Silica Sand Recovery: Wet & Dry Processing at Sumner Mine
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
| Parameter | Value | Unit | Notes |
|---|---|---|---|
| Wet Plant Throughput | 500 | tph (short tons per hour) | Nameplate capacity; approximately 454 metric tonnes per hour |
| Dry Plant Throughput | 375 | tph (short tons per hour) | Nameplate capacity; approximately 340 metric tonnes per hour |
| ROM Stockpile Capacity | 60,000 | short tons | Approximately 54,000 metric tonnes |
| WIP Stockpile Capacity (Dry Plant) | 300,000 | short tons | Approximately 272,000 metric tonnes |
| Target Product Sizes | 20/40, 30/70, 100 mesh | mesh | Final products after dry processing; also 8/50 and 30/70 as WIP |
| Processing Capacity | 500 (wet) / 375 (dry) | tph | Combined nameplate capacity of wet and dry plants |
| Operating Schedule | Year-round | Wet and dry plants operate continuously with downtime for maintenance | |
| Employees | 50 (wet) / 20 (dry) | employees | Approximately 50 at mining and wet plant; 20 at dry plant |
| Historical Production (2013-2025) | 13.43 | million short tons | 12.19 million metric tonnes of finished product |
| 2025 Annual Production | 1.26 | million short tons | 1.16 million metric tonnes; 20/40, 30/70, and 100 mesh |
Overview
Source Energy Services Ltd. operates the Sumner Silica Sand Mine in Barron County, Wisconsin, utilizing a comprehensive two-stage recovery method to produce high-quality frac sand for hydraulic fracturing. The processing operations are split between a wet processing plant located adjacent to the mine and a dry processing plant in Weyerhaeuser, Wisconsin, approximately 8 miles east on U.S. Highway 8. The dry plant began operations in December 2013, while the wet plant runs year-round with scheduled maintenance. This silica sand recovery system crushes, washes, dries, and sorts run-of-mine sandstone to yield products such as 20/40, 30/70, and 100 mesh (50/140) that meet stringent specifications for the oil and gas industry. The wet plant has a nameplate capacity of 500 short tons per hour (454 metric tonnes per hour), while the dry plant processes up to 375 short tons per hour (340 metric tonnes per hour). Together, these facilities have produced over 13.43 million short tons of finished product from 2013 to 2025, with 1.26 million short tons produced in 2025 alone. The process involves crushing without damaging individual grains, density and size separation in the wet plant, trucking work-in-process material via third-party contractor Antczak Trucking, and final drying and sorting at the dry plant. Quality control labs at both locations ensure product consistency, making Source Energy Services a key supplier of silica sand for hydraulic fracturing operations across North America.
Key Process Stages
- Stage 1: Crushing and Scalping – Run-of-mine sandstone is fed through an in-line crusher and scalping screeners to reduce rock to manageable sizes while preserving individual grain integrity. The crushed material is stored in a 60,000-short-ton ROM stockpile before entering the wet plant.
- Stage 2: Wet Separation – The crushed material passes through 10×10 and 8×8 density separators, attrition scrubbers, and cyclones to remove contaminants and classify particles by size, shape, and density. This stage produces 8/50 and 30/70 sized work-in-process material.
- Stage 3: Dewatering and Clarification – Slurry from the wet plant is treated using belt presses, dewatering beds, and a clarifier with process water tanks to recover water and produce dewatered sand. The clarifier enables water recycling, reducing fresh water consumption.
- Stage 4: Trucking to Dry Plant – The dewatered work-in-process material is transported by Antczak Trucking to the dry processing plant in Weyerhaeuser, WI, where it is stockpiled in a 300,000-short-ton WIP pile prior to drying.
- Stage 5: Drying and Final Sizing – At the dry plant, three fluid bed dryers remove moisture, and Rotex mineral separators sort the sand into final products: 20/40, 30/70, and 100 mesh (50/140 mesh). Quality control laboratory sampling is performed at each stage to ensure product specifications are met.
Additional Interesting Data and Summary
Beyond the core recovery stages, the Sumner silica sand operation incorporates several technical and operational features that enhance efficiency and product quality. The wet processing plant is enclosed to minimize dust and noise, and it operates year-round with scheduled maintenance downtime. Key equipment includes density separators (10×10 and 8×8), attrition scrubbers, cyclones, belt presses, dewatering beds, and a clarifier with process water tanks – all designed to maximize fines removal and water recovery, reducing environmental impact. The dry plant features three fluid bed dryers and Rotex mineral separators, allowing precise control over final product sizing. Quality control measures are implemented at multiple stages through laboratory sampling, ensuring the 20/40, 30/70, and 100 mesh products meet strict API specifications for hydraulic fracturing. Economically, the mine and processing facilities support approximately 70 direct jobs (50 at the wet plant/mine site, 20 at the dry plant), plus indirect employment through trucking contractor Antczak Trucking. The 13.43 million short tons of finished product shipped between 2013 and 2025 represent a significant contribution to the regional and national frac sand supply chain. In 2025 alone, production reached 1.26 million short tons, indicating stable demand from oil and gas operators. Environmental considerations include water recycling via the clarifier, enclosed processing to reduce fugitive emissions, and managed stockpiles to minimize land disturbance. While the technical report does not detail specific energy or water consumption metrics, the use of modern equipment suggests industry-standard efficiency. Looking ahead, the continued operation of both plants year-round and the availability of substantial permitted resources position Source Energy Services to maintain its role as a reliable supplier of premium silica sand for hydraulic fracturing, supporting energy development in the United States. Future expansions or optimizations may focus on further reducing water usage, increasing automation, and adapting to evolving proppant specifications.
Key Processes: Crushing
Target Commodities: N/A
