Their solution led to the establishment of Cyber Square, a pioneer in damp frac sand technology. With support from Powerscreen Texas, Terex Washing Systems and the Bell Machine Company, they’ve developed a quality product and pioneering production process which is helping the local community thrive.

Emerging from disaster

Since a dam was constructed south of the Cyber Square site around 30 years ago, sediment and sand has been building up in the bed of the Red River. This has led to flooding and caused catastrophic damage to the Haynesville community.

Since co-founders Marcus and Denzil started dredging this damp sand from the river and processing it for use in the oil and gas sector, they’ve made a huge impact on both the local and wider environment.

Marcus explains, “Our operation is essentially a startup company going into its third year. We’ve created a bunch of new jobs that didn’t previously exist. We’ve also become pioneers and leaders in the damp sand movement which lowers the carbon footprint within the supply chain for natural gas.”

Alongside the usual challenges faced in producing frac sand, such as water management, maximising efficiency and creating a consistent product, Cyber Square’s plant machinery needed to overcome another hurdle.

As Marcus sets out, “The raw material we make our product out of is a little bit different to that of our competitors. To process it, we needed a highly specialised and customised plant and that’s where the Terex AggreSand 206 really shines for us.”

Floods in 2015 and 2016 destroyed the community’s honey production businesses. Cyber Square took unused excess acreage on its site and dedicated it to honey manufacturing. Partnering with Hummer and Sons, the largest local tri-state manufacturer, this has benefited the local environment and economy.

A custom approach

The set-up is large and customised to Cyber Square’s application. Central to the operation are four Terex AggreSand 206 sand washing plants, which are part of the modular design. A highly integrated washing station, the market version can offer up to five different washed and sized products (three aggregates and two sands).

It also has a highly portable format and an installation time significantly lower than conventional builds thanks to factory pre-fitting and connections. This is helpful for the Cyber Square operation, which has to quickly adapt to changing conditions.

As Barry O’Reilly, Vice President of Powerscreen Texas, explains, “The fluctuating prices of the material in the oil sector and the water levels on the river all affect how much product needs to be made and when the team need to make it. This plant has a rapid set-up so they don’t have to plan too far ahead to meet market influxes or respond quickly to changes.”

Another priority when creating the plant was to ensure a high production output, which is particularly challenging with silicone sand. To meet this need, Barry’s team, Terex Washing Systems and the Bell Machine Company, led by Senior Vice President Shane Bell, worked with manufacturers to create a custom solution.

As Barry explains, “The first plant wasn’t going according to plan and the Cyber Square team asked us to get involved. With long-term growth in mind, we got our heads together to see how best we could serve them. We have a great dealer and manufacturer team who could help us achieve that.

“We set up a week of visits with engineers and production and went through all aspects of the plant from the ground-up, feeding directly into the Terex factory. We’re really proud of the end result and it will change how we approach plants on damp sand going forward.”

Shane adds, “We find the Terex 206 is very easy to work with and the screen box is extremely easy. When there is a bearing failure, the rotating assembly is easily disassembled and bearing changes are very timely. Parts are also readily available.

“In tonnes per hour, the production rates on the machines are outstanding. This custom machine is going to exceed the rates of those sold on the market, which is why we were excited to commission it and get it running.”

Maintenance designed for growth

To meet the demand and needs of the emerging damp frac sand market, Cyber Square didn’t just need to upscale production, but be adaptable to changing specs and make a consistent product. Bringing his experience of the market to the project, Craig Rautiola, Business Development Manager for Terex Washing Systems, said the plant design also had to adapt to the site’s features.

He says, “The perpetual feedstock coming from upstream means the material is quite consistent, which caters really well to modular plant design. Parts of the plant can be easily adapted. Typically, this involves refining the top end of the scalping and minor adjustments to some of the cyclone geometries.”

“The modular aspect and the repeated footprint of the plant also allows for linear growth within the Cyber Square business. As the market demand has increased, they’ve been able to strategically plan for growth periods and work with Powerscreen Texas on defining critical spares stock alongside Terex Washing Systems.”

As a 24/7 operation that only closes on Christmas Day, the quality and professionalism of the aftersales service has been fundamental to maintaining Cyber Square’s throughput. To reach the business’s ambitious growth targets, all teams had a huge amount of input.

Shane, whose team are responsible for plant maintenance, explains, “Normally we stock a full wash plant of parts, but there are those occasions when we don’t have the specific one we need. We make a phone call to Powerscreen and we have it here the next day. I don’t find that with other customers we deal with, but we’re pretty much guaranteed next-day service with Powerscreen.

“From the engineers to the service team, everyone is very responsive. If there’s a question on-site they’ll show up pretty much the next day. It’s really nice having back-up when we’re against the line needing extra hands and support.”

This has allowed Cyber Square to transition and meet the demands of this emerging market successfully, as well as pioneer a new approach in damp sand production. As Marcus sets out, “We continue to use Terex Washing Systems because they’ve been the most responsive to our needs. The team is always problem solving and making the machines do exactly what we want them to do.

“We feel the machines are the most reliable we could find, but it's the people who make the big difference for us. Engineers and field people are all responsible, which is what we need in a 24/7/364 environment.

“Powerscreen Texas has also been a phenomenal partner for us, it’s almost like having extra employees. If we have a problem, either myself or Denzil or Shane reach out to them and they’re here almost immediately.

IT’S A GREAT RELATIONSHIP, THEY’RE VERY RESPONSIVE AND IN A HIGH-STRESS INDUSTRY LIKE FRAC SAND IT’S CRITICAL TO HAVE THAT SUPPORT.”