Blair Silica Sand Mine: Frac Sand Recovery Methods & Yield

Source: Source Energy Services Ltd (2026)
Website: https://www.sourceenergyservices.com/news-releases/source-energy-services-ltd-files-updated-ni-43-101-technical-reports-for-its-mineral-projects-in-wisconsin-united-states

Critical Data

Overview

Source Energy Services Ltd. operates the Blair Silica Sand Mine in Trempealeau County, Wisconsin, a premier facility for producing high-quality hydraulic fracturing sand (frac sand). Established in 2016-2017, the mine employs a multi-stage recovery method that includes crushing, wet processing, slurry transport, and dry sorting to yield mesh products such as 20/40, 30/50, 40/70, and 100 (70/140). The crushing plant prepares run-of-mine (ROM) sandstone using a jaw crusher and vibratory feeder, feeding a 350 short tons per hour (tph) wet-processing plant where density separators, attrition cells, and dewatering screens remove contaminants and produce work-in-process (WIP) material. This WIP is then transported via the Blair Facility Slurry Line (BFSL) to the 200 tph dry-processing plant, featuring a Starkeaire fluid bed dryer and four Rotex screeners for final sizing. The facility’s strategic location on both sides of U.S. Highway 53 and the Trempealeau River allows efficient logistics, with the wet plant operating from March to November and the dry plant running year-round, 24 hours a day. Historical production from 2017 to 2025 totaled 7.30 million short tons of finished product, with 2025 achieving a wet plant yield of 62% and dry plant yield of 75%. Quality control through laboratory sampling ensures product consistency for the oil and gas industry.

Key Process Stages

• Stage 1: Crushing – ROM sandstone is fed from a 70,000 short ton stockpile via vibratory feeder into a jaw crusher. The crushing process reduces rock to manageable sizes without damaging individual sand grains, preparing the material for wet processing.
• Stage 2: Wet Processing – The crushed material enters the wet-processing plant (350 tph nameplate capacity) where Diester scalping screens remove oversize, McLanahan density separators sort by specific gravity, Liberator attrition cells scrub surfaces, and McLanahan dewatering screens and plate press recover water. An ultra fines recovery circuit captures fine particles. This stage produces 8/50 and 20/70 sized WIP material.
• Stage 3: Slurry Transport – WIP material is slurried and pumped through the Blair Facility Slurry Line (BFSL) to the dry-processing plant located across the highway and river. This eliminates trucking, improves efficiency, and enables year-round dry plant operation.
• Stage 4: Dry Processing – The dry-processing plant (200 tph nameplate capacity) receives WIP from a 400,000 short ton stockpile. A Starkeaire fluid bed dryer removes moisture, followed by four Rotex screeners that sort the sand into 20/40, 30/50, 40/70, and 100 mesh products.
• Stage 5: Quality Control & Loading – Throughout the process, laboratory sampling tests product quality. The finished frac sand is loaded onto railcars adjacent to the dry plant for shipment. The integrated system ensures consistent mesh sizing and purity for hydraulic fracturing applications.

Additional Interesting Data and Summary

The Blair Silica Sand Mine’s recovery methods have proven highly effective, with cumulative finished production of 7.30 million short tons (6.63 million metric tonnes) from mid-2017 through 2025. In 2025 alone, the operation processed 1,979,000 short tons of ROM feed through the wet plant, yielding 1,227,000 short tons of WIP (62% yield), and the dry plant produced 982,000 short tons of finished product (75% yield from dry plant feed). The facility employs approximately 60 people, contributing significantly to the local economy in Trempealeau County. A key innovation is the Blair Facility Slurry Line (BFSL), which replaced trucking of WIP material between the wet and dry plants, reducing road traffic, emissions, and operational costs. This slurry system allows the dry-processing plant to operate year-round, maximizing throughput. Environmental considerations include water management through the McLanahan plate press and ultra fines recovery circuit, which reclaim process water and reduce freshwater demand. Although specific water and energy consumption metrics are not disclosed in the recovery methods section, the presence of dewatering and fines recovery equipment indicates a focus on sustainability. Quality control measures, including laboratory sampling at multiple stages, ensure that products meet API specifications for hydraulic fracturing sand. Looking ahead, Source Energy Services continues to optimize the Blair Mine’s processing to maintain consistent supply to North American oil and gas markets. The facility’s robust design, with separate wet and dry plants and a 400,000 short ton WIP stockpile, provides operational flexibility to handle market fluctuations. Future developments may include further efficiency improvements in the crushing circuit and enhanced fines recovery to boost overall yield. The Blair Silica Sand Mine remains a strategic asset in the frac sand supply chain, combining innovative slurry transport, proven processing equipment, and a dedicated workforce to deliver high-quality proppant to the energy industry.

Key Processes: Crushing

Target Commodities: N/A