity in active workings. Finally, the study details the "circular economy" benefits of blending recovered fines into commercial base aggregate at a 6% mass ratio, converting a historical liability into a value-added product that meets TDOT mineral aggregate base specifications (Type A or B) by maintaining material passing the No. 200 sieve (75 µm) within the required 0–15% range for structural stability. </p>

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Mitigating Drought Vulnerability and Underground Slurry Migration: An Integrated Water Recycling and Fines Recovery Case Study at Vulcan Materials Franklin Quarry

  • 期刊论文

  • 发表日期：

    2026年5月15日

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  • Venkata Aneesh Kona

摘要

As the aggregates industry faces increasing regulatory and environmental pressures, sustainable water management and the mitigation of subsurface operational risks have become critical priorities. This paper presents a comprehensive case study of the integrated water recycling and fines recovery system implemented at Vulcan Materials Company’s Franklin Quarry in Tennessee. Historically, the facility faced dual challenges: extreme municipal water expenditures during drought cycles, exceeding $100k per month during peak season, and the “walking leak” phenomenon caused by injecting slurry into abandoned underground workings, which threatened active mining faces. To address these issues, a $5M+ closed-loop circuit was engineered, featuring a high-rate thickener and a belt filter press. The system was founded on a repurposed 25-ft deep wash-out pond utilizing specialized shot rock structural fill. Results from the 2024 operating year demonstrate a 98.9% reduction in municipal water costs and the successful recovery of fines produced annually. Furthermore, the transition to mechanical dewatering has eliminated subsurface slurry migration, enhancing mine safety and structural integrity in active workings. Finally, the study details the "circular economy" benefits of blending recovered fines into commercial base aggregate at a 6% mass ratio, converting a historical liability into a value-added product that meets TDOT mineral aggregate base specifications (Type A or B) by maintaining material passing the No. 200 sieve (75 µm) within the required 0–15% range for structural stability.