Preston Silica Sand Recovery: Wet & Dry Processing for Frac Sand

Source: Source Energy Services Ltd (2026)
Website: https://www.sourceenergyservices.com/

Critical Data

Overview

Source Energy Services Ltd. (SES) operates the Preston Silica Sand Mine in Trempealeau County, Wisconsin, a facility dedicated to producing high-quality frac sand for hydraulic fracturing operations. The recovery methods employed at the Preston property integrate three primary stages: crushing, wet processing, and dry processing, designed to transform run-of-mine (ROM) sandstone into precise mesh sizes—20/40, 30/50, 40/70, and 100 (70/140)—meeting stringent industry specifications. Established with a historical production record exceeding 9.51 million short tons of frac sand from 2014 to 2025, the facility achieved 831,000 short tons in 2025 alone. The process begins by crushing ROM material without damaging individual grains, followed by wet processing that separates particles by size, shape, and density to remove contaminants, producing a 20/70 work-in-process (WIP) material. This WIP is then dried and further sorted in the dry-processing plant. Crushing and wet operations are weather-dependent, running March through November, while the dry plant operates year-round, both on a 24-hour schedule. With a workforce of 40 employees across the plants, the Preston silica sand recovery methods ensure consistent product quality through rigorous laboratory sampling at multiple stages. The facility’s significance lies in its ability to supply the oil and gas industry with reliable, high-purity proppants, underpinned by robust equipment including Metso impact crushers, Carrier fluid bed dryers, and Rotex mineral separators.

Key Process Stages

• Stage 1: Crushing and Screening – ROM sandstone is fed from a 250,000 short ton stockpile into a Metso impact crusher, which reduces material to manageable sizes without damaging individual quartz grains. A Telsmith vibrating screener classifies the crushed material, preparing it for wet processing.
• Stage 2: Wet Processing for Contaminant Removal – The crushed material enters the wet-processing plant (nameplate capacity 450 short tons per hour) where three 8×8 hydrosizers and four cyclones separate particles by size, shape, and density. This stage removes clays, silts, and other contaminants, yielding a 20/70 sized work-in-process (WIP) material.
• Stage 3: Dewatering and Waste Management – Slurry from wet processing is treated by a Prominent waste system. A clarifier and process water tanks recover water for reuse, while two Matac plate presses and one Jing Jang plate press dewater solid waste, producing filter cakes for disposal and minimizing environmental impact.
• Stage 4: Drying and Dry Processing – The WIP material (stored in a 500,000 short ton stockpile) is fed to the dry-processing plant (nameplate capacity 180 short tons per hour). A Carrier fluid bed dryer reduces moisture content, then three Rotex mineral separators screen the sand into final mesh fractions: 20/40, 30/50, 40/70, and 100 (70/140).
• Stage 5: Quality Control and Final Product Handling – Laboratory sampling is conducted at multiple points in both wet and dry circuits to verify product specifications. Finished frac sand is conveyed to storage and load-out, with historical production data (2014–2025) confirming over 9.51 million short tons shipped. The dry plant operates year-round 24/7, while the wet plant runs 24 hours/day from March to November.

Additional Interesting Data and Summary

The Preston silica sand mine’s recovery methods are supported by a comprehensive array of technical systems designed for efficiency, quality, and environmental stewardship. The wet-processing plant’s equipment includes three 8×8 hydrosizers and four cyclones that achieve precise size segregation, while the clarifier and process water tanks enable water recycling, reducing freshwater demand. Two Matac plate presses and one Jing Jang plate press dewater waste solids, producing filter cakes that minimize landfill impact. The dry-processing plant’s Carrier fluid bed dryer and three Rotex mineral separators ensure consistent moisture control and mesh sizing, critical for frac sand performance. Economically, the facility has produced over 9.51 million short tons of finished product from 2014 to 2025, with a 2025 output of 831,000 short tons, demonstrating sustained operational capability. Sustainability initiatives are evident in the closed-loop water system and waste dewatering, which align with modern mining best practices. The plant’s seasonal operation for crushing/wet processing (March–November) optimizes energy use and weather-dependent conditions, while the year-round dry plant maintains steady supply to customers. Although specific energy and water consumption metrics are not disclosed, the use of high-efficiency equipment like the Metso impact crusher and Carrier fluid bed dryer implies industry-standard performance. Looking forward, the Preston facility is well-positioned to continue serving the hydraulic fracturing market, with processing assets deemed suitable for their intended purpose by qualified persons. The integration of robust quality control—including laboratory sampling at multiple stages—ensures that each mesh product meets API specifications. This combination of technical rigor, environmental responsibility, and proven production history makes Source Energy Services’ Preston silica sand recovery methods a benchmark for frac sand processing in North America.

Key Processes: Crushing

Target Commodities: N/A