CPI – Concrete Plant International – 5 | 2013 www.cpi-worldwide.com 84 CONCRETE TECHNOLOGY Section 1 is located in Hall 1. The concrete mixing plant with a total of three concrete mixers is located here. Following the mixing process the concrete is transferred to one of the two bucket tracks and transported to the necessary place in the works. Section 2 is located in Hall 2. The post-treatment of was- hed concrete elements takes place in this area using high pressure water lances. Since the demands on the recycling process or the recycling plant respectively are diffe- rent in the two areas, a separate concept was developed for each area. However, these two systems are connected to each other via an interface. Hall 1 Since the largest quantities of residual con- crete accumulate in the area of the mixing plant, a Bibko recycling plant of type ComTec 20 was provided here. Quantities of residual concrete can be fed directly to the plant from the three mixers or the bucket tracks. Washing water accumulating during washing of the mixers and bucket tracks is similarly fed directly to the recycling plant. The costs of treating residual concrete are reduced significantly as a result. The actual recycling or washing process then takes place in the recycling plant, whe- reby aggregates > 0.2 mm (sand, gravel) and water with cement containing fines with a grain size < 0.2 mm are produced. Whilst Residual concrete recycling system for Irdon’s new precast plant in South Russia Bibko Umwelttechnik & Beratung GmbH, 71717 Beilstein, Germany When the newly-built precast plant in Schachtu (Russia) officially went into operation, this also represented a further milestone in the success story of Bibko Umweltechnik und Beratung GmbH, because the new plant’s equipment also includes a comprehensive recycling concept. The Irdon company’s plant mainly produces facade and wall elements as well as stairs. Depending on the customer’s wishes or project, untreated or washed concrete surfaces are manufactured. Therefore the Bibko recycling plant is divided into two sections. Flow diagram - Hall 1 and Hall 2 Hall 2 Hall 1
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CPI – Concrete Plant International – 5 | 2013 www.cpi-worldwide.com84
CONCRETE TECHNOLOGY
Section 1 is located in Hall 1. The concretemixing plant with a total of three concretemixers is located here. Following the mixingprocess the concrete is transferred to one ofthe two bucket tracks and transported to thenecessary place in the works. Section 2 islocated in Hall 2. The post-treatment of was-hed concrete elements takes place in thisarea using high pressure water lances.
Since the demands on the recycling processor the recycling plant respectively are diffe-
rent in the two areas, a separate conceptwas developed for each area. However,these two systems are connected to eachother via an interface.
Hall 1
Since the largest quantities of residual con-crete accumulate in the area of the mixingplant, a Bibko recycling plant of typeComTec 20 was provided here. Quantitiesof residual concrete can be fed directly to
the plant from the three mixers or the buckettracks. Washing water accumulating duringwashing of the mixers and bucket tracks issimilarly fed directly to the recycling plant.The costs of treating residual concrete arereduced significantly as a result.
The actual recycling or washing processthen takes place in the recycling plant, whe-reby aggregates > 0.2 mm (sand, gravel)and water with cement containing fines witha grain size < 0.2 mm are produced. Whilst
Residual concrete recycling system for Irdon’s new precast plant in South Russia
When the newly-built precast plant in Schachtu (Russia) officially went into operation, this also represented a further milestone in the success story of Bibko Umweltechnik und Beratung GmbH, because the new plant’s equipment also includes a comprehensive recycling concept. The Irdon company’s plant mainly produces facade and wall elements as well as stairs. Depending on the customer’s wishes orproject, untreated or washed concrete surfaces are manufactured. Therefore the Bibko recycling plant is divided into two sections.
Flow diagram - Hall 1 and Hall 2
Hall 2
Hall 1
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the aggregates are discharged via thescrew conveyor attached to the ComTecrecycling plant, the fines and the excesswater (residual water) run into the pumpsump via the machine’s water overflow. Inthis pump sump there is a pump that pumpsthe water with the fines into agitator tank 1.The agitator mounted in this tank preventsthe sedimentation of the fines, so that theyare kept in suspension. Residual water fromthis tank is used on the one hand to washthe hopper that receives the washing waterand residual materials from the bucket trackand mixer washing process and, on theother, to supply the Bibko material transportsystem with water. In order to make residual water availablefor the actual mixing process with the mostuniform, specific properties possible, asecond agitator tank was provided in theseworks. Whilst tank 1 serves to accept theunevenly accumulating residual water andto buffer it intermediately, the residual wateris pumped into tank 2 after a certain time,mostly in the morning on the following day.Fluctuations in the density of the residualwater and differences in the degree of che-mical reaction (hydration) of the cement par-
ticles during the course of daily productionare compensated in this way. Following thetransfer pumping process, agitator tank 2then contains residual water with a uniformdensity and uniform chemical properties.
The volume of the agitator tank is dimensio-ned so that the water requirement for oneday’s production can be covered by thistank. The adjustment of the concrete recipesor compliance with the prescribed specifica-
Recycling plant, type ComTec, with pump sump
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CPI – Concrete Plant International – 5 | 2013 www.cpi-worldwide.com86
CONCRETE TECHNOLOGY
tions is hence simplified considerably. Sub -mer sible motor-driven pumps installed direct-ly in the agitator tank serve to pump the resi-dual water to the mixing plant or to thewater weigher.
The density meter installed in agitator tank2 represents a further component for quali-ty-assured concrete production. The currentmeasured density values are made availa-ble to the plant controller continuously sothat corrections can be made if necessary.The quality of the end product can hencebe ensured at all times.
In order to make the cleaning of concretedistributors possible, a second pump sumpwas provided in the floor of the factory hallin the hall 1 area. This is part of the Bibkomaterial transport system and collects all ofthe material produced by the concrete dis-tributor cleaning process. Using water as a
transport medium, the residual material isfed to the ComTec recycling plant for treat-ment.
If the above-described recycling processshould result in an excess of water in the hall1 area, there is a possibility to pump thisexcess water into a multi-stage settling tank.Sedimentation of the fines is desired in thissedimentation tank, so that the last chamberof the settling tank contains clarified water.This clarified water serves the refilling of agi-tator tank 1, as washing water for the recy-cling plant and, if necessary, can be useddirectly in the mixing plant as mixing water.
Hall 2
In the post-treatment of washed concreteelements using high pressure water lances,the concrete surface, which has not yet setdue to chemical retarders, is washed out.
This uppermost layer, which is composed ofcement containing particles, sand and smallaggregates, is thereby loosened. This mate-rial is collected in a gully together with thewater used.
The material moves from there into theBibko type RWS recycling plant, where theactual recycling process then takes place.
Aggregates with particle sizes > 0.2 mmare discharged via the plant’s screw con-veyor, whilst the excess water (residualwater) with the fines < 0.2 mm runs into apump sump via the machine’s water outlet.In this pump sump there is a pump thatpumps the water with the fines into a multi-stage settling tank. The pump for transfer tothe hall 1 plant section is installed in the lastchamber of the tank alongside the rinsingpump for the collection gully for the was-hed-out material.
Overview of the Bibko plant engineering Concrete distributor cleaning area
Gully for receiving the material Gully to RWS plant transfer area
ComTec 20
Spray booth
Floor channelpump sump
Agitatortank 1
Agitatortank 2
Rinne
RWS
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In addition to the aforementioned process forthe manufacture of washed concrete ele-ments, there are some processes in the hall 2area in which acid is used. The water/acidmixture produced here is similarly collectedand fed to the first chamber of the settlingtank. This mixture thus leads to a reduction inthe alkaline pH value of the residual water of11 - 13.
Interface between the Hall 1 and Hall 2 areas
The transfer pump or transfer pipe repre-sents the interface between the two systems.If there is a lack of water for concrete pro-duction in the hall 1 area, it is refilled withwater from the settling tank in the hall 2area. In this way it is always ensured thatthere is sufficient mixing water available forconcrete production.
Summary
With the recycling concept from BibkoUmweltechnik und Beratung GmbH descri-bed above, all residual materials accumu-lating in the Irdon plant are fed to a com-prehensive recycling process. The sand andgravel contained in the residual material aswell as residual water with cement/sandfine aggregates are reused as aggregatesor residual water in the concrete producti-on. A closed material circulation is thuscreated. The high demands placed onBibko Umweltechnik und Beratung GmbHin the project engineering were completelyfulfilled. �
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