Eco Aggregates establish recycling centre with the help of DUODUO Equipment has recently supplied Eco Aggregates with a full washing and water-management plant which will operate at a previously disused quarry near Welwyn Garden City.
Having obtained temporary planning permission to recycle imported C&D waste etc, from local sites, the project has been partly funded by a grant from WRAP (the Waste and Resources Action Programme) Whilst the primary objective of Eco Aggregates is the restoration of the quarry from the recovered silt and clay derived from the recycling operation; the resulting processed aggregates will enable Eco Aggregates to operate a recycling centre. The company will then supply materials to the local construction materials market which will be used for asphalt and concrete production as well as for sub-base, capping and drainage materials. Production ProcessThe imported material is fed by excavator into a high capacity, heavy duty, Powerscreen Warrior. Acting as the primary screen the material is dry screened into 3 sizes, with the midsize being directly fed into the Powerscreen Commander 1400 feed hopper of the wash plant. From the hopper material is fed onto an inclined lattice frame feed conveyor complete with belt magnet; this conveyor delivers material onto the primary screen, a Powerscreen 12 x 5 static rinser. Featuring six spray bars on both top and bottom decks the vibrating top deck of the screen rejects all oversize material and delivers this via a stock conveyor to an adjacent ground stockpile. Midsize material is fed onto a second inclined static transfer conveyor which provides material to the final 12 x 5 dry screen. This screen splits the material into three final single-size products - 10mm, 20mm and 40mm which are then delivered to their respective ground stockpiles by three radial conveyors. Sand from the first screen is fed to a pre-wash system to remove the majority of the silt. The pre washed sand is then fed into a Linatex twin sand plant to further remove silt and dewater the sand. This plant then delivers the two grades of sand to stockpile via radial conveyors. Water ManagementBeing an essential part of the project DUO supplied a Tecnoidea multi-plate filter press complete with 68 plates. Situated in a penthouse structure 5m from the ground the press provides a fully automatic silt management system that is specifically designed and sized to minimise operator input and maintain low running costs. As well as the press, the system includes the foul water pump, automatic flocculent mixing and dosing plant with a SADF system which samples every 50 seconds, 7m diameter dynamic thickener tank with 140m³ storage in cone, 80m³ buffer sludge stocking tank with internal rake, 43m3 lime silo with automatic mixing and dosing tank and fresh water tank. Once in the thickener the silt settles to the bottom of the cone and is automatically discharged into a silt buffer tank where the lime is added. The quantity of lime is automatically controlled using a rotary valve which then feeds the lime onto a rotary screw which in turn feeds the lime into a mixing tank. At this point water is added to the lime to create a solution which is automatically distributed into the silt buffer tank as required. The lime solution reacts with any clay material in the silt to facilitate the water drainage in the press. The quantity of lime can also be adjusted depending on the quantity of clay in the silt to maintain throughput through the press. The installation of the new washing plant has been very beneficial for Eco Aggregates. Commenting on the success of the project, Paul Dalrymple, Business Development Manager said “Because we wanted to put a soils washing plant in what is effectively the green belt, the project has taken in excess of two years to become operational. Eco Aggregates and our parent company, Anderson Group, have worked closely with the County Council’s planners and other regulators to deliver an environmentally friendly aggregate recycling facility that will not only benefit the construction industry but also local communities, building companies and the environment.” “The facility at Welwyn Garden City will recycle over 1.5 million tonnes of C & D waste and recover over 1 million tonnes of reuseable aggregate during it’s time on site. Recycling at this level needs more than just a financial injection it needs an environmental commitment and a long term sustainable strategy. It’s fair to say that the success of this project has been heavily dependent on the support of Herts County Council, the Environment Agency and WRAP, without them the majority of the feedstock material would have been lost to landfill.” SHAP Goes DUOHaving enjoyed a six year working relationship as a supplier to CEMEX’s quarries at SHAP, Powerscreen Washing Systems Ltd has introduced Hydrex to provide the customer with a complete one stop package under the DUO brand.
DUO process 450,000 tonnes of blue granite per annum. This is supplied to a secondary CEMEX operation for final grading and supply as rail ballast. Dave Warwick, DUO Contracts Manager responsible for the SHAP project comments: “The figures speak for themselves. The demand for rail ballast with over a million tonnes of waste ballast being removed from trackside each year necessitates an ongoing requirement for new ballast.” Hydrex Warrington depot provides local facilities for service and maintenance. CEMEX Angerstein
CEMEX approached DUO to provide a complete aggregate processing plant to work in conjunction with their existing water management system. With an impressive range of capabilities and support structure, coupled with a quick turn around time DUO were successful in their bid to supply a 16,000 tpw wash plant. The plant designed to cope with 16,000 tonnes per week of sea dredged ballast fulfills the requirements of CEMEX and produces 10mm, 20mm and a concrete sand, with the +20mm being crushed by a Pegson Maxtrak 1000 cone crusher and re-circulated. Operation
The -5mm is fed into a Powerscreen Fines Master 120 where it is dewatered. Although the requirement of CEMEX called for only one concrete sand the Fines Master is capable of producing 120 tph of one or two grades of sand. (Renowned for maximum retention of fines and the dryness of the final product, this market leading Fines Master 120 machine was specifically requested by CEMEX). The concrete sand from the Fines Master is stockpiled via a T5032 conveyor. Foul water from this plant is then pumped into CEMEX’s existing water management plant which is positioned 50 mtrs away from the processing plant for conditioning. The clarified water is then pumped back for continued washing. OverallThe DUO capability of being able to provide a high performance processing plant when needed was a major advantage to CEMEX who can now provide their mass market with clean aggregate. The turn around time was crucial to CEMEX who did not want to leave a supply gap within the South London market. Rigorous health and safety demands applied by CEMEX also represented a key issue addressed by DUO. Eco Aggregates go DUO
Resplendent in its striking red livery the plant is the first venture for ECO into washing aggregate under a partnership agreement with Taywood. The plant is currently employed recycling material from the construction process for reuse, as part of the residential development of Colchester Garrison. PSWS Provide Efficient Recycling For KSDKSD Recycled Aggregates is a family owned business of some 35 years experience. Originally supplying haulage for the Construction Industry, the business has recently diversified and in 2000 the company acquired a 10 acre site at Coleshill near Birmingham.
In 2004 with the aid of a government grant and a five year planning permission KSD decided to purchase a washing plant and process the on site material, Powerscreen Washing Systems of Coventry were successful in tendering for a state-of-the-art washing plant complete with a water management system. Two of the main problems on site were the general lack of water and the inability to utilise lagoons due to the overall small footprint. This meant that a closed loop system was essential, the only water on site being a domestic supply. Working within a small footprint PSWS designed and installed a Powerscreen washing plant that included the very latest technology including a complete water management system from their Italian partner Technoidea. Production ProcessWith production of recycled aggregates currently at 80-100 tph on site material is fed by excavator into the tipping grid of a mobile Chieftain tracked 1400; this machines acts as the primary screen facilitating the removal of more silt out of the material. The machine is unique in that it has a patented 11’ x 5’ four bearing “free floating” screen box which eliminates the need for any fine tuning; as the material passes through the integral screen decks it feeds left onto a folding side conveyor providing a stockpile of +40, a direct feed onto the second conveyor providing a stockpile of top soil and a third folding side conveyor to the right feeds to the latest design of Powerscreen Recycling Logwasher.
In the production process any material from both the bottom of the recycled logwasher and final part rinser is then fed into Powerscreen Fines Master 60, static sand recovery unit where it is classified and dewatered. Working for maximum sand grade flexibility, the Fines Master Compact 60 produces a combined total of around 60 tonnes/h; comprising a single18” hydro cyclone, a centrifugal slurry pump, a collection tank and a high-frequency 8ft x 4ft dewatering screen fitted with 500µm polyurethane mats mounted on a single carrier chassis, the machine delivers one grade of course sand to stockpile.
Once in the thickener the silt settles to the bottom of the cone and is pumped into the Tecnoidea press. When the press has filled and drained the water, it opens and the silt cake drops down into a concrete bay below; the press then automatically cleans itself ready for another cycle. As in any application, PSWS selects the correct size of press and takes into account such factors as the silt content, clay content and settlement rate of the raw material. The flocculent mixing and dosing system maintains a continuous supply of clean water and automatically mixes a batch of flocculent solution when the level drops. An operator only has to add the powder to a storage bin. The installation of the new washing plant has been very beneficial as KSD can now sell three BS specified products of +20-40/+10-20/-10mm as well as a type ‘g’ general building sand. This has provided new markets for the sale of these construction materials to national construction companies at a local level. Additionally there are further potential markets in the sale of the dry silt cake which is now produced. Commenting on the success of the project, Site Manager, Brinder Bullar commented “We are very pleased with the materials that are coming off the washing plant, which are up to the high standards required by the construction industry. Our target was to produce high end recycled aggregates, which we are doing, the challenge now is to increase our presence in the market and establish recycled aggregates as an alternative in newer markets such as concrete batching.” World Class Sand ClassificationMaking its debut appearance at this year’s Hillhead exhibition the latest version of the Greystone Aggre-Spec Classifying System caused much interest on the PSWS stand. The new windows based Aggre-Spec V6™ Re-Blending System offers greater computing powers, efficiency and ease of operation than any other system currently available in the World.
Their latest version of the patented Aggre-Spec V6™ sand washing and classifying plant re-blending system, provides plant operators with a consistently maintained production of specification sand products, and the ability to store unlimited recipes and specified products within an automated Windows® -based controls system offering greater computing power and more user-friendly visuals on one screen. The advantages of the system are that it is percentage based; other DOS based systems generally use minimum and maximum timers, the Aggre-Spec system provides a 2% yield advantage due to the faster reaction time of the percentage method versus the minimum/maximum timer method. Additionally the system allows a stockpile sample to be inserted into the program which adjusts the calculations to bring the output into even tighter control. The user-friendly Aggre-Spec V6™ control program is designed for exclusive multi-tasking with other Windows® programs for data logging, trending and reporting, allowing operators to view both products on the screen at the same time. Its user-friendly design enables simple, immediate product specification changes without searching for "hidden" command keys of DOS-based re-blending systems. The system holds tight product specifications and reduces the possibility of out-of -specification material, automatically monitoring feed material to warn the operator of any potential mix or mechanical problems. Additionally plant management can also observe trends and predict potential sales with accurate production records. The Aggre-Spec V6 is accessible from a laptop, so producers have seamless control of their operation from any vantage point. Displaying real –time FM and yield graphs a stock pile analysis checks finished product against expected products and input settings. Furthermore a report module collects data, including FM, yield, feed gradation and output gradation, and stores in spreadsheet format for flexible reporting Additional features include:
Other design features include abrasion resistant liners in the feed box, rising current cells at the first three stations to improve classifying efficiency and a collecting flume which is fitted with abrasion resistant liners (urethane liners optional). Additionally the valve bridge utilizes stainless steel hydraulic tubing, allowing high pressure fluid to move the valves to open and close rapidly, allowing for an overall better response to the control system. With over 30 different classifier configurations to choose from,
any system can be custom designed to suit specific application
and production requirements. Retrofit is also available to
most existing classifying systems from other manufacturers. Considerable Success for PSWS at the Recent Hillhead Show
To complete the line-up group member LJH exhibited a trommel out of their standard range and a mobile picking belt, model MPB 1204. Containing a host of new design and safety features, the machine is used for manual picking, enabling safe and efficient picking of waste. PSWS would like to thank all the customers who attended the stand; Hillhead is a major show which takes some considerable planning and all its success is due to the visitors who come from all over the world. PSWS Provide Top Class Production For RMC CostesseyRMC Materials’ Costessey Quarry is the company’s third largest site in Norfolk and, in addition to aggregate processing, boasts a ready mixed concrete and mortar plant, as well as a full recycling facility. The quarry also supplies a nearby asphalt plant. Now part of CEMEX, the global building materials company, RMC Materials operates over 700 quarries, plants and units in Great Britain. The Costessey site plays an important role in the local construction materials market particularly in respect of supplying ongoing development in the city of Norwich.
Powerscreen Washing Systems of Coventry successfully tendered for a washing and screening plant that would produce high quality products whilst maintaining an efficient water management system. Supplied and installed by PSWS the plant deals with the problems of lagoons and their elimination through installation of a plate press providing a closed loop system for the whole operation. The plant is fed by wheeled loader into a 20 Tonne Commander 1400 feed hopper complete with remote controlled tipping grid; located close to the stockpile the material is fed onto an inclined transfer conveyor which delivers onto the primary screen, a Powerscreen 12 x 5 static rinser. Featuring six spray bars on the top and bottom decks the rinser is fitted with polyurethane screen modules. The vibrating top deck of the screen rejects all oversize material and delivers this to an adjacent ground stockpile via a T4026 radial conveyor. Any midsize material passes from the rinser and is discharged into a Powerscreen Powerscrub. Capable of producing up to 120 tonnes/h of contaminant-free sand and gravel, the Powerscrub 120R unit comprises an inclined trough fitted with two counter-rotating axles with high-tensile exchangeable blades and an elevated spray-bar system. The unit mixes incoming feed while milling and washing the material at the same time. Any lumps of earth or clay are broken down during this process and carried away in the wash water, while any lighter particles are floated off through specially designed outflow exits. Two spray bars are mounted at the discharge end of the unit to provide a final rinse.
The material from the bottom deck feeds a Powerscreen Fines Master 120 where it is classified and dewatered, working for maximum sand grade flexibility, the Fines Master 120 produces a combined total of around 120 tonnes/h of fine and coarse sand. Comprising a twin bucket wheel with 28 buckets, a centrifugal slurry pump, twin hydrocyclones, a collection tank and a high-frequency 12ft x 5ft dewatering screen mounted on a single carrier chassis, the machine delivers two grades of sand to stockpile via T4026 radial stockpile conveyors. As water management was an essential part of the project PSWS in conjunction with their partner Tecnoidea supplied a Multi-Plate filter press complete with 36 plates. Based on its impressive technical specification, quality of build and technical support, PSWS always work in tandem with Tecnoidea Impianti to offer a fully automatic silt management system that is specifically designed and sized to minimise operator input and maintain low running costs. As well as the press, the system includes the foul water pump, automatic flocculent mixing and dosing plant; 6m diameter dynamic thickener tank with pneumatic discharge valve; silt buffer tank with two stirrers; 43m3 lime silo with automatic mixing and dosing tank, fresh water tank; and all the support framework, structure, walkways and access platforms. Once in the thickener the silt settles to the bottom of the cone and is automatically discharged into a silt buffer tank where the lime is added. The quantity of lime is controlled using a rotary valve which then feeds the lime onto a rotary screw which in turn feeds the lime into a mixing tank. At this point water is added to the lime to create a solution which is automatically distributed into the silt buffer tank as required. The lime solution reacts with any clay material in the silt to facilitate the water drainage in the press.
As in any application, PSWS selects the correct size of press and takes into account such factors as the silt content, clay content and settlement rate of the raw material. The flocculent mixing and dosing system maintains a continuous supply of clean water and automatically mixes a batch of flocculent solution when the level drops. An operator only has to add the powder to a storage bin. Commenting on the success of the project, Mark Wood, RMC’s Operations Manager, said: “from initial quotation to the fitting of the last nut and bolt, PSWS have performed extremely well. Aspects such as build quality and the health and safety regime have been exceptional and any problems that have arisen have been dealt with efficiently and effectively”. The plant is now in the final stages of handover. |
More News
|
Tel.
024 7640 5100 Fax. 024 7640 5020
This is a completely new venture for Eco Aggregates who are part
of the Anderson Group and specialise in the cost effective recycling
of clean construction and demolition materials. 
Any midsize material passes from the rinser and is discharged into
a Powerscreen Powerscrub which is basically a three-in-one machine
which provides a water bath, scrubber and final rinse. Capable
of producing up to 120 tonnes/h of contaminant-free sand and gravel,
the Powerscrub 120R unit comprises an inclined trough fitted with
two counter-rotating axles with high-tensile exchangeable blades
and an elevated spray-bar system. The unit mixes incoming feed
while milling and washing the material at the same time. Any lumps
of earth or clay are broken down during this process and carried
away in the wash water, while any lighter particles are floated
off through specially designed outflow exits. Three spray bars
are mounted at the discharge end of the unit to provide a final
rinse.
When the press has filled and drained the water, it opens
and the silt cake drops down into a concrete bay below;
the press
then
self-cleans itself ready for another cycle. As in any application,
DUO selected the correct size of press and took into account
such factors as the silt content, clay content and settlement
rate of
the raw material. The flocculent mixing and dosing system maintains
a continuous supply of clean water and automatically mixes
a batch of flocculent solution when the level drops. An
operator
only has
to add the powder to a storage bin.
Complementing a Kleeman 122 Primary Duel Crusher and Warrior Screening
equipment Hydrex have supplied a Hitatchi 350 excavator, a Bell
40 tonne dump truck, a Volvo L120 loading shovel and a Volvo L150
loading shovel.
Angerstein Wharf is a key site for CEMEX due to its strategic
location in London. Last year their 16,000 tpw plant burnt down
meaning a shortfall in supply to the London market, and CEMEX without
a wash plant.
This high performance plant is fed by a wheel loader into a 20
tonne feed hopper with a remote control tipping grid; material
is then transferred onto an M100 feed conveyor. This conveyor feeds
the material onto a 16 x 5 full rinser which is fitted with polyurethane
modules on both the top and bottom decks. The material is then
injected with water through eight spray bars on both decks whilst
travelling over a high performance vibrating screen. The top deck
of this screen rejects the entire +20 mm product and delivers this
on to a T4026 conveyor to be crushed by a Pegson Maxtrak 1000 cone
crusher. This material is then fed back on to the primary feed
conveyor for processing.
The + 5mm to 20mm product discharged onto a T6532 Conveyor is
then fed onto a 16 x 5 dry screen for sizing; with the 10mm and
20mm being stockpiled by T5032 conveyors.
Duo Equipment of Coventry has recently supplied and commissioned
a new full washing and water-management plant for ECO Aggregates
in Colchester. ECO Aggregates are part of the Anderson Group who
specialize in cost effective recycling of clean and contaminated
construction and demolition materials.
Originally a landfill site containing approximately 1 million
tonnes of construction and demolition waste, KSD have for the past
four years operated a crushing and screening plant utilising imported
construction and demolition materials from the local area.
Capable of producing up to 120 tonnes of contaminant-free sand
and gravel, the new Powerscreen Recycling Logwasher comprises an
inclined trough fitted with two counter-rotating axles with high-tensile
exchangeable blades and an elevated spray-bar system. The unit
mixes incoming feed while milling and washing the material at the
same time. Any lumps of earth or clay are broken down during this
process and carried away in the wash water, while any lighter particles
are floated off through specially designed outflow exits onto a
6 x 2 trash screen. Two spray bars are also mounted at the discharge
end of the unit to provide a final rinse. Exiting the logwasher
the material is then fed onto an 8 x 4 single deck vibrating part
rinser, fitted with four sets of spray bars and polyurethane screen
modules the material is washed and then fed onto a static T4026
inclined transfer conveyor which feeds the material directly onto
the conveyor of a second “dry” Powerscreen Chieftain
1400 which again screens the material and delivers through its
three integral conveyors to provide stockpiles of +40/+20/+10.
As water management was an essential part of the project PSWS
in conjunction with their partner Tecnoidea supplied a multi-plate
filter press complete with 47 plates. Based on its impressive technical
specification, quality of build and technical support, PSWS always
work in tandem with Tecnoidea Impianti to offer a fully automatic
silt management system that is specifically designed and sized
to minimise operator input and maintain low running costs. As well
as the press, the system includes the foul water pump, GFA automatic
flocculent mixing and dosing plant, a SADF system which samples
every 50 seconds, 6m diameter dynamic thickener tank with pneumatic
discharge valve, sludge and fresh water tank; and all the support
framework, structure, walkways and access platforms.
Designed and manufactured by Columbus, Nebraska based Greystone
Inc the Aggre-Spec 111 system was originally introduced to the
American market in 1993 as the first windows based system in the
world. Since then Greystone have developed their range of Aggre-Spec
classifying systems and now offer the Aggregate Industries a ‘cutting
edge tool’ which offers even greater control and efficiency,
ultimately providing the producer with tighter specifications and
increased production.
Producers can now scalp excess water, reject excess material, separate
and size sand particles and re-blend up to 3 sand products including
2 controlled specification sand products simultaneously using single
or twin tank controls, and achieve an increase in production by
up to 15% over programs using single-method systems.
As good design is imperative long life wear parts are also an
important part of the in-built quality that the Greystone classifying
systems have; the classifying tanks now come with new urethane
discharge valves, the seats offering self-alignment which keeps
the valve centred in the seat providing maximum flow and a long
trouble-free life. With the introduction of these valves producers
can now achieve 25% more production from their classifying systems
and again these can be retrofitted to existing systems. Urethane
is also utilized in the directional discharge boots, producing
maximum flow with the optimum angle to reduce wear of the flume’s
abrasion-resistant lined bottom runners, urethane allows for maximum
boot wear.
The Powerscreen Washing Systems stand took centre stage at the
recent Hillhead quarry exhibition at Buxton, Derbyshire. A proven
market leader in washing and screening the company not only provided
a platform for the launch of the new company DUO (Europe) plc but
exhibited for the first time as a force in their own right providing
a plush air- conditioned hospitality suite complete with outside
patio area. All of the many visitors to the stand enjoyed the corporate
hospitality where graphic displays and three large plasma screens
featured all the latest company products alongside the many successful
washing and recycling projects of the last twelve months.
There was a continued high level of interest shown over the three
day show, many visitors were impressed with the quality of the
products exhibited and several orders were confirmed along with
a significant number of enquiries.
Exhibits on the stand featured some “significant firsts” for
the show; a Tecnoidea multi-plate filter press, which is the largest
in the range with an impressive technical specification, and quality
build, including a fully automatic washing system. A Greystone
multi-blend sand classification tank featuring controlled sand
re-blending seen for the first time in this country was also a
huge attraction for the many visitors to the stand.
Also on show was the new Powerscrub recycling Logwasher, the new
Powerscreen Fines Master 60 compact sand plant, and also a Chieftain
1400 tracked rinser, a highly robust, compact and easily manoeuvrable
machine offering low maintenance and low running costs.
Over the past few years the site has been reduced in size as land
was allocated to housing development; the original static plant
relied on lagoons for silt disposal and as the site diminished,
a decision was made to install a new plant with the technology
to manage water efficiently without the need for lagoons.
Midsize material is then fed onto a static transfer conveyor,
which in turn provides material to the final screen; identical
to the primary screen, except that it is fitted with a partial
rinsing system, it splits the material into three final single-size
products whilst recirculating foul water back to the Fines Master.
These materials - 10mm, 20mm and 40mm - are then delivered to their
respective ground stockpiles by three T4026 radial stockpiling
conveyors.
When the press has filled and drained the water, it opens and
the silt cake drops down into a concrete bay below; the press then
cleans itself ready for another cycle.