FOCUSWASHING

PLANT

A revolution in mobile washing

For more information or to book an advertisement in the next feature please contact:Telephone: 0845 680 0024 www.hub-4.com

CDE Global LtdBallyreagh Industrial Estate, Sandholes Road, Cookstown BT80 9DG Northern IrelandT: 028 8676 7900 F: 028 8676 1414 www.cdeglobal.com

NOVEMBER 2010

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nt Revolutionisingmobile washingequipmentAt the launch of the new M2500mobile washing plant during theBauma exhibition in Munich earlierthis year CDE Global promised todeliver a revolutionary product tothe mobile washing equipmentmarket.

The success of the M2500 to datesuggests this revolution is wellunderway with installations in manycountries including Ireland, UK,Germany, Poland, Australia, Turkeyand Lebanon.

“The success we have had throughoutthe world with the M2500 confirms thebelief we had that it represents anentirely new approach to mobilewashing” says CDE MarketingManager, Peter Craven.

The M2500 integrates a feed system,aggregate washing, sand washing andstockpiling system on a compact,easily transportable chassis and isavailable in a variety of configurations.There are 4 models available in therange allowing for the production of 2aggregates and up to 2 washed sandproducts.

According to CDE the integration ofthe sand washing element on theM2500 has been key to its success.“The existing mobile washing plantoffering required a separate aggregate

washing and sand washing systemwhich caused a lot of problems foroperators in relation to the efficienttransfer of material from one stage ofprocessing to another” explains SeanKerr, Senior Design Engineer on theM2500. “We have eliminated this issueand ensured that operators can nowchoose a complete sand andaggregate washing plant with adramatically reduced plant footprint.”

The integrated Prograde P2-75 screenon the M2500 also offers operatorsimproved aggregate washing whencompared to the previously existingmobile washing plant offeringaccording to CDE. “The Progradescreen is designed with washing inmind” says Sean Kerr. “This is incontrast to other rinsing screens whichare all too often dry screens with thecrude addition of a few spray bars.”

The Prograde screen is designed toensure maximum performance inrelation to the washing of aggregateswhile also considering ease of accessfor replacement of screen media andmodifications to the washing system.The double deck Prograde screenmeasures 5m x 1.5m and operatorscan choose the screed media to suittheir specific application. The designof the screen allows for wire mesh,rubber or polyurethane screen decksto be specified and should there be arequirement to change the type ofmedia at any stage this can be donewith no requirement to make anymodifications to the screen. This notonly ensures a degree of flexibility not

available from other similar systemsbut minimises the time spent onmaintenance ensuring maximumproduction from the M2500.

The M2500 has been designed forease of transport as can be seen inthe specification of the machine inAustralia, Turkey and Lebanon inparticular. “The M2500 is exclusivelymanufactured in Northern Ireland andthe success in securing installations inseven countries this year is evidencethat it represents an entirely new offerfor those with a requirement to washtheir material” says Peter Craven.

The new system from CDE can beused in the processing of a widerange of materials including sand andgravel, crushed rock, soils,construction and demolition waste andvarious mineral ores. “Theopportunities for further installations ofthe M2500 in 2011 are significantbased on enquiries we already have”says Peter Craven. “Securing the firstinstallations in some very importantmarkets will lead to many more as theM2500 is proved to be the mostefficient mobile washing plant on themarket.”

Further details on the M2500 andother products from within the CDEwashing equipment portfolio can befound on their web site atwww.cdeglobal.com.T: 028 8676 7900

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Finedoor Ltd is a family ownedand run business which has beenestablished for over 25 years. Thebusiness is comprised of adynamic group of professionalswith one aim - to provide bespokequarry and recycling solutions toour customers.

With a customer base across thewhole of the UK and Ireland from themajor quarry groups through to thesingle site owner operators plusinternational sales in territoriesincluding Middle East, West Africa andIndia. The sales vary from the supply ofspares through to replacement andnew machines to the design, detail andsupply of all necessary components fornew, or upgraded plants.

In order to provide turn-key solutionsFinedoor has established a portfolio ofpartners that has enabled them to offera broader portfolio.

As a result of this an agreement wasreached with SOTRES S.A. of Franceto distribute their range of sandwashing and effluent treatmentequipment in the UK

SOTRES Sand Plants:

SOTRES has been a specialist inwashing and preparing concrete sandsin quarries and pits for more than 25years.

SOTRES designs and manufacturessand washing units based on samplesanalysed in their laboratory or on theresults of analyses supplied by theclient.

These elements mean that they canoffer units designed to meet qualityrequirements (particle size, curve,cleanliness).

The sand processing units arecomposed of modular elements whichmean that they can produce standardassemblies for the simplest installations

or adapt the sand processing units tosuit each site's requirements and thematter to be treated.

Working principle:

The water and sand are collected inthe tank. The pulp which is conveyedby a centrifugal pump feeds thecyclone tangentially. The centrifugalmovement inside causing liquid-solidseparation.

The clay, waste and ultra-fine particlesare removed by suction by theoverflow. Centrifugal force makes thesolids and heavy elements spiral downthe cone, which are rejected onto thedewaterer.

Featuring a rising slope and fitted withtwo vibrating motors and slottedscreens, the dewaterer track makesthe sand move along its whole length.

The outlet chute collects the dry sandand dewatered undersize elementsreturn to the tank.

Offering all possible permutationsthese modules can also standcompletely alone to meet installationrequirements, in particular formodifying existing installations.Processing requirements may result inthe need for: single, double or triplestage cycloning, with or withouttechnical separation. Thesespecifications are determined fromanalyses of the products to beprocessed and the results to beachieved.

Current Installations:

Earlier this year Finedoor installed thefirst mainland SOTRES compact 80tphfor Lightwater Quarries at their PotgateQuarry near Ripon. Well established,the quarry supplies a hard magnesianlimestone for road construction andother applications throughoutYorkshire.

With a busy operation of this nature itwas of prime importance that theprocessing plant operates efficiently;however it had become apparent thatthe existing screw/bucket dewateringunit was losing fine sand to the settlinglagoons. It was therefore decided afterconsultation with Finedoor that it wouldbe beneficial to replace the inefficientunit with a modern hydro cyclone sandtreatment unit.

With a requirement that the new unitmust recover 100% passing 150micron Finedoor guaranteed theperformance and offered a suitable unitwhich was available for immediatedelivery from their sand processing andwater treatment partner SOTRES SA inFrance.

Installed during a holiday period initialgrading taken after a few days aftercommissioning reflected excellentresults, with tests on the waste waterindicating nothing passing 75 micronwas entering the lagoons.

Capable of producing up to 80tph theSOTRES unit supplied is a compactsand plant featuring a galvaniseddewatering screen unit which issupplying a single grade of sand.Finedoor also supplied a Warmanpump specifically supplied 'one sizeup' to minimise wear. Finedoorengineers commissioned the sandplant and all the civils were provided byLightwater engineers.

Kevin Parker - General Manager,commented, "It was clear to me thatSOTRES have plenty of experience insand plant design and their confidencein their product made the purchasingdecision easy. Finedoor gave goodsupport and ensured the plant wouldslot into place in the short shutdownperiod and despite the bitter weathereverything went to plan."

SOTRES Sand Washing and EffluentTreatment Equipment in the UK.

STOP PRESS:

Finedoor has just installed andcommissioned a SOTRES QuarryWaste Water Treatment Plant for aclient in Yorkshire. Designed toeliminate the on-site lagoon theplant will effectively deal withspecified rates of waste water andmud from the wash plant and isspecifically designed for lowmaintenance and running costs.

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T: 0113 252 7601www.finedoor.co.uk

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Leicestershire-based WilemanEngineers Ltd designed, installedand commissioned the mainprocessing plant to Hills QuarryProducts' specific requirementswith great success.Erection of the low-level plant (allelements are less than 8m in height)was completed during summer 2009,with final commissioning taking placeduring October and November.It is designed to wash and size theprimary screened 'as dug' sand at amaximum throughput rate of 180tonnes/h to produce, in conjunctionwith a Linatex sand plant, a full rangeof washed sands, single-size gravelsand ballast materials for supplythroughout Dorset and neighbouringSomerset. The plant is equipped witha PLC system, supplied by BridgesElectrical, which controls all aspects ofits operation, such as feed rate andstart/stop sequencing. In addition, allconveyors are fitted with rotationsensors to facilitate unmannedrunning. The quarry's weighbridge and ticketingoperations are conducted through acomputerized system supplied byAvery Weigh-Tronix.Recovery of material from the surgepile is achieved via a 30m long x 3mdiameter Armco-type tunnel, suppliedby Asset International. A rubber-linedchute in the roof of the tunnel feedsmaterial, via a Rowecon motorizedcut-off gate, on to a variable-speedbelt feeder which, in turn, dischargeson to a 160m long x 800mm widetroughed and part-inclined tunnelreclaim/field conveyor for delivery tothe plant. The belt feeder is PLCcontrolled via a Siemens Acumassbelt weigher to maintain a consistentfeed from the surge pile to theprocessing plant at the desired rate.On arrival at the processing plant, the-50mm material is fed in to a HewittRobins 4.2m x 1.8m double-deckwashing screen equipped with SCSpolyurethane deck modules. The topdeck cuts the material at 40mm whilethe bottom deck cuts at 5mm. Any+40mm rejects are sent, via conveyor,to a ground bay for subsequentreprocessing by a mobile crusher,while the -40mm +5mm fraction isconveyed to a Wileman 2M3 Pnu-Drive 2m diameter x 3m long contraflow scrubber barrel for attrition torelease the sands and clays ahead ofthe final grading screen. Fresh waterfeed requirements to the washingsection amount to approximately1,100 gal/min.The second and final screen is aHewitt Robins 4.2m x 1.25m double-deck horizontal screen. Once again,both decks are fitted with SCSpolyurethane modules, the top deckcutting at 20mm and the lower deckcutting at 6mm and 10mm. Any 5-6mm product is sent to a groundstorage bay while the 6-10mm and

20-40mm fractions are conveyed totheir respective ground stockpiles by apair of static inclined conveyors.The predominant 10-20mm fraction isconveyed to its ground stockpile by aradial conveyor.All the stockpiling and transferconveyors used within the plant arepowered by Renold drives andgearboxes of varying sizes andequipped with either 800 or 600mm

wide x 500/3-ply all-nylon belts withrubber covers, supplied by RAPConveyors. The conveyor drive shaftsrun in INA FAG self-aligning ballbearing plummer blocks, while thebelts themselves travel on 102mmdiameter three-roll, equi-length, drop-in idler sets with sealed-for-lifebearings supplied by Rulmeca UK Ltd.Scraper sets from RH ConveyorServices are fitted under all headdrums for belt-cleaning purposes.Meanwhile, the sand and finesreleased by the washing screen andthe scrubber barrel are pumped to theholding sump ahead of a Linatexcompact sand plant and dewateringscreen system. Some 1,150 gal/min ofwater and up to 100 tonnes/h of -5mm solids are pumped from thesump to the centre of a1.22m diameter Linatex S-Typeclassifier. Here, the coarse fractionreports to the base of the classifiervessel and is extracted by a Linatex200/150mm bore pump and fed to aLinatex 660 G4 hydrocyclone. Thisapparatus washes and thickens theproduct, removing -75 micron materialvia the overflow while the underflowdischarges 'coarse' sand on to aVD15 dewatering screen, whichremoves the free moisture prior tostockpiling via conveyor.Concurrently, the overflows from theS-Type classifier and the coarsehydrocyclone are directed to acollecting sump and then pumped by

a 150/125mm bore pump to a Linatex375 G4 hydrocyclone. As before, thisunit washes and thickens the productand removes, via the overflow, anyunwanted -75 micron silts and excesswater. This time however, theunderflow discharges 'fine' sand on tothe VD15 for dewatering prior tostockpiling. The single dewateringscreen is fitted with a dividing platedown its length, to maintain separationbetween the coarse and fine sands.

Silt and excess water from the sandplant is discharged to a ground sumpwhere a Warman 150SP vertical pumpdelivers the liquor through 300m of280mm diameter HDPE fused pipework to the quarry's silt lagoons.Connected by a series of channelsand with a potential silt storagecapacity of 98,000m3, these allowhindered settlement of the solids andprovide clean water for re-use in thewashing process. The clean waterpump, a 37kW Flygt electricsubmersible, delivers 350m3/h backto the plant via 360m of 250mmdiameter HDPE fused pipe work.The loading out and rehandling of thefinal sand and gravel products iscarried out by a Volvo L120F wheelloader equipped with an on-boardweighing system, with deliveries tocustomers being made by thecompany's franchised vehicle fleet aswell as additional contract hauliers, asrequired. The Volvo L120F loader isalso used to feed aggregate materialsto Woodsford Quarry's on-site readymixed concrete plant.

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wilemanwww.wilemanengineers.co.ukT: 01530 413477

Aggregate Washing Specialists

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The Powerscreen® Aggwash wasvoted the winner of the SeriesInnovation Category at the 2010World Demolition Awards. Thenew concept is a development inmobile wash plant which unifies forthe first time rinsing, screening,scrubbing and sand washingcapabilities on a singletransportable chassis.Launched in June 2010, the Aggwashwas previewed at the Hillheadexhibition by DUO (Europe) plc, the UKPowerscreen Washing distributor.Award Winning Features:Primarily designed for the processingof construction & demolition waste theAggwash is equally suited to virginmaterial applications and is capable ofproducing 4 grades of aggregate andup to two grades of sand at up to 60tonnes per hour. Electrically poweredand delivered pre-wired, it is perfectlyat home for operations in built-upareas, which are subject to noise oremission controls.Drawing on its mobility, quick set-uptime (approx. 1 day) and versatility inoperation, the Aggwash is an essentialtool for any small to medium sizedmulti-site operator, or contractors'fleet.A key design feature of the Aggwash isits ability to offer operators the flexibilityto quickly and easily re-locate acomplete wash plant operation,thereby eliminating the need formachinery duplication. Additionally, theAggwash also allows operators towork in space and emissionconstrained sites because of itscompact size and zero exhaustemissions.The Aggwash is typically capable ofproducing 5 saleable products and 1trash product, some of these saleableproducts include; ferrous metal, finesand, coarse sand, 5-10mmaggregate, 10-20mm aggregate, 20-40mm aggregate and +40mmaggregate. The polyurethane screenmeshes can also be easily changed toproduce different grades of stone asrequired.

Awards Ceremony:The World Demolition Awards, held inAmsterdam on 5th November 2010,were judged by industry figures fromthe demolition, construction safety, andrecycling, mining and environmentalsectors. Within the panel there were awide range of industries representedwhich led to a host of diverse opinionsand views. The ability of the Aggwashto service the needs of so manyapplications was just one of thereasons for its success. The fiercecompetition from within the categorymade winning the award even sweeter,with the Aggwash fending offcompetition from Caterpillar, Liebherr,LST Group, Komatsu, Volvo andSagro.Water Treatment:DUO, within their wide productportfolio, offer a mobile watertreatment plant in the form of acentrifuge that compliments theAggwash, eliminating silt and waterbeing despatched to a lagoon. Centrifuges dewater sludge on acontinuous process using the principleof centrifugal force. They are becomingmore popular in the aggregatesindustry due to their compact sizerelative to the production levels, theirlower capital cost and their loweroperating costs. They produce a drysilt cake typically ranging from 35% to45% moisture.The centrifuges that DUO distributesare manufactured by Gennaretti whohave over 10 years' experience inprocessing silts from aggregates.Gennaretti are so confident in thequality of their products that they offera warranty of 5000 hours on the mainwear part of their machines.

In addition to the centrifuge, the DUOWater Treatment Package includeseverything required on site includingautomatic powder flocculent mixingsystems, thickeners, water tanks andsludge tanks.DUO Aggwash and WaterTreatment Projects:Two of the latest Aggwash projects tobe installed by DUO will both bereceiving full washing and watertreatment plants. One will be installedprior to Christmas, with the secondfollowing early in the New Year.The installations at both sites willprovide processing facilities for up to60tph of feed material. The system willfloat out any unwanted lightweightmaterials such as polystyrene, plasticsand wood. Once the lightweights areremoved the aggregate is washed,sized and stockpiled; all on onechassis.The closed-circuit water treatmentplant compliments the Aggwash byremoving silt from waste water andreturning it back to the wash plant tobe reused; thus reducing the waterconsumption and removing the needfor a lagoon.DUO are looking forward to invitingpeople to visit both sites in the nearfuture.For further information please contactDUO (Europe) plc.

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T: 0845 22 22 386 E: office@duoplc.comW: www.duoplc.com

Award Winning PowerscreenAggwash a big hit for DUO!

The Award winning Aggwash at work

DUO Mobile Water Treatment Plant.

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Hanson Aggregates maximise efficiencywith a Latham International Filter Press.

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Hanson Aggregates UK Ltd.produce construction materialsthroughout the UK includingcrushed rock, construction sandand gravel, asphalt, premixconcrete, and mortar anddecorative aggregates, rail ballast,agricultural and burnt lime; armourstones, granite paving, dimensionstones, and recycled aggregates. When Hanson Aggregates at WhatleyQuarry decided that they needed moreefficiency in separating the water fromthe sludge, slime and slurry after thewashing process, they selected a fewspecialist companies within thefiltration industry to fully investigateviable solutions.

They were advised to trial both a beltand a filter press to evaluate whichmachine would provide maximumefficiency in separating the used waterfrom the slime and slurry. Arriving at the final most successfuloutcome would be beneficial and costeffective in two different ways; thewater captured from the filtrationprocess, could be recycled, and usedrepeatably in the washing process ofthe aggregates. Additionally, the cake(dry soil/slurry) could be used aslandfill in this quarry or any otherquarries throughout the company andthe UK.

During the trial period, it was foundthat the Latham plate filter pressseparated more water from out of the

slime/slurry when compared withthe belt press, hence

HansonAggregatesdecided that LathamInternational Ltd, commencedesign and commission of a2000mm x 1500mm Filter Press, with139 separate release chambers withfilter cloths, each chamber measuring2.0m x 1.5m x 40mm in thickness,with 15 bar operation pressure.

The complete automated cycle withthe Latham International Filter Presstakes around 45 minutes, and leaves afilter cake, weighing on average, 0.16tonnes, which equates to around 22-24 tonnes per pressing. The test alsoshowed an achievement ofapproximately 85% dry solidsoperation at 11bar during the cakeformation state.

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www.lathaminternational.comT: (0)1782 565364

Product Focus Nov 10 6/12/10 16:16 Page 6

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Some five years ago a customer came to SE Davis &Son with a problem they thought Redditch-basedconstruction and quarrying plant for hire companywould be able to solve. As a result of undertaking thesurface dressing contract with a particular countycouncil over several years the customer had amasseda stockpile of several thousand tonnes of 'waste'chippings, the excess that had been swept up duringthe surface dressing operation.

These chippings were too valuable to 'write off' and disposeof, but not clean enough to be reused. The main problemfaced by SE Davis & Son was that they were stockpiled ona disused airfield miles from the nearest water supply andthere was not sufficient space (nor environmentalpermissions) for settlement lagoons.

SE Davis put together (by today's standards) a 'Heath-Robinson' solution that achieved the desired result andwashed and screened the waste chippings into a reusableproduct.

It was a very steep learning curve and in the years that havefollowed the company has - as a result of theknowledge and experience it has built up - refinedthe process into the mobile washing systemsthat it currently operates.

In addition to the mobile centrifuges,cyclones and sand-plants that SEDavis & Son now operates, in late2009 the company finishedconstructing the mobile plant that itused to wash the 'waste' surfacedressing chippings for seven countycouncils' contractors this year fromas far afield as Norfolk and Kent.

The number of councils that the company is washing for isgrowing year on year as it is not only cost effective for thembut it is also kinder to the environment. As well as theobvious cost savings achieved by recycling the 'waste'chippings instead of importing new, the 'green' benefitsspeak for themselves. These include often recycling inexcess of 90% of the 'waste' chippings and reducing thecarbon footprint by not having to haul new chippings in fromthe nearest hardstone quarries, which are often over 100miles away.

The plants have also been used to great success to washother recycled aggregates including used railway ballast anda recycled 6F1/Type1 to produce a +20/-40mm drainageaggregate, a +10/-20mm recycled pipe bedding, and +4/-10mm recycled pipe bedding and a recycled sharp sand.

www.sedavis.co.uk T: 01527 893343

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Every aspect is covered, includingthe latest innovations in waterclarification and silt recovery -with the expertise to deliversolutions in harmony with planningand environmental restrictions -and market-leading on-site back-up and support.As well as Terex Finlay, the company -part of the Finlay Group - also holdsPilot Crushtec and TRIO dealerships,as well as the Italian Centrifugemanufacturers Baioni.John Dunne, MD of AggregateProcessing Solutions, said: “Weintroduce machinery on site, from an'off the shelf' design and enhance it toa specification that meets the exactneeds of the client - leading to thedelivery of high volumes of product,combined with significantenvironmental benefits.”Aggregate Processing Solutionsrecently opened a new office inCambridge to support the work of itsheadquarters in Stafford and give aplatform for growth in the southernregion.An example of the company's 'off theshelf' expertise is demonstrated atLafarge Aggregate's Mangreen Quarryin Norfolk.The Terex Finlay MP300 - featuring aCedarapids 16' x 6' triple deckwashing screen, the proven Terex-Finlay 206 Logwasher, a productdewatering screen and two productdischarge conveyors - is itself areused system for Lafarge Aggregates. Along with a Terex Finlay TC15Hydrocyclone Sand System, it wasoriginally introduced under a contractbasis to Lafarge Aggregates'Brooksby Quarry in Leicestershire,where it was used to initially open upthe site and prove the products to themarket.

After a successful two-year period atthe location, Lafarge Aggregatespurchased the plant - which hadproduced 500,000 tonnes of material -to their new Quarry at Mangreen,where it is processing on an ongoingbasis.

The MP300 and TC15 combination issupported by a Terex Finlay 390Feeder, again brought from BrooksbyQuarry and a new Finlay 683Hydrascreen three way split scapling,screening and stockpiling unit has alsobeen supplied by AggregateProcessing Solutions. The complete system enablesMangreen, which produces highquality glacial gravel with a significanttop coating of clay - to produce aclean product to a high volume - to40mm, 20mm, 10mm and oversizeproduct, as well as soft and sharpsands. The flexibility of the plantenables sizes to be changed.See a video of the plant at www.youtube.com/user/finlaygroup#p/u/11/OGZGT9a-IYAwww.apswashing.co.uk

Aggregate Processing Solutions (APS) Ltd Lakeside House Ladford Covert Industrial Park Seighford Stafford ST18 9QLTel. 01785 282360Fax. 01785 282991Email finlay.technical@btconnect.com

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Aggregate Processing Solutions provides a bespoke,turnkey solution in the provision of screening-washingand crushing equipment - be it selling completesystems, the hire of process equipment or contractprocessing on a price per tonne basis.

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Editorial Schedule 2011Feature Exhibitions Type

Jan Mobile Equipment for the Recycling and Quarrying industries Mag

Feb Weighing Systems Email

March Regional Focus - Australia Email

April Asphalt Plants/Recycling/Storage Systems Mag

May Bulk Handling Systems MHEA May Email

June Plant & Vehicles PAWRS/Futuresource Email

July Crushing and Screening Mag

Aug Spare parts/used equipment Email

Sept Waste & Recycling RWM Sept Email

Oct Conveyor Systems Mag

Nov Washing plant Email

Dec Drives & Transmissions Email

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