Materials Handling | Recycling | Quarrying

Materials Handling | Recycling | Quarrying

Check out the very latest industry news at

www.hub-4.comIssue 7

DUO (Europe) plc T: 0845 22 22 DUO F: 0845 22 22 387 W: www.duoplc.com386

hub cover issue 7 23/10/08 12:24 Page 1


1

There’s more toquarries thanmeets the eyeQuarries are visited not only by those whoseprime concern is to extract aggregate andother material from the ground. The widerpublic – whether knowingly or not – access

quarries for a variety of reasons. Often they are simply old quarries,which have provided suitable sites for a diverse range of new usesfrom shopping malls to nature reserves. Indeed, this editor regulardives in what used to be an old cement works in Somerset. But it’s notjust old quarries that have to adapt to and welcome the widercommunity, it’s working operations also.

Archaeologists are among the frequent visitors to quarries around thecountry. Quarrying has resulted in many interesting archaeological findsand the industry has become a major funder of digs. Take for examplethe CEMEX site at Kingsmead featured in this issue, where a significantNeolithic find required accommodating an archaeological dig. Cemex isfunding the £5 million archaeological study at the site.

This is just one find in a long association between quarries andarchaeology. Quarries have even been referred to as ‘laboratories oftime’ and, in the 19th century it was the results from deep sequencesfrom a quarry that established the geological time depth of the planetand, thus, overturning scientifically the Ussher chronology, devised inthe 17th century when Bishop James Ussher suggested the world wasformed in 4004BC!

Biodiversity brings in other visitors to quarries because, contrary totheir image, many provide wildlife havens. In fact, according to MineralsUK, 20% of all Sites of Special Scientific Interest (SSSIs) in the UK arelinked to minerals extraction. Many of the UK’s best angling lakes,nature reserves and recreational sites have been created from formersand and gravel excavations. The Kingsmead site also hosts a topangling venue. CEMEX’ commitment to this activity is considerable:with 40,000 members, CEMEX Angling is today the largest commercialangling organisation in the UK, offering over 70 mature, fish-filled lakesand 20 stretches of river.

The QPA Restoration Awards held in the summer celebrated the stepsoperators continue to take to restore quarried land to beneficial after-uses and reward some of the best examples of sustainable practice.Hanson Aggregates’ Otley Quarry in West Yorkshire, which has beentransformed into a first class nature reserve, won the coveted top prizefor outstanding quarry restoration: the Cooper-Heyman Cup. Theformer sand and gravel operation displayed leading practice onrestoration for wildlife, going far above and beyond the level expectedby planning authorities.

Eton Aggregates’ Dorney Lake in Berkshire won the Chairman’s Trophyfor the social contribution it has made, locally, nationally andinternationally. Dorney Lake has been restored to a 2200 metreOlympic standard rowing course, park, arboretum and natureconservation area, and will be used for the 2012 Olympic rowing andcanoeing events.

The QPA has found that the industry’s land holdings amount to over300 km2 - equivalent to the area of a National Park such as the NorfolkBroads. This land provides real opportunities for the industry toincrease its contribution to UK biodiversity.

It only takes the right planning and management to minimise many ofthe negative environmental effects of quarrying. More of the kinds ofefforts demonstrated here will help to build closer relationship with localcommunities and in so doing will not only help individual quarries intheir daily operations but will also promote a more positive image forthe industry as a whole.

Ross Matthews - Editor

Ross Matthews - Editor07711 347701Email: [email protected]

Lloyd Arkill - Contributing Editor01923 777897Email: [email protected]

Daren Thomas - Sales Manager0845 680 0024Email: [email protected]

Linda Rainbow - Sales & Marketing Administrator0845 680 0024Email: [email protected]

Hub Digital Media Limited33 Church Street, Rickmansworth, Herts WD3 1DE

Autumn 08

www.hub-4.com

CONTENTSNEWS page 2

COVER STORY page 8

RECYCLING page 13Wind of change

Wheeldon scores a hatrick

Waste industry feels the grab of material handlers

Tyrone Brick resolves waste issues

New service for customers

Long-term investment in efficiency and emissions protection

Preferred supplier for waste management company

Black gold

QUARRYING page 25Kiln support roller shaft at Lafarge

Just the job for Baryte processing

Soil washing plant in the front line

Newbold quarry installs five new screens

Asphalt screen project goes smoothly at Minffordd quarry

Double success for Stelex in the gulf

On-site weighing and load management

system for Tarmac

DUST MANAGEMENT page 35Instrumental in maximizing potential

Explosion-proof controls enable dust free loading

INMALO takes on DustBoss distributorship

NEWS FROM RWM 2008 page 41

FINES SCREENING page 45

MATERIALS HANDLING page 47

Denby meet stringent quality standards with

magnetic filters

CONVEYOR FOCUS page 48

PRODUCTS page 62

Hub-Mag-Issue-7 23/10/08 11:06 Page 1

2

www.hub-4.com

new

s Marine aggregatesindustry teams upwith environmentalgroups to launchjoint marine billstatementThe British Marine Aggregate Producers’Association (BMAPA) has become a signatoryfor a joint statement on the Marine Bill thathighlights areas of common agreement onthe draft Bill with fellow seabed users. Thejoint statement between the Seabed Userand Developer Group (SUDG), to whichBMAPA belongs, and the Wildlife andCountryside Link (Link), shows how themarine sector and environmental interestgroups can work together to ensure thesustainable development of the marineenvironment.BMAPA has been at the forefront of theconsultation process on the draft Marine Billsince its launch on 3 April. Director ofBMAPA, Mark Russell, commented on theBill: “From the marine aggregate sector’sperspective, the Marine Bill represents anunprecedented opportunity to deliver a moreconsistent and robust policy and planningenvironment across UK seas, against whichindustry operators should be able to takemore confident business decisions.”And welcoming the joint statement, he wenton to say: “The fact that UK marinedevelopment interests have been able todevelop a common position with theenvironmental NGOs on the Bill demonstrateshow far both sides have come in workingtogether, and shows the degree of commonground that exists between both interestgroups in securing the sustainable use of UKseas. While the Bill sets out some very positivehigh level principles, inevitably the devil will bein successfully delivering the detail over thenext few years.”BMAPA’s positive welcome for the jointstatement was echoed by Lisa Chilton of TheWildlife Trusts, an environmental signatory:“We are delighted that we can stand togetherwith the SUDG in support of Marine

new

s

www.hub-4.com/usefulsites

Construction sector “bleak, not terminal”Neil Edwards, chief executive of trade association and market intelligence provider Builders’Conference, believes that the current outlook across the construction sector is bleak and that furthercost-cutting and redundancies are inevitable.New statistics from trade association and market intelligence provider Builders’ Conference highlight asharp decline in tenders and workload in the house building and other key construction marketsectors. “According to our latest figures, the number of projects currently being tendered for in the firstsix months of 2008 is 10% down by number and 25% down in value on the same period in 2007,”said Neil. “We have also seen a number of companies being forced to refocus their attention on less

profitable but more reliable sectors such as education and health.” Neil further believes that the current downturn will last till “atleast January 2009”. He said: “Our figures indicate that the entire building and construction sector is unlikely to see any upturnthis side of the New Year,” he adds. “Further cost cuts and job losses are inevitable, unfortunately.”Yet, while he is concerned at the short-term future for the construction sector in general and The Builders’ Conference membersin particular, Edwards says he believes the current crisis to be a “correction rather than a collapse” and that most companieswill retract rather than shut-down.

Conservation Zones, marine planning and other key elements of the Bill thatare essential for sustainable management of UK seas.”The joint statement on the draft Marine Bill was similarly welcomed byJonathon Shaw, Marine and Fisheries Minister, as a highly beneficialcollaboration for the future of the seas: “This joint statement between industryand environmentalists is a great example of how we can all work together toget the Marine Bill right and ensure clean, healthy, safe, productive andbiologically diverse oceans and seas for future generations.”The joint statement coincided with SUDG launching a brochure entitled‘Sustainable Development and the Sea’ that sets out an industry perspectiveon the Marine Bill. Commenting on the brochure, Chairman of SUDG PeterBarham added: “This brochure highlights how a Marine Bill that provides betterregulation and marine management that benefits both business and theenvironment will help ensure the sustainable development of our seas. We areboth proud and pleased to have set out our aims and objectives in thisbrochure.”

www.hub-4.com/usefulsites


3

new

s

ww

w.h

ub-4

.co

m

www.hub-4.com/directory/1890

Hill signsAuto-locquick hitchdeal with USdistributorHill Engineering has signed anagreement to supply its ‘SafetyFirst’ Auto-Loc excavator quickhitch to Woods EquipmentCompany, one of the USA’slargest independentmanufacturers and suppliers ofconstruction and agriculturalequipment attachments.Woods Equipment Companyprovides customers in the USAand Canada with a largeselection of attachments forexcavators, wheel loaders,tractor loader backhoes andskid steer loaders. Auto-Locsare now being manufacturedby Hill and delivered to Woodsfor sale in the United States.All hitches are produced atHill’s factory in Newry, Co.Down, Ireland. Invest NorthernIreland has helped HillEngineering to ramp up itsoverseas marketing capability,as well as significantly improveproductivity and efficiency atits Newry factory. The supply deal was signed byHill’s founder and managingdirector, Ian Hill, andrepresentatives of WoodsEquipment Company at theCONEXPO 2008 event in LasVegas. Ian Hill said: “The salesagreement represents a majorbreakthrough for us as it givesus inroads into Woods’ vastdistribution network of morethan 2000 constructionequipment dealers acrossNorth America and Canada.” Woods Equipment Company’schairman, president & CEO,Fred Korndorf, said: “TheAuto-Loc is fully automatic,with a visible safetymechanism, so there is noneed for the operator to leavethe excavator cab to removeor insert a safety pin whenchanging from one attachmentto another. This rules out therisk of a safety pin beinginserted incorrectly or notbeing inserted at all, which iswhy we consider it to be thesafest and best engineeredquick hitch on the markettoday.”

German‘workingexhibition’providesgateway forHippowash’sentry intoEuropeanmarket

As part of its strategic expansion, leading wheel washer manufacturer Hippowash hasappointed Mick Walley as its International Business Development Manager. Based inGermany, Mick has extensive experience in the international wheel washing arena and tolaunch the Hippowash brand onto the European market place the company exhibited atthe SteinExpo bewteen 3-6 September 2008. Similar in format to the UK’s Hillhead Show,SteinExpo is a ‘working exhibition,’ situated in Europe's largest basalt quarry, north ofFrankfurt at Homberg/Nieder-Ofleiden.On show at SteinExpo for the first time was its new automatic sludge discharge system,which eliminates onsite manpower requirements. Hippowash’s sales and marketing manager Carol Godfrey is excited about the future andas she concludes: “We are confident we have world beating designs and SteinExpo is theideal launch pad for our entry into the European marketplace.”

CEMEX launches first Sustainable Development Report



CEMEX has launched its firstSustainable Development Report tobuild on its corporate reportingframework, which was launched in2006, and shows that improvementshave been made in a number of areas,most significantly in the areas of healthand safety, where employee lost timeinjuries reduced by 56%, alternativefuels use, which increased by 52% andrail and sea freight, which rose by 36%.CEMEX has found that as a result of itsapproach to combine visible leadership,training and worker involvement initiatives,improvements can be achieved byrecording a 56% per cent drop (from 41 to18) in employee lost time injuries in 2007. During 2007, CEMEX UK increased the useof alternative fuels to part replace fossilfuels, such as coal, to heat its cement kilns.This included chipped tyres and Climafuel,which is derived from household andcommercial waste. Last year’s energyrecovery from Climafuel alone meant thatmore than 12,500 tonnes of waste wassaved from landfill. This is equivalent to thewaste that more than 35,000 people (thepopulation of a small town, such asWinchester) send to landfill every year.Based on the biomass content in thealternative fuels used, the company alsosaved more than 14,500 tonnes of CO2,the equivalent to the annual CO2 emissionsof nearly 6000 cars.

As one of the country’s top 20 logisticsoperators, CEMEX UK transports over 30million tonnes a year of aggregates andcementitious products by road, rail andsea. Emissions by rail are five times lowerper tonne transported compared with road,and so it is a key target to minimise roadtransport. In 2007, CEMEX UK increasedthe use of rail and sea transport by 36%. According to CEMEX UK’s sustainabilitydirector, Andy Spencer, building productsare essential for the development ofsustainable communities: “Our productsand services have a key role to play incontributing to a more sustainable builtenvironment. In producing these, it is achallenge to find ways to minimise theimpact that we have, while continuing tomeet society’s need for constructionmaterials. “While the 2007 report shows that CEMEXUK is now in control of data and makinggood progress in a number of areas, theaim is to further improve performanceacross all our key indicators. In particular,we shall be focusing on the company’senvironmental footprint and life cycleperformance of products, which is thebiggest challenge for CEMEX and thebuilding materials industry as a whole.” CEMEX UK will report again on itssustainable development in 2009


Red Rhino customer, Rubble Monkey in Thame, crushed Corianworktops to be used as decorative stone for a project at theRHS Chelsea Flower Show in May.The five day show attracts over 600 exhibitors and over 700,000enthusiastic visitors annually. This is the ultimate event in thegardening industry, which shows the latest garden trends, features thenewest and most desirable gardening products and creates anexplosion of colours and scents.Rubble Monkey was selected to work alongside MCD Marketing inPitstone, Buckinghamshire, to help create a project “Gavin JonesGarden of Corian”, designed by Philip Nash who received a Gold FloraMedal for it. This display was one of the main gardens at the show.The Rubble Monkey crew travelled to Mega Marble in Wembley,London, where they were crushing the Corian worktops for 3 dayscontinuously. The worktops are 90% granite with a 10% added polymerto give it its colour and were approximately 1.2 m by 3 m and weighedup to 400 kg each. The three partners of Rubble Monkey, Steve Bailey, Ian Newton andGarry Brown, have always worked well together and in no time at allhad the “production-line” going. The forklift truck delivered theworktops where it then got broken with a sledgehammer and loaded byhand into their 4000 series crusher set at 5mm. A screener attachmentwas used to separate the aggregate from the finer material and thedust suppression was connected to minimize the dust. The aggregatewas shoveled into a cement mixer, tumbled to smooth out the sharpedges and bagged up to be delivered to the showground, ready to beused as decorative stone.Two colour stones were used in the garden design, black, which wasused mainly in the pond and blue, which was used around the gardenflowerbeds. “It was really hard work but it was great being part ofsomething so extraordinary.” said the crusher men. Rubble Monkey’s story demonstrates how versatile a compact crushercan be – the crushing of worktops is just one of the many ways variousmaterials you can be recycled and then used for something as simpleas garden decoration.

QMS successfully exhibits atStein-Expo 2008.

Between the 3rd and 5th SeptemberQMS exhibited at Stein-Expo 2008,Germany. Interest was high as QMSexhibited its B3 Cone Crusher completewith the latest version of its sophisticatedCrusher Control System; C3. C3 is themost advanced crusher control system inthe market fully automating all aspects ofcrusher operation. Ease of use isparamount with adjustments possible inseconds using touch screen technology.The operator is able to remain fullyinformed of the current state of the

crusher with real time recording and logging of all key operatingparameters. Included on the stand alongside the B3 Crusher wasQMS’s fully enclosed and integrated single lubrication and hydraulictank.QMS also exhibited a selection of aftermarket spares and wear partsfor a range of crushing machines, confirming their position as Europe’spremier supplier of aftermarket crusher spares. Underlying their abilityto supply and service breakdown needs from stock throughout Europe. The exhibition supported QMS’s growing presence in Europe withgrowth of crusher sales in Germany, and Eastern Europe. QMS isfurther seeking to expand sales through 2009.QMS has also recently obtained ISO 9001 Certification in recognition ofits commitment to quality throughout its production and serviceprocedures.

New Waste andRecycling show forPaigntonTourism Bosses have welcomed a band ofBinmen bringing the big business of“rubbish” back to Paignton Green.A group of waste and recycling businessleaders have decided to stay loyal to Paigntonafter the Chartered Institution of WasteManagement decided to pull its annualconference from the resort and relocate to aconference centre at London’s Docklands.Burt now an alternative three day Plant andWaste Recycling Show will be held on PaigntonGreen from June 15 to 17.It is headed by Hampshire businessmanRichard Hunt, who has visited Paignton for theconference for the past 23 years.The new show will not be on same scale asCIWM, said Mr Hunt, but hopes that this yearwill be a sell-out with a waiting list in futureyears.“A lot of Exhibitors are members of theChartered Institute and are obliged to attendthe London Show but I think they will comeback in years to come”

“We also expect about 95% of local authoritiesthroughout the country to attend the show”Confirmation of the new look show, which isbeing promoted as the international event forplant and waste recycling, has been welcomedby Bay councillors, tourism and businessleaders.Cllr Beryl McPhail, cabinet member for tourism,said “We are delighted that Richard Hunt andmany of his colleagues have stayed loyal to theBay. They have rightly recognised that we havesome wonderful facilities for events such asthis. Which do so much for our tourismindustry and for local businesses. We haveworked extremely hard with others in thecommunity to help them in the early planningstages, and we look forward to them staging asuccessful show.”Matthew Clarke, deputy chairman of Paignton,Chamber of Commerce said : “We are pleasedthat this is happening in Paignton. It is goodthat there has been recognition of the servicethat Paignton can provide and shows like thisare an important part of our economy”“A lot of people who attend these events saythat a lot of business is done over a pie and apint and not necessarily in an exhibition hall”“That is what theses show organisers haverecognised and CIWM have not”Show Co-ordinator Alan Bowman has 30 yearsexperience in organising major events.Exhibitors have already started to book hoteland exhibition space and a new sales teamhas been appointed for the show.

Crushing Corian worktops into decorative stone


www.hub-4.com/directory/701 www.hub-4.com/what’son4

new

s

ww

w.hub

-4.com


5


6

new

s

ww

w.hub

-4.com



NEUENHAUSER TRACKED STAR SCREENSFOR SCOTTISH WASTE INDUSTRY

Screening compost and sludges at Scottish Water Screened material

Precia-Molen, based in Redditch, Worcestershire hasrecently been awarded a weighbridge preventativemaintenance contract with building solutionscompany CEMEX UK for a period of 3 years. Precia-Molen specialises in industrial weighing, both staticand dynamic within the minerals, cement, waste andagricultural industries and has an enviable reputation forinnovation and quality at the forefront of weighingtechnology. CEMEX is a global provider of aggregates, cement andready mixed concrete of consistently high quality andreliable service to customers and communities around theworld. The agreement between the two international companiescovers the support for over 200 weighbridges nationwide.Previously, CEMEX UK was using a number of differentsuppliers to service and calibrate its weighbridges whichmade it difficult to track performance. With a desire tostreamline this process CEMEX UK chose Precia-Molen asits sole service provider.Peter Holmes, Customer Service Manager – Precia-Molen,said “The contract has been set up to minimise the risk ofunnecessary repairs and weighbridge unavailability whichcan lead to financial losses, whilst at the same timeextending the life of the weighbridge.”Precia-Molen was one of a number of CEMEX UK suppliersthat recently won a ‘highly commended’ award in the globalInnov8 competition for the generation of innovative costsaving ideas that add value to CEMEX business.The fully inclusive contract between Precia-Molen andCEMEX UK provides a single point of contact for all serviceissues, saving time, effort and cost. It includes emergencyvisits, repairs & verification, planned maintenance andregular calibration for weighbridges regardless ofmanufacture or condition.

With all support from anational response centreoperating 24/7, 365days a year a specificmatrix for each individualsite was established toenable CEMEX todecide the level of coverapplicable depending onsite operating times.The contract will provideCEMEX UK withexcellent geographicalcoverage and responsetimes which will be vitalfor sites that only haveone weighbridge andcannot risk down-time.Additionally, reports produced on the volume and type ofbreakdown and spare parts used, will help CEMEX UKfocus on improving particular sites and to schedulereplacements.A schedule for response times and pricing alongside acommitment to working under the current CEMEX UKHealth and Safety Policy with all Precia-Molen personnelcarrying their SPA/EPIC safety passport has also beenagreed. A minimum quarterly review has also been includedwithin the agreement which will allow both companies toevaluate performance against key performance indicators.It is envisaged that this agreement will be the start of a longservice partnership, providing CEMEX UK with highlycompetitive costs, whilst at the same time meeting agreedquality and service standards.

Precia-Molen awarded 3 year contract with CEMEX UK.

EXCEL PLANT UK: JOHN O’NEILLT: 0121 351 6969 F: 0121 351 6966 M: 07766 405688W: excelplantuk.com E: [email protected]

Two of the major players in the Scottish waste industry have recently taken delivery of Neuenhauser Tracked Star Screensfor the screening of green waste and wood for biofuel.Scottish Water have taken delivery of a 3 Fraction Tracked Star Screen at their Glasgow site and Keenan Recycling basedoutside of Aberdeen have taken delivery of a 2 Fraction Star Screen.The Neuenhauser Star Screen is becoming well favoured by companies throughout the country as it screens at hightonnages in all weather conditions.


7


8

Co

ver

sto

ry

ww

w.hub

-4.com

Cover

Sto

ry

At its Kingsmead site, near Horton inBerkshire, where CEMEX producesaggregates to service its concrete plantand to supply the marketplace, newplant has increased both throughputand flexibility as Ross Matthews foundout during a tour.

The 40 hectre Kingsmead site, owned and operated byCEMEX UK has extensive reserves of sand and gravel andhas been recently redeveloped as part of its current nationalinvestment programme of over £60 million this year. A state-of-the-art concrete plant, which can produce over 120cubic metres of readymixed concrete per hour (enough to fillmore than a double decker bus), replaces the old plants onthe site and provides material for construction projects inWest London, Berkshire and Surrey. The site is estimated toprovide 2.5 million tonnes of sand and gravel over a 10-yearperiod. Following two successful projects for CEMEX UK,DUO (Europe) installed the new washing and crushing plantthat will allow CEMEX to not only process sand and gravelfor its concrete plant but also to provide materials forexternal markets. “With the current decline in the housing market, there hasobviously been a decline in the readymix concrete market.Aggregates from the quarry have been used not onlyinternally for the concrete, but increasingly externally,” saysMatt Wild, south east director of aggregates.This trend is confirmed by the Quarry Products Association,which reports that the downturn in construction activity isreflected in the 6% decline in sales of ready mixed concretein the first half year. This product tends to be used early inthe construction process and confirms that the reduction inorders for new housing, commercial and industrialconstruction recorded to date in 2008 is now impacting inthe market.“The CEMEX quarries and readymixed concrete plants inthis area have contributed materials to large projects suchas Heathrow Terminal 5 and the M25 widening scheme,both of which are approximately 10 miles away. In this area,currently there aren’t such large construction projects, butthe 2012 Olympics will make a huge demand on suchresources in the south east,” continues Matt. To process its aggregates CEMEX had previously beenusing the same static for some 25 years. It had come to theend of its useful life. When it came to choosing a supplierfor the new plant, DUO already had a foot in the door as inaddition to providing hire plants on a cost per tonnethroughput basis at CEMEX’s Stanwell site, DUO was alsoat the time installing plants at the company’s sites at

Angerstein and Northfleet – featured in previous issues ofHUB 4.“We looked at other plants then looked at how Angersteinand Northfleet were delivering and the relationship we hadwith DUO,” says Matt. Having selected DUO’s scheme,CEMEX went through its requirements with the company.“We required a plant capable of achieving a throughput ofup to 300,000 tonnes a year from a stone-rich dig, whichthis site is, and produce a 10, 20 mm and sharp washedsand product primarily for the concrete part of the business.The plant also needed the facility, if required, to make a 40mm single size product.” Matt explains. This versatility was an important consideration for CEMEXas Matt explains. “We are primarily looking for aggregatesuitable for our concrete production but we can alsoproduce the 40 mm down crushed aggregate for landfillblanket drainage, which is called for on a regular basis inthis area, and the ‘all-ins’ (10 mm and 20 mm) for buildersmerchants. We supply everyone from the collect customerwho wants to come in and buy a tonne of aggregate for acash price through to the building supplies company andbuilders merchants and on to the big projects such asTerminal 5, which requires 300,000 tonnes, and anything in-between.”

Washing and crushingReplacing the aged plant, DUO installed a new washing andcrushing system, based on a simple modular arrangement,which meets the required specification of one sand, 10 mm,20 mm and 40 mm, with the +40 mm -125 mm beingcrushed in closed circuit.Raw material is derived from a wet dig dragline excavation.The material is put into stockpiles and allowed to drain -CEMEX extract 3-4 days ahead of processing to allow thematerial to drain well. A large wheeled loader picks thematerial up and drops it into a variable speed hopper, whichthen deposits it onto the main feed conveyor coming up tothe plant in the yard. The variable speed hopper allowsthroughput to be controlled if, for example, CEMEX ismaking a 40 mm down then the throughput can beincreased. “We can vary throughput at the excavation endso that if we are not getting a full quality material we canadjust the throughput of the plant down to cope with that.”The main feed conveyor then deposits the material onto a24 m long electric/hydraulic powered radial conveyor, whichgives CEMEX the option – depending on the current statusof the plant – to either feed the material to the hopper of aPowerscreen Commander processing plant or to a 5000tonne surge pile stockpile out into the yard. Fitted with a man grid and a variable speed feeder the 20tonne capacity hopper of the Commander delivers materialonto an inclined conveyor which feeds a 20 x 6 double-

CEMEX cleans up with new plant


9

Co

ver

sto

ry

ww

w.h

ub-4

.co

m

deck rinsing screen where theoversize +20 mm material isscalped off and dischargedonto a 34 m long lattice framecrusher feed conveyor. This conveyor feeds materialforward for crushing via a 10tonne crusher surge bin. Thecrusher, a Pegson 1000Automax, is surge fed via avibrating tray feeder, withcrushed material then fed ontoa 24 m long surge feedconveyor. Rated at 300 tph thisconveyor re-circulates crushedmaterial back into the system.Any underflow from the rinser isflumed off to a PowerscreenFines Master 200 sand plant.Working for maximum sandgrade flexibility, the FinesMaster 200 produces acombined total of around 200tph; comprising a single 18"hydro cyclone, a centrifugalslurry pump, a collection tankand a high-frequency 8 x 4 ftdewatering screen fitted with500μm polyurethane matsmounted on a single carrierchassis, the machine deliversone grade of course sand via a24 m x 800 mm wide poweredradial stockpile conveyor. All siltbeing fed to a sump where it ispumped to a silt water lagoon.The -20mm +6 mm aggregatefrom the rinsing screen is thensent forward via a 24 m long x800 mm wide inclined transferconveyor. This conveyor feedsonto a 16 x 5 double deck dryscreen.The material from both topdecks of the dry screen is fedonto a 24 m long poweredradial conveyor providing astockpile of 20 mm product.Any material from the bottomdeck is fed onto a further 24 m long powered radialconveyor stockpiling a 10 mm product.

Control and PerformancePlant operation is controlled from an operator’s cabinsituated alongside the crusher panel and incorporates aPLC control system for automatic start up and shutdown ofthe plant, which includes a provision for the manual startingand stopping of the plant, out of sequence in test mode.The system also incorporates an alarm, history recordingand fault diagnostic capabilities.

The DUO Equipment divisionthrough its UK dealershipsupplied the PowerscreenFines Master sand plant, allscreens, and Pegson conecrusher. Working alongside,the DUO Manufacturingdivision (LJH) designed andmanufactured all the fixedconveyors including theinstallation of fully galvanisedheavy-gauge steelwork withguarding throughout.

Increased throughputHigh among the advantagesCEMEX has found from usingthe plant is the increasedthroughput, which is now upto 150 tph. “If we were to doa 40 down product, we canup throughput by about 20%up to 180 tph but there is abalance between throughputand quality of product so 150tph is the optimumthroughput,” says Matt.The plant has also improvedworking flexibility. When set tomaking 20 mm, 10 mm andsharp washed sand it can beswitched to making the 40mm product simply bychanging the screen modules.“We stop the production, getup on the screen decks andchange the modules. Within35 minutes we can convertthe plant back to making 40mm down,” explains Matt.“We would normally make astock of 40 mm when we getan order and when that startsto deplete then we look atmaking some more. It’s not aproduct that moves on a dailybasis; it can stay on site andthen we can move up to 4000tonnes in a week, but 90% of

the time we are set up to make a 20 mm down and crushedplus 20.”The new system has also speeded up drying. The sandsystem’s dewatering screen allows the sand to basicallydrain and be loaded out within 3-4 hours whereas the oldsystem took a day or two to drain. It goes across adewatering screen and comes through the plant reasonablydry as well. “We also have from the feed a radial conveyor atthe end of the feed conveyor that allows us, if the plant isdown, to put a stockpile in the yard. We can then feed thatstock pile through the plant as a failsafe”.


Main feed conveyor

Pegson 1000 Automax Crusher


Co

ver

sto

ryAngling and Archaeology The CEMEX Kingsmead site is not only notable for it aggregate production but also as a site of archaeologicalsignificance and angling excellence.

The new plant installed at the CEMEX Kingsmead site became operational on 1 July. The previous day, the companywelcomed customers and local community to the site for the official opening by CEMEX UK country president, GonzaloGalindo. In fact CEMEX is used to welcoming all kinds of people to Kingsmead. Archaeologists were working on site when arare and important historical ‘find’ at the site revealed one of the best preserved examples of the site of a Neolithic house,over 5000 years old, in mainland UK. This is one of two or three prime examples in this country and was unearthed as partof CEMEX’s £5million archaeological programme on the quarry site.

The Neolithic house was initially discovered in June and was investigated to see if parts of the house were used forparticular activities. Andy Spencer, CEMEX Sustainability Director says: “In comparison to today’s houses it is relativelysmall, but it is almost 6000 years old! The discovery provides us with one of the best plans of one of the oldest houses inBritain.

“From the layout we can picture a rectangular building with the walls made from split logs and a thatched roof. It probablydidn’t have a chimney and smoke from the hearth would have seeped through the thatch, which was high enough to avoidcatching fire from the sparks. It is a truly great find for both historians and the community.”

To date other finds on the site have included some 10,000 year old flint tools which were used when man used to gatherwild fruits and nuts and hunt animals, traces of broken pottery in small rubbish pits approximately 6000 years later indicatingtraces of the first farmers at Horton, a unusual find of cache of eight flint arrowheads from around 2000BC and a largeelegant bronze pin believed to be used to pin the cloak of a farmer dating back to around 1500BC, in the middle of theBronze Age.

These archaeological finds by specialists, Wessex Archaeology, arekey to enhancing the knowledge and understanding of the historyaround the Rivers Colne and Thames. They reflect the scale ofchanges in society over the centuries with quarrying being apositive contribution to the needs of society by providing valuablebuilding materials and subsequent restoration of the land, in thisinstance, back to agricultural land.

Angling

The Kingsmead site also has another claim to fame as the jewel inthe crown for CEMEX Angling; The Kingsmead site has beendeveloped into 5 superb carp waters. Other fish species includePike, Bream, Tench, Roach, Perch, Eels and Grass Carp, helpingto make it one of the top big fish complexes in the country. In the

complex, there are carp to nearly 50 lb, Catfish to 80lb+, Grass carp to over 40lb, eels to over 8lb, Perch to over 4lb andtench well into double figures. Last season saw a stocking of CEMEX Angling’s own Sutton strain carp introduced to thevenue. These were mainly between 8-10lb and are now being caught regularly over 17 lb with a few of them touching themagical 20 lb weight, all of which are real stunners.

Digging for relics


A recreation of the Neolithic house found at Kingsmead

10




13

Rec

yclin

g

ww

w.h

ub-4

.co

mR

ecyc

ling

DTS Environmental is changing. It has set its coursetowards a greener future by making a significantmove into recycling more skip waste rather thansending it to landfill. A “serious investment” in a newbuilding, plant and equipment at its Recycling Centresite in Carlton, near Barnsley, will play a central role inthis development.The company’s name itself reflects a new, greener ethos.Originating from D Thackery & Sons, formed in 1964, thecompany developed through the years to become, in May2007 DTS Environmental Ltd and today operates in theareas of skip hire, demolition, excavation, plant hire andhaulage and, of course, waste management.Having previously operated a mobile trommel and a mobilepicking station on site, where a limited amount of pickingfrom waste took place out in the yard, DTS began to look atwhat others were doing in the wider recycling world.“We wanted to grow into something entirely different,”explains Darren Jones, DTS Environmental Limited’s general- waste manager, “and become a total waste managementcompany so we looked at the technology across Europe.”When it came to replicating at its site in Barnsley thetechnology they found during their search, DTS werepresented with a variety of solutions but it was Steve Hill,whom DTS had worked with previously, who grabbed theirinterest with a Waste Separation System offered by thecompany where he is the UK sales agent: Smulders WasteTechnology.“It wasn’t the cheapest plant nor was it the most expensivebut Smulder’s solution offered the best value,” says Darrenwho also saw the company as something of a soul mate.“We are a relatively small company going to the next leveland through Smulders’ active cooperation we were able tocome up with the best solution to suit our requirements.”To provide a good working environment and reduce noiselevels at its Recycling Centre DTS constructed a buildingwith a 30 x 50 m footprint and a 9 m ceiling height to housea Waste Separation System. Completed last year, thebuilding’s dimensions were dictated by planningrequirements. Smulders produced a plant design that fittedneatly inside and commenced installation during the springof 2008. Work was completed by the end of the summerand during HUB 4’s visit in mid-September the plant wasrunning through the commissioning process to be fullyoperational at the end of September.

Sorting out the wasteWith a capacity of 120 m3 per hour, the new WasteSeparation System is designed to handle generalconstruction, industrial and skip waste. DTS has its ownfleet of skip wagons to bring in about 100 skips a day ofmixed waste from the local area. Once over the weighbridgethe skips are tipped and the waste is presorted tosegregate large and unwieldy pieces. The remainder is thenprocessed by the Waste Separation System.The system starts with a 10 m3 hopper manufactured fromHardox, which makes it tougher than the average hopper,into which the presorted waste is loaded by a grab. Wastematerial is then fed to the high stroke vibratory feeder,which transfers the material onto a 1200 mm wide trommelfeed conveyor. Impact bars at each transfer point of thiswaste recycling system cater for handling the heavier itemscoming through.From the feed conveyor the material enters an 8 m long x 3m diameter trommel screen, which is equipped withchangeable decks. With its lifting and tumbling action, thisheavy duty, chain driven unit is fitted with 40 mm diameterdecks to separate the fines that are then collected by aconveyor and transferred up to a fines screening station, onto a single deck screen, which is 1800 mm wide x 4000mm long fitted with 20 mm rubber screening panels. The -20 material is too small to go through cleaning - “It’s thebig problem everybody has as currently there’s no means ofcleaning the small fines,” says Darren – and is conveyedinto a bay outside the building.The 40/20 mm material then travels under Smulder’s AirWaste Separator unit mounted across the vibrating screento suck off the lighter materials.The contaminated materialsare sucked towards a heavy, rust-free chain belt anddischarged at the side via a chute into a skip. The dustcontrol is via a fully automatic reverse air jet filter unit.The material that passes under the waste separator thendischarges onto a conveyor to remove any ferrous metals.The material left on the conveyor then passes through aone-bay picking station to remove any non-aggregatematerials and the aggregate then discharges into the bayoutside the building.The +40 mm oversize material from the trommel dischargeson a 1200 mm wide conveyor, which has an overbandmagnet mounted above it to remove any ferrous metals.The material left on this conveyor is then conveyed up tothe picking station, which provides a far better workingenvironment than the situation before when staff were

Wind of change

Ross Matthews visits DTS Environmental in Barnsley to see how a new Waste Separation System, incorporating air separation technology, operates at the heart of the company’s developing recycling business.

DTS’s waste separation system

▼


www.linatex.com

GROWING TOGETHER

THROUGH EXPERIENCEWhen it comes to setting the industry standard in abrasive throughput solutions, Linatex has no equal. We have been partnering with the minerals processing industry for over 80 years. Our expertise ranges from sand and aggregates processing through to hard rock mining.

But sitting back and resting on our past achievements isn’t really our style.

The Linatex that you have relied on for premium quality abrasion resistant rubber can also provide equipment for your minerals processing needs, utilising our unique rubber technology.

For more information on Linatex products and services, contact us now on +44 (0) 1252 743 000 or visit www.linatex.com

We have a lot more to achieve and a lot more to prove; to ourselves and to our partners.

We recognise that it is only by moving with the times that Linatex can maintain its position as an industry leader.

Having spent the last few years expanding our range of process equipment, Linatex is now better placed than ever to support the growing needs of your business.

14


15

Rec

yclin

g

ww

w.h

ub-4

.co

m

picking what could easily be picked from the waste pileoutside. The modular picking station, which can beextended if required, comprises a cabin with four chuteseither side of the 1200 mm wide conveyor belt, allowing 10pickers to work simultaneously to sort out the material to berecycled, which is dropped into the chutes leading tocontainers for each material below the station.“I don’t think there is enough time to segregate all of thecardboard and paper up here and that will get re-picked,”explains Darren. “We are thinking of refurbishing our existingequipment to use as a secondary picking station and pick itdown into different streams again.”Material leaving the picking station discharges onto aconveyor and passes under another overband magnet toremove the ferrous metals – the non-ferrous metals arehand-sorted and collected inside the picking station. Theremaining waste then passes into an air separation system.The air separation system comprises a 250 High PressureFan with an air knife mounted under the head of theconveyor blowing light waste away from the heavy waste,light waste is then sucked into a 500 Heavy Duty ChoppingFan and then via ductwork up to a WS 16 Waste Separator,which separates the air from the waste, with the wastedropping into a container and air discharged directly into theatmosphere outside the building. The heavy material, whichis mainly clean hardcore, finally then discharges into a bayoutside the building transported on conveyors constructedby DTS itself. “We have designed this so that we can backour mobile crusher underneath the belt so providing directfeed to a crusher as we know it’s clean and withoutcontaminates,” explains Darren. “Rather than have a fixedcrusher we can use our mobile plant for crushing or move itout to allow the hardcore to fall into the bays.”The plant’s electrical control system incorporates a PLC withbuilt-in safety features. The system starts and stopssequentially at the press of a button. The air suction units on this system are an interestingalterative to traditional fan blowers. “The Dutch call it awood magnet as it can pick up bits of wood as well as hardplastics, paper, polystyrene etc. It’s something thatSmulders has developed over 20 years. A Reverse Jet Filterremoves any small material and dust from the air which thendischarges air inside the building the air being much cleanerthan the defined maximum exposure of 10 mg/m3 sothere’s no external discharge,” says Steve Hill. “There’s no way anybody could pick all of that off,” saysDarren looking at a skip full of wood-leaf collected by the airsuction unit. “What has surprised us is the amount that weare lifting off. Originally we only had a small skip to collectwhat we thought would be emitted but it fills a full skip inabout an hour.” In fact DTS plans to add a conveyor belt totake this material to a bigger skip.

Benefits for DTSThe new plant will enable DTS to recycle 85-90 percent ofincoming waste – that’s a significant 40% improvement overwhat it could previously achieve – and to clean the fines upas much as possible.“This system can handle 120 tonnes per hour so it’s up tous to get the business up to that level,” says Darren. “Weare reducing what we are sending to landfill and maximisingrecycling and also gaining, cleaner, more saleable productsfrom the waste. We have identified markets for the variousmaterials that we are recycling and we are going to start abailing system also.”DTS’s development of its Barnsley site doesn’t stop withthis new plant: a new office block and staff welfare facilitieswill also be constructed. “Our vision is to grow the business and become a majorplayer in the market,” says Darren. “Landfill tax andlegislation means that the sector has to be morecommercially aware. More and more materials, such asplastics, are becoming recyclable and the technology isdeveloping all the time – even between the conception of arecycling plant and its installation – while the markets forthese products continue to open up,” says Darren whoexplains that to capitalise on this opportunity does requireconfident investment: “You either recycle in a big way or youwill not get anywhere so you need a major investment intokit such as our new system. We decided if we are going toget involved in this we needed to invest heavily and startrecycling from day one rather than installing outdatedequipment. Having been round other plants where theequipment we saw is now outdated we wanted to start fromday one with a state-of-the-art system. We can adapt thissystem and keep moving on; there will be a growing numberof larger companies entering the market and a facility suchas this will give us the edge.”The areas’s local construction companies are happy as thefacility will provides them with a cost saving. However withthis sector currently being credit crunched, so the amountof C&D waste produced is reducing. However, there willalways be waste and the private sector and domesticsectors continue to provide plenty. DTS is also looking tobroaden its working area into other parts of Yorkshire.Darren concludes: “We are recyclers now, we are notsending waste to landfill. We have the machinery here forrecycling and helping companies meet their recyclingtargets.”


Smulder’s air waste separator The end of the line

CleanHardcoreheadingoutside,separatedfrom waste


Wheeldon scores a hatrickIncreased construction and demolition (C&D) recyclingcapabilities, further reductions to tip-to-landfill volumesand a boost to its output of saleable reclaimedmaterials were the objectives of Wheeldon Bros Wasteof Bury and Oldham.Incorporated in 1965, the family owned business is fullylicensed to provide a waste and recycling collectionservice for commercial, industrial and construction wastethroughout the Greater Manchester area. Over the past 12months Wheeldon Bros has installed two EMS McCloskeyrecycling systems supplied by CDP Plant, Which is theappointed distributer for McCloskey International and EMSRecycling systems throughout Central England, to helpachieve its objectives.Improved recycling rates, greater waste throughput and an

improved working environment for personnel are just some of the benefits that Wheeldon Bros is now seeing at its wastetransfer station since the installation of the new systems. The latest newly commissioned system marks a hatrick ofMcCloskey trommels and EMS picking station combo’s on the 9 acre Bury site and is part of an ongoing expansion planfor the company with two further waste plants already on order for their Oldham site.James Wheeldon, MD at Wheeldon Bros, has been instrumental in the design and layout of all the systems incorporatinga number of designs to improve the efficiency and flow of materials.“We have 43 years of experience handling a wide range of waste types, with 1800 tonnes of waste going through oursites each week. We prefer the McCloskey screeners and think they are the best in the business. The design is betterthan many others with a wide feed aperture, robust construction and ease of use. Because the feed aperture is large forthe size of the trommel we do not have problems with bridging that can lead to belt cutting and repair downtime. Theyare just less hassle than many other screeners on the market, requiring minimum maintenance,” explains James.The majority of Wheeldon’s waste is processed through a twin line system under the main shed. This incorporates twin8 ft diameter by 23 ft length McCloskey trommels, complete with variable speed hoppers operating in conjunction withtwin four bay EMS picking stations with magnets. This system separates MRF material into eight key streams:cardboard, paper, plastic, aluminium, steel, wood, electric products and 25 mm down fines.The plant handles approximately 300 tons per day achieving an 80% recovery on saleable products.At the end of the system the 20% waste (landfill) is conveyed into a compactor to give maximum weight thus reducingassociated transport costs.The remainder of the heavier wasteflow is processed through the newly installed system. This incorporates a 6 ftdiameter by 12 ft length McCloskey trommel and four bay EMS picking station complete with Enviro Cabin, overbandmagnet and air knife. This plant processes C&D waste into six streams: 25 mm down fines, wood, paper, plastic, metaland hardcore.The plant currently processes in the region of 100 tons per day with the capacity to handle 300 tons per day. Themajority of this heavy waste is tipped at the site by Wheeldon’s own vehicles but with plenty of room for growth thecompany have witnessed an increasing number of other firms now tipping on site. Before installation of the third wasteplant, segregation was done using one of the company’s previous trommel screening systems. Explains James Wheeldon: “Because we were running the heavy waste through a screener that was not ideally designedfor such a task we were not getting good results and we also had to do some handpicking which was slow. The newsystem gives us cleaner waste and is quicker which means we can handle more capacity and produce an improved endproduct. “From the initial discussions, right through the installation and commissioning of the plants James has been extremelyhelpful. He has worked closely with Harry McCourt (EMS) and myself and has managed to improve what was already anextremely well run and successful business,” explains Sean Lynn of CDP Plant.With three McCloskey trommels and EMS picking stations on site, Wheeldon Bros. is well aware of the positiveadvantages of the equipment and is confident of the equipment’s rapid payback on investment.Says James: “CDP Plant is extremely helpful in its equipment recommendations, they know our business and what willwork. We are very happy to place our business with it and have just ordered two more systems for our Oldham site.”

Waste Industry feels the grab ofmaterial handlersWorking on high profile civil demolition waste materials requires a reliable andefficient material handler that keeps on providing the muscle day in, day out.GRC Recycling had just that need and has now purchased a 825M D-SeriesGreenline Material Handler to join its team.Based in Dundee GRC operates an efficient and busy business processingconstruction and demolition waste and scrap metals the company has found themachine an extremely versatile performer.Weighing at 28 tonnes the Sennebogen 825M D-Series features a heavy-dutyboom with extra large bearings for permanent high performance operation.Capable of operating at superior speeds the 825M is of completely redesignedconstruction utilising the latest HD axle technology. The machine is mounted on alarge cross section frame from boom to counterweight and the upper carriagedesign offers comfortable and safe access.

The 825M has a completely redesigned upper structure and provides strong, dynamic swing drive for fast working cycles.With improved stability on the elevating cab the operator is fully catered for in an ergonomic air suspended comfort seat,which is adjustable with lumbar support, seat heating and adjustable arm rests.GRC Recycling has a new dependable member on the team; Greg Cosgrove, commented, “The 825M has been a veryvaluable addition to our company recycling equipment, with strong reliability, fast operation and back-up from Hassells ifneeded; so much so that we are now considering the purchase of another 825M.”



Rec

yclin

g

ww

w.hub

-4.com


17

Reduce Landfill Tipping Costs Now!

Mobile and Static Trommel ScreensPicking Station solutions ideal foruse with skip waste.• Dust suppression solutions• Large & Compact solutions

CDP Plant Ltd. t/aMcCloskey CentralDunston Road, Sheepbridge,Chesterfield, Derbyshire S41 9RL

Mobile: 07801 695171Website: www.cdpplant.co.ukEmail: [email protected]

Telephone 01246 269 450

Reduce Landfill

Tipping Costs

NOW!

Reduce Landfill

Tipping Costs

NOW!

RecyclingSolutionsRecyclingSolutions

DUO Rentals

Your complete mobile crushingand screening solution

Call the DUO Rentals Hotline now!

0845 22 22 3864 Rye Hill Office Park, Birmingham Road, Allesley, Coventry CV5 9AB

• Crushing,screening & washing

• Maximum throughput

• One-stop-solution• Long & short term

rental

• Full service back-up• 16 depots nationwide

NNAATTIIOONNWWIIDDEE DDEEPPOOTTSS:: Birmingham • Bristol • Bury St Edmunds• Cwmbran • Doncaster • Durham • East Midlands • Horsham • Liskeard • London

• Scotland • Sheffield • Sittingbourne • Swindon • Warrington • Winchester

• Heavy Duty Lubricants • Biodegradable Lubricants • Clean Solutions • Waste Disposal Package

For more information contact: Rosemary Mellor 01782 203706

Fuchs Lubricants (UK) plc Tel 08701 200400 www.fuchslubricants.comWE ARE THE LUBRICANTS BRAND LEADER FOR THE QUARRYING INDUSTRY. YOUR SILENT PARTNER! WORLD LEADERS IN LUBRICANT TECHNOLOGY

Protecting the Environment ...


New service forcustomers SRM, part of Hanson UK, hasannounced another new servicefor its customers after beinggranted a transfer station licencefor its Heysham plant inLancashire. This licence enables it to acceptinorganic wastes such as drumsof rags and wipes, even though itis not able to process these itemsitself. The benefit to customers isthat they will not have tosegregate drums of material theybelieve SRM might be unable toprocess. Wastes that SRM cannot handlewill be sent on from the Heyshamtransfer station to selectedrecycling and disposal plants.These will all have been inspectedby SRM’s own experts to ensurethey reach the highest standards.Dr. Chris Brown, SRM’s Heyshamsite manager, commented: “Weconsidered that many of thetransfer stations we have seenwere poorly run and at thebottom of the waste managementfood chain.“Having thought long and hardabout obtaining transfer stationcapability at Heysham wedecided that applying our ownrigorous and professionalapproach to transfer stationactivities would benefit many ofour customers who wouldappreciate the convenience ofdealing with SRM for even moreof their wastes.We would also be unusual in that,unlike most other transferstations, we have a range of ourown processing options, whichoffer further synergies to ourcustomers.”

Tyrone Brickresolves wasteissuesA successful installation of a BrickRumbler and two conveyors for thewaste processing line of its planthas provided Tyrone Brick with theability to create a range of ‘OldWorld’ type bricks, and minimisethe amount of brick wastage dueto the process.Part of CRH - the International BuildingMaterials Group, Tyrone Brick hassince the 1970s been the only claybrick manufacturer in Northern Ireland.Continually developing new brick typesusing the latest technology andmanufacturing equipment its clay isextracted locally once a year from fournearby reserves in County Tyrone andCounty Down.As sustainability of building materials isbecoming increasingly important forarchitects, specifiers and end users;the company has with regard toimpacting on the environment,invested heavily in ways to furtherreduce its carbon footprint.Where possible the company re-usesprocess waste materials and utilisethem in the manufacturing process.For example, the excess heatproduced by the kilns is recaptured foruse in the drying process, ensuringthat all energy is employed asefficiently as possible. Grey watergathered from collection points aroundtheir factory mix with their clay keeps

mains water consumption to an absolute minimum which is aimed to meet theirEnergy Reduction Targets of 2% per annum up to 2010. Some brick types have a 20% recycled content. These are created by crushing ‘Non-First’ bricks and using the resulting ‘Brick Grog’ material, instead of natural sand. Anextra bonus is that these bricks can be fired in a shorter cycle time, therefore ensuringthat all energy is used as efficiently as possible. Old Colliery, Restoration Blend,Kingston Red and the Rumbled Brick Range contain this recycled material and thesebricks now represent approximately 15% of the company’s total sales. A range of brick types is produced, with stocks of all the popular types being available.The company also has a dedicated facility for the production of special shape bricks.With a flexible production process Tyrone Brick can offer shorter lead times onpurpose-made special shapes. In a recent project for the company Haith Industrial supplied a Brick Rumbler and twoconveyors for the waste processing line of the plant.Taking into consideration several issues of space and after consultations with the clientHaith produced a working plan to achieve the maximum result.Haith supplied a 7000 x 1200 mm Brick Rumbler for the brick production. Constructedwith a steel barrel the rumbler is internally fitted with a steel backed wear resistantrubber lining. Supported by a single line shaft mounted above the barrel the rumbler isdriven by a shaft-mounted 11 kW motor fitted directly to the line shaft. A pressed steelguard fitted over the top of the barrel also acts as a dust cover should dust extractionbe employed. A main frame mesh guard whilst eliminating any access for safetyreasons incorporates enough area to allow any waste fall-out from the machine.Design of the machine also facilitates the angle of the machine to be changed allowingcontrol of the throughput and the amount of distress on the brick edges.Fitted in-feed and out-feed chutes were also supplied complete with replaceable steelliners.Material is fed from the brick rumbler onto a 16.5 m long x 1 m wide Haith standard,totally enclosed design, heavy-duty picking conveyor. This picking belt also extendsback under the rumbler enabling the belt to catch any dust or waste that spills outbetween the barrel and chute. A small hopper is also incorporated at the tail end ofthis conveyor, which includes a 1 m tunnel guard extending back from the head of theconveyor. The rumbled bricks are manually packed by a team of selectors at the picking belt.The remaining brick material moves off the picking belt onto an inclined wasteconveyor to a collection bin at the line end. This material is subsequently recycled inthe brick production process.Ian Irwin of Tyrone Brick, comments: “Haith has a good understanding of what themarket requires from this type of equipment. The ability to optimise material useincluding waste is very important for manufacturers in this age of sustainability.”

SRM’s works at night



18

Rec

yclin

g

ww

w.hub

-4.com



Scrap metal dealer Kunz Rohstoffhandel, based in the Oberhausen district of Augsburg, was when faced witha need for the acquisition of a new stationary loading machine, securing the sustainable efficiency and earningpower of the company was a prime consideration. With 20 years and some 30,000 operating hours on theclock, the company’s key machine, a pylon-mounted stationary loading machine from O & K, was no longereither reliable or powerful enough.

“A number of verydifferingrequirementsneeded to becombined in onemachine”, washow a spokesmanat KunzRohstoffhandeldescribed thesituation. The newmachine’s chief

task would be to feed an 800-tonne scrap press witharound 4000 tonnes of scrap metal per month in one- andtwo-shift operation. The loading machine would also beused in the pre-sorting of scrap metal. The investment hadalso become necessary because the works site is located ina mixed-use zone and a new loading machine could help tosignificantly reduce noise emissions. The decision finally fell on the stationary loading machineAHL840 from Terex Fuchs, which was offered through thecompany’s marketing partner, Kiesel GmbH. In addition to

the powerful overall output of 110 kW, a notable feature ofthe electrically driven loading machine is its stability androbustness. In developing its mobile and stationary loadingmachines, Terex Fuchs has specialised in the harsh realitiesof everyday materials handling in the scrap-metal andrecycling sectors. The flexible machine concept suited the requirements ofKunz Rohstoffhandel; the loading machine’s mobility wasless important than the highest possible handling ratecombined with maximum reliability. Other positive pointsfrom the customer’s point of view were the convenientcontrol of the scrap press from the cab, and the electricdrive – at a time when oil and diesel prices are increasing byleaps and bounds, the cost of electricity as a fuel is easierto calculate than that of diesel. Before the deal was struck the Terex Fuchs team still hadsome problems to sort out. The pylon belonging to the oldloading machine was still in good condition and the ownerswanted to re-use it. With some alternations to the under-carriage of the AHL840 this request was met.

Hadley Recycling & Waste Management of Theale near Reading haschosen Doosan as its preferred supplier of wheeled loaders andexcavators and recently took delivery of its first batch of eightmachines from local dealer Promac Solutions of Aldermaston.Hadley, celebrating 75 years of trading this year, currently employsapproximately 130 people across six sites in Berkshire and besideshandling 400,000 tonne of waste/year also operates a tipper fleet, awashing plant for recycled aggregates plus a comprehensive bodyshop.Commenting on the choice of Doosan, head of logistics and operationsMartin Elford said: “We looked at several potential machinery suppliers butDoosan not only came highly recommended but also offered the bestoverall package of price and performance.”

Martin has also been impressed by the effort and commitment made by the staff at Promac Solutions and looks forward tobuilding a long-term close working relationship with them.In addition to three DL400 wheeled loaders, four DX225LC excavators and a 1.5 tonne mini, used for general clean-upduties, a further six large Doosan models are planned to be purchased by the end of this year to replace a variety of leasedand hired-in older machinery. The entire fleet spends most of its time handling waste and aggregates, helping Hadley torecycle 85% of the waste it collects - a figure it hopes to increase by the investment in these new machines and by usingthe most recent technology and processes available

Long-terminvestment inefficiency andemissionsprotection


Preferred supplier for waste management company

20

Rec

yclin

g

ww

w.hub

-4.com



21

Rec

yclin

g

ww

w.h

ub-4

.co

m

“Ah, black gold,” says Peter Sanderson, director atNottinghamshire Recycling. He’s not talking about oilbut the Grade 1 topsoil stockpiled at the company’simpressive Worksop Recycling centre. “We can’tproduce it quickly enough, it’s absolutely flying out.”This ‘black gold’ is recycled from virgin soil sent tothe site by local firms as waste. NottinghamshireRecycling blends the soil with compost, as well ashaving a few other techniques and ingredients toensure the product’s uniqueness and quality. Thealchemy is created with the aid of equipment suppliedby Powerscreen Pegson, with whom NottinghamshireRecycling has invested some £1 million for plant at itsthree sites to carry out sorting of construction anddemolition (C&D), skip waste and compost/ soilrecycling. As well as a trommel used for sorting itsskip waste – more about that later - the investmentcovers three Powerscreen Warrior 1400s used forscreening, a Powershredder 2400 for shredding treesa XR400 Pegson Crusher and a Phoenix 2100Trommel. The company is Powerscreen right through. “If it’s onwheels it's JCB and if it’s a static plant or on tracks, thenit’s Powerscreen.“The relationship we now have with Powerscreen Pegsongoes a long way. “So when we ring up somebody comesquickly because downtime is a major issue for all our sites.”For the soil recycling the two Warriors work in tandem. Theinitial machine processes the soil and bricks arriving on site,removing hardcore, soil and sticky mid products. Itseparates larger material using a punch plate top deck anda mesh bottom deck. The 40 mm material travels on aconveyor that feeds the second warrior, which blends thesoil with compost. This screen uses a Flexi-Mat 3 deck that, according to TimWinslow, area sales manager of Powerscreen PegsonEquipment, stays cleaner than standard meshes, which canbecome blocked by the sometimes very sticky blend of soiland compost. This is thanks to polyurethane strips centeredon each screen deck crown bar support that allowindividual wires to vibrate independently at differentfrequencies, preventing material from accumulating betweenwires as it typically does with woven wire, thus throughputin blinded, pegged and clogged applications can beincreased.Screening to 10 mm in the secondary screen leaves a finalproduct to be sold as the very high quality topsoil. In factthis recycled soil is on the verge of getting Soil Associationaccreditation, according.

Not many companies carry out soil blends in the wayNottinghamshire Recycling does. “It’s essentially compostand ‘as-dug’ soil.“The quality comes from the way we blendit. Everything is natural, there are no fertilisers. It’s takenKevin Burgess owner and Peter many years to develop.”“The Warriors are both identical but the meshes are set updifferently. When the weather is good we run them intandem, which means you only need one machine to loadas opposed to two.Before acquiring the new machines, NottinghamshireRecycling was carrying out a similar process with an olderWarrior but it involved changing decks, which was a timeconsuming process. “As demand for the end product has grown we needed toincrease capacities. This basically drove us to replace theold machine with two new warriors.He adds: “The new machine with its added features keepsdowntime to a minimum, not just through reliability - with itswarranties and service and back up - but by avoiding theneed to change decks.”Nottinghamshire Recycling is negotiating supply deals forthis high quality product with major companies. “We arequite happy to supply a client with 15,000 tonnes ofmaterial a year. This niche market is opening into a varietyof interesting sectors, such as with football stadiums,cricket clubs and golf courses. “That gives you an idea ofthe product’s quality,” says Peter.Other waste material arriving on site with the soil includesblown down trees. This is one of the roles at Worksopwhere the Powershredder 2400 takes the stage. Installed at the end of 2007 it is one of only four in thecountry and was purchased to carry out several functionsbut Nottinghamshire Recycling requested that it be able tohandle large tree stumps before Powerscreen Pegsonprovided a demonstration the machine. The shredderproved that it was more than capable of performing thetask. A 30 rpm slow-speed performance of thePowershredder provides an end-product, the quality ofwhich is sufficient to be used as biomass fuel.

Meeting the hardcore demandThe XR400 crusher, meanwhile, is used predominantly toproduce a 40 mm Down Type 1 crushed recycledaggregate as well as producing a 6F2 product, which is a75 mm Down crushed aggregate.

Black goldNottinghamshire Recycling hasestablished a comprehensive facilityat its Worksop site where it carriesout a variety of recycling activitiesincluding turning virgin soil into highquality topsoil. Ross Matthews visitedthe site in May to see what goes onthere. The Powershredder

▼


22

Rec

yclin

g

www.hub-4.com

Hardcore is currently in short supply in a market where it’snow popular to use 40 mm hardcore base rather than a40 mm aggregate base, particularly as it avoids theaggregate tax.The XR400 crusher, which has been on site for a year, isperforming at up to 130 tonnes per hour to provide thetonnage for the contract and provides NottinghamshireRecycling with the flexibility it requires to win largecontracts.“At the moment we can’t crush quickly enough’’ adding:“Last week we produced 6000 tonnes. That’s a bigcontract. I’m convinced that we got that because we hadthe material.” This performance was dwarfed however bythe record achieved last October of 17,500 tons loadedout in 10 days.The crusher’s plates are easy to change according to Tim.“In the old days to change from 40 to 75 mm would havebeen a two to four hour job to change the settings,whereas on this new crusher it’s done at the touch of abutton and takes just 10 minutes. So you can switcheasily from 40 mm if you get an order for 75 mm,” hesays.Peter adds: “We always crush at 40 mm, stockpile andthen switch to 75 so we don’t get cross contamination;the other way round would be unacceptable.”Quality is the ever-important issue for NottinghamshireRecycling. Again, it’s a pleasure selling the 40 mmmaterial. I went to a site last week, a load of our 40 mmmaterial tipped up next to a load of 40 limestone – therewas no comparison. The limestone was 40% fines. Thefine content in our material was probably only 10%, and itis stronger than limestone.”

The complete recycling facilityThe site at Worksop has developed into a comprehensiverecycling facility. “Bearing in mind we are not finished yet –we are recycling at 82% of gate input.

In addition to the C&D and soil waste screening operation,the company erected a waste transfer station housing thetrommel.During Hub’s visit a 350 tonne pile of waste brought ontosite in skips was standing by the plant waiting to besorted. After a pre-sort the line will operate for 15consecutive days to process the waste, taking out wood,green waste, anything that’s biodegradeable, paper,scrap, and non-ferrous metals. “We recycle even down to the metals, so we segregatesteel, copper, lead, household wire, heavy armoured wire,everything is individually graded. “We pull out any plasticitems also and are currently looking at getting a baler tobale the plastics.”The wood goes through the slow speed shredder to bebroken down as much as possible, while being careful toconfigure a coarse shred so as not to break the wood uptoo small so that when it is then processed through thepicking station it’s not a nightmare to pick out the bits.The shredder allows the high throughput required byNottinghamshire Recycling. Among the uses of the cleanfiner material is animal bedding, providing an alternative tostraw, which is currently quite expensive. Nottinghamshire Recycling is due to erect another buildingto accommodate the wood shredding operation.“The recycling has taken off very well we pleased with theachievements that the company has made,” says KevinBurgess owner. “Every tonne that we divert from landfill it’sobviously a saving but by generating income also we arereinvesting in infrastructure. Nottinghamshire Recycling ishere now and here to stay.“All of us at Nottinghamshire Recycling would like to thankall at Powerscreen Pegson for providing a service secondto none. Nothing is too much trouble. At last a dealershipthat cares about its customers. 10 out of 10 keep up thegood work.”

Tree waste to be shredded

Who is Nottinghamshire Recycling?

Nottinghamshire Recycling, which is owned by KevinBurgess a successful business man, and managedby his wife Alison and Peter Sanderson both directorsof the company. Kevin has three sites all within tenminutes of each other, a very successful skip hirebusiness and a fleet of 11 trucks. In addition toWorksop, the company has a ‘green-waste’ site anda new site for C&D waste. The company has invested collectively £5.5m intoproviding a waste management facility on all threesites. “There’s no reason why that could not be paidback within ten years. And we won’t stop there. Weaim not only to be the biggest but also one of thebest.Peter has a lot of expertise in the waste managementsector and is an active member of the Institute ofWaste Management. Seeing for himself the situationin Sweden, Finland and Holland has shown him thatthe UK is ten years behind in terms of recycling.“The UK produces enough waste on a daily basis tofill the Albert Hall, which is frightening. The wasteinfrastructure in the country is collectively estimatedat some £9 billion under invested in terms of what isrequired to achieve the statistics the governmentwants for 2015-2020.”





25

Qua

rryi

ng

Qua

rryi

ng

www.hub-4.com

Kiln supportroller shaft at LafargeA kiln support roller assemblyhas been manufactured andinstalled by Corus NorthernEngineering Services (CNES)on the 58 m long rotary kiln,the heart of the cementmaking process at LafargeCement’s Cauldon Works inStaffordshire.

Cauldon Works has production capacity tomanufacture up to one million tonnes ofcement each year and distributes this tocustomers in the Midlands and the NorthernHome Counties. It is increasing use of waste-derived fuels as part of its drive for increasedsustainability in its operations. The Works uses a combination of traditionalfossil fuels – coal and petroleum coke – withtyre chips and Processed Sewage Pellets. It isalso permitted to use Recovered Fuel Oil (RFO)and has recently been given a permit toevaluate Solid Recovered Fuel (SRF), which, itis estimated, could reduce its carbon dioxideemissions by around 17,000 tonnes each year.One of the existing kiln support roller shafts atthe Works needed replacing as it was badlyworn. This roller shaft is one of six thatsupports the kiln. The rollers themselves weighbetween 8 and 9 tonne each and have a typicaloperating life of around five years.Lafarge decided to replace the worn roller shaftat the next available plant shutdown, whichwas in February 2008. However, due to theheight and accessibility of the unit under thekiln, Lafarge decided to outsource this work toan experienced contractor, who would beresponsible for removing the old roller andinstalling the complete new roller shaftassembly.Stephen Haywood, project engineer at CNEScommented: “We have a very close workingrelationship with Lafarge and this, coupled withCNES’ vast experience in heavy lifting, removaland installation work, resulted in Lafarge invitingus to tender for the installation work, as well asthe manufacturing of the replacement rollershaft. We beat off fierce competition to securethe contract.”

The removal and installation work took fivedays to complete. First, in order to remove theexisting damaged roller shaft, CNES engineershad to jack up one end of the kiln that the rollerwas supporting. This was carried out usingtwo, 150 tonne hydraulic jacks and the rollerremoved in a two-day time frame.This process involved moving it out from itsposition on skates using lifting slings and liftingbeams, connecting to chain hoists and

lowering it 8 m to a sunken floor. The roller was finally removed from sitefor scrapping and recycling the steel.Fitting the new roller was effectively a reversal of the removal procedure.The new roller shaft was manufactured at Corus Process Engineering atWorkington. The rotary kiln was then lowered back onto the new rollershaft ready for commissioning by Lafarge’s engineering team. In total,CNES engineers spent around eight days on site changing the rollersover.As well as the removal and installation work, CNES manufactured thereplacement roller shaft assembly. CNES Scunthorpe manufactured theshaft and then machined it to suit the roller at Corus Process Engineeringin Workington. Alan Holgate, Estimating Engineer at CNES commented:“For Lafarge at Cauldon, we manufactured the forged steel shaft atScunthorpe, while the roller forging was delivered to CPE Workington.Engineers at Workington machined the inside diameter of the roller, forScunthorpe to machine the shaft to just one thousandth of an inch largerthan the roller bore. The shaft was shipped to Workington, where theroller was placed in an oven to expand the bore before it was droppedonto the shaft to cool down to a tight fit. Once this had taken place, themain diameter of the roller was machined in a large lathe to the requireddimensions and concentricity, before final inspection and despatch toLafarge.”




27

Qua

rryi

ng

Just the job for Scottish Baryte processingIn July, Barhaul (2003), located in Aberfeldy,Perthshire, took delivery of a Rubble Master RM80compact crusher. The first machine of its type inScotland, it has become a vital piece of equipmentto the Barhaul fleet, as the company is undercontract with MI-SWACO, the US miningconglomerate, to process the 50,000 tonnes ofBaryte produced annually by the nearby FossMine.Patrick Bradley, MD of Barhaul, saw the machine beingdemonstrated at Hillhead 2007 and realised that theone machine could outperform the existing jaw crusher,impactor crusher and screening unit.“With rising diesel costs and increasing maintenanceand unreliability of the existing equipment, we had eitherto replace the existing configuration or find a moreefficient solution. My only concern was whether theRubble Master could cope with the density of thematerial and the volume. It has proved more productivethan envisaged, and the mobility of the unit allows us toprocess the material according to grade, directly into thedifferent bays. With the static machines we had to rehandlefrom a central crushing area,” says Patrick.The RM80 has not only proven its capability of handling thematerial but such is the throughput of the machine thatBarhaul have been able to include it in their hire fleet forother work including crushing aggregate, asphalt andbuilding rubble. It is easily transported on a low loader. The performance of the RM80 also meets the satisfaction ofthe MI-SWACO Quality Control Manager on site who saysthat the consistent quality of the end material, <25 mm,reduces the time required in the pan mills as part of the finalprocessing. The highly efficient magnetic separator ensuresthat all metal contamination is removed.The RM80 is equipped with an OS80 screen and OS80RFBrecirculation unit, which eliminates rehandling of the materialby loader. Barhaul believes it achieves a throughput ofsome 180 tph more than anticipated. The material, sized to less than 450 mm is fed into theRM80 with a Volvo L120. The 2.5 m3 feed hopper has anopening dimension of 860 x 600 mm. The 23,000 kgmachine is powered by a Deutz 4 cylinder Tier 3 compliantdiesel engine delivering 123 kW at 2000 rpm.The Environmental Agency also rated the machine highly forminimal dust and low sound levels. According to Patrick:“The Rubble Master RM80 has done everything weexpected of it and more.” Peter Hunt, sales manager, Rubble Master UK says that theinterest in the range of compact recyclers is very highthroughout the UK and that the application demonstratesthe robust nature of the machines, which can process arange of materials, not just recycled material.”

Baryte MiningThe unprocessed materialis brought to Barhaul’s yardin Aberfeldy from the Fossmine, which is 15 km awayat a height over 600 m onthe slopes of MeallTairneachan. Theunderground mine isowned by the ForestryCommission and worked,under licence, by MI-SWACO. The mineproduces over 80% ofBaryte used in the UK.Pilot production of the minebegan in 1981, with fulloutput coming three years

later. The mine is approximately 150 m below the surface atits deepest vertical point and comprises 6.5 km of tunnels.The baryte beds are typically 3 m thick but variations in thegeological structure can reduce this to less than 1 m or todepths in excess of 15 m of pure material. In early 2008,the mine recorded a milestone with the production of its onemillionth tonne. The material is extracted using drill andblast. It is then hauled to a stockpile at the mine head.The raw material is hauled by Terex articulated dump truckfrom the mine head to the end of a undulating 5 km accessroad which follows a ridge up to the mine. During thewinter, access for the 8 miners often has to be done bysnowcat and Barhaul have a snow-blower to help keep theroad open. “Last year, the snow was so deep that wecould not access the mine for 11 weeks”, say PatrickBradley.The material is then hauled with DAF truck with Chieftainhalf-pipe tractor unit with a capacity of 29 t. After primary processing and blending by Barhaul, it is thentransported by road to MI-SWACO’s facilities in Aberdeen, adistance of 170 km away. Patrick Bradley explains “We havemanaged to put together a good transport logistics plan toensure that the trucks coming back from Aberdeen are nottravelling empty. “Over 80% of the world’s production of Baryte is used in theoil and gas industry from drilling mud where the specificgravity of 4.2 minimum and low abrasive properties makes itthe ideal weighting agent.Adjacent to the Foss Mine are much more extensive high-grade deposits of baryte (specific gravity of 4.4). Thesedeposits contain over 13 million tonnes of recoverablemineral. However, planning permission has yet to be givenbecause of environmental concerns.

www.hub-4.com



28

Qua

rryi

ng

www.hub-4.com

Soil Washing Plant inthe front line and stillgoing strongLinatex has provided market leading Heijmens Blackwell Remediation(HBR) with processing equipment that has performed well in soilwashing projects for a significant time.

HBR was formed in 2002 tocombine the capabilities of CABlackwell (Contracts) Ltd, a wellestablished earthworks and civilengineering contractor withHeijmans Milieutechniek - aleading remediation technologysupplier in Holland.Originally working with HBR on acontract basis the plant, whichwas designed and supplied byLinatex, contains all the standardequipment: dewatering screens,pumps, separators,hydrocyclones, sumps, S-typeclassification and includedadditional machinery to ensurethat HBR had a complete workingplant.

The first two projects for the plant were operated as a Linatex Heijmans JointVenture (LHJV) and involved soils washing which was selected as the bestpractical environmental treatment option for the projects.The Basford Gaswork Remediation Project at Nottingham involved theprocessing of some 150,000 tonnes of contaminated soil. As specialist soilswashing sub-contractor LHJV were responsible for the supply and operationof the soils washing installation along with a clean product and plantthroughput performance guarantee.With clean product validated on a daily basis the contract ran over a durationof 18 months. Utilising selective excavation to minimize the volume fortreatment and maximisation of plant throughput the quantity treated was152,000 tonnes of successfully processed material.

Site remediationIn a second project at the Arjo Wiggins factory site at North Hykeham inLincoln the plant was again put to the test to process materials for siteremediation; formerly used in the manufacture of thermal papers it hadbecome contaminated with metalliferous mercury, zinc and asbestos.Primarily driven by high ground water vulnerability a comprehensive optionstudy showed that volume reduction by soils washing was the best practicalway forward.With a contract period of 51 weeks the soil washing plant was set up on aprepared impermeable surface complete with leachate collection system forwashed stockpiles and the ‘dirty’ area. With all process water, productleachate and surface run-off being treated and recycled within the plant, theon-site application soils washing resulted in the removal of 4.5 tonnes ofmercury and 26 tonnes of zinc. Additionally, residual levels of asbestos werereduced to below the required standard of trace or non-detectable.On-site treatment also saved in excess of 6,000 lorry movements that wouldhave resulted from bulk disposal and reinstatement with clean fill. The savingin landfill void was approximately 84% when compared to dig and dump. Theaverage production achieved over the project was 500t/day with the totalquantity treated 72,000 tonnes.Having now purchased the semi-mobile plant (now based in Europe) fromLinatex, HBR successfully completed a phase one enabling work project atMiddlehaven Docks where the general philosophy of the reclamation projectwas the re-use of all materials available on the site. Comprising nearly 250,000 m3 of reworked oversite clays, lagoon dock silt,builders’ spoils, demolition arisings and dredged silt from the main dock areathe plant was successfully employed over a period of 70 weeks.Today, the plant is currently situated in the south east of England employedon a high profile site remediation project involving the on-site removal ofcontaminates and heavy metals plus the recovery of soils with all materialbeing recycled, and sized into standard gravel and sand fractions for re-usewithin the site.

Soil WashingThe main process employed in a Soils Washing plant is particle sizeseparation by hydrocyclone. This should however only be considered as thecentral element of a plant comprising a large number of process stepstailored to a specific application. Linatex Cyclones are an extremely simple and economical means ofclassification, especially in open and closed circuit grinding operations. Theyare also widely used to dewater solids from slurry streams, to separate slimesfrom sands and to recover fine particles from effluent streams. LinatexCyclones are fully lined internally with Linatex Rubber to maximisecomponent wear life, and minimise maintenance requirements.

Newbold Quarryinstalls five newscreensOwned and operated by AggregateIndustries, Newbold Quarry is locatedat Barton under Needwood, nearBurton-on-Trent, Staffordshire.Supplying sand and gravel to localmarkets the quarry has recentlyinstalled a new processing plant.Within the sand classification anddeligniting plant, designed and built byMEP of Salisbury, Hewitt RobinsInternational (HRI) was awarded thesupply of the screens.Five screens were supplied for the project;comprising of a HRI 2200 mm wide x4200mm long LPE-11 horizontal vibratingscreen with a duty of 160 tph of –6mmsand and water; 60% solids by weight toseparate excess grit.An HRI 1800 mm wide x 6000 mm longLPE-9 horizontal vibrating screen with aduty of 100 tph of –1mm sand and water;50% solids by weight to separate coarselignite with fine sand and water passingthrough.Three de-watering screens (angled at 5°)were also supplied, which included a HRI2500 mm wide x 6000 mm long E-13 de-watering screen with a duty to de-water350 tph of -6 mm (concrete) sand with upto 200 m3/hr of water. A HRI 1600 mmwide x 4800 mm long LPE-9 de-wateringscreen with a duty to de-water 100 tph of-1 mm (building) sand with up to 60 m3/hrof water. A third HRI 1000 mm wide x2400 mm long LPE-6 de-watering screen,with a duty to de-water 6 tph of –0.25 mmsand with up to 6 m3/hr of water capturesany residual sand.All five screens were twin shaft, fourbearing single-deck machines equippedwith Eliptex vibrator units and fitted with a450 mm feed box and 150 mm dischargelips both complete with 10 mm thick PUliners, support springs, spring base plates,v-belt drive and motor pulley. The Eliptex vibrator mechanism imparts athree-way motion, with horizontal, verticaland elliptical components, productcapacity and efficiency is maximised. Themechanism is of simple construction,rugged design and is built from highquality components assuring extra longlife. The elliptical motion provides highercapacity and cleaner material and isavailable in either oil or grease lubrication.All screens were successfully delivered ontime; Martin Owen – engineering managerat Aggregate Industries comments: “TheHewitt Robins screens have lived up totheir reputation for sturdy and reliableoperation in this high tonnage application.”

www.hub-4.com/directory/507www.hub-4.com/directory/1901



30

Qua

rryi

ngAsphalt screen project goessmoothly at Minffordd QuarryA project to supply a new asphalt screen for a Barber Greene batch tower atMinffordd Quarry has recently been carried out. Owned and operated byTarmac Western, Minffordd Quarry is located near Penrhyn, North Wales. Agranite quarry opened for setts in the 1870s, following the opening of theAberystwyth and Welsh Coast line; today Minffordd is now operated on asignificant scale incorporating a crushing and screening plant with a coatingplant playing a significant part of the daily operations.The 2 ton, 80 tph Barber Greene batch tower currently operating at Minfforddwas previously supplied by BG Europa. Having being originally installed atTarmac Western Dolyhir, the plant was subsequently moved to its presentlocation.As principal contractor for the recent project BG Europa supplied a newFinedoor 4 x 1.4 m – five full and one half deck vibrating screen. Constructedof 10 mm thick rigid side plates complete with heavy duty bolted in decks thenew asphalt screen incorporates greased bearing lubrication. High tensilewoven wire mesh panels were fitted with apertures as specified.BG Europa also supplied a replacement screen base frame complete with sealrubbers to suit the new screen and existing hot stone bins. The screen springsupports and an 18.5Kw electric motor drive are all located on this frame.Screen dust housing was also supplied which incorporated bolt-on panels anddischarge hood with folding division plates to allow access to screen meshes. Several ancillary items were also supplied including additional ducting, asection of hot stone elevator complete with chain and buckets and a wearplate lined discharge chute, which was installed between the hot elevator andscreen. A stairway extension with handrails to modify existing access to thehot elevator head completed the specification.The new screen was fitted onto a new base frame supplied and enclosedwithin the dust housing at the BG Europa - Ashbourne workshop. Thisallowed the entire new screen section to be lifted into the Barber Greenebatch tower in one operation. Installation was completed on Good Friday withthe removal of the tower roof, with the new screen lifted into position on BankHoliday Monday resulting in full plant operation by the Wednesday.“A very professional and extremely well executed operation carried out safelyand to a high standard,” concludes Malcolm Ellis, quarry manager,

Two heavy dutyHerculesTrommelsmanufacturedby StelexConstructionEquipment Ltdof Whitchurch,UK, arecurrently

operating on a major port extension project in Qatar.The construction project, the largest in Qatar, is a jointventure operation between Qatar Quarries andBoskalis Dredging for the building of the Rashaffanport extension, on Qatar’s northeastern coast.Both Trommels, Model HT232s, have a barrel diameter of2.3 m and are capable of through putting as-dug rock at arate of 1000 tonnes/h. Working 24 hours per day, sevendays a week, the machines are supplying clean graded rockfor the building of a deep-water harbour and breakwater.The two machines are the largest Hercules Trommelsoperating outside of the UK.Rock blasted and dug from the quarry face is fed to theTrommels, which are positioned side-by-side at the rockface, by a fleet of dump trucks.The feed hopper, which can accommodate 160 tons, ismade of Hardox steel to provide high wear resistance. Avariable speed reciprocating plate feed table, which issupported on rollers beneath the hopper, moves materialinto the barrel via hydraulic rams that can be adjusted to therequired tonnage.The 2.3 m diameter barrel (made up of two 4 m longsegments) is manufactured from high-grade steel bars

welded to form segments which are bolted together. Theapertures were made to suit this customer’s individualrequirement. The barrel is supported on four steel rollers,two of which are driven by heavy duty, variable speedhydraulic motors (no drive chain or sprockets to maintain).The speed of the barrel, which is variable, can be set to suitthe type of material that is being fed to ensure optimumcleaning and grading at all times.Drive for both the feeder and barrel is provided from aseparate, remotely stationed electric/hydraulic power pack.As part of the contract the machines were specified tooperate in temperatures of up to 50oC.The cleaned limestone rock is loaded direct from thetrommels into large road transport vehicles for delivery to theconstruction site storage yards.All the equipment was designed, built and commissionedwithin the scheduled timeframe and put to work on site byStelex engineers. When the project is completed, theHercules Trommels will have processed over 30 milliontonnes of rock for the construction of this new breakwater,which will provide additional deep water port facilities for theincreasing shipping traffic through this important seaway,including large LNG container vessels bound for the UK.In recent weeks, Stelex have been busy installing their latestrental mobile trommels in several large quarries in the UKand Europe, as quarry operators are recognising thepotential value of their hidden reserves. These machines arecarrying out recovery trials on overburden and difficultmaterials which would normally be tipped as waste. Theseoperating trials have shown recovery rates of up to 90 percent can be achieved.

Double success for Stelex in the Gulf– two hercules trommels on majorport extension in Qatar





www.hub-4.com32

Qua

rryi

ng

On-site weighing and loadmanagement system forTarmacAn integrated weighing system system has aligned Buxton Lime andCement business processes and systems with other Tarmac operationsto increase flexibility and allow for future development

The construction of a new cement plant at Tarmac’sTunstead Quarry in Derbyshire has helped to createone of the busiest sites in Europe, with productmovements in excess of 6 million tonnes per annum.With more than 650 vehicle and multiple trainmovements every day carrying cement, lime, chemicalstone, concrete aggregate, and raw materials into andout of the site, Tarmac needed an integrated weighing,automated cement loading and traffic managementsystem capable of interfacing with its own SAPsystem to meet the diverse needs of this huge multi-operation facility.

Precia-Molen was chosen to design and build asystem based around the market-leading GeneSYSand GSM software.

Three Tarmac units are based at Tunstead Quarry.Aggregates, cement and lime (both bagged and bulk)are sold from the site, primarily under the name ofTarmac’s subsidiary Buxton Lime and Cement, anddelivered by road to locations throughout the UK.Chemical stone for delivery into the soda ash industryand to several of the companies’ power stationswhere it is used for flue gas desulphurisation andcement are also dispatched by rail. In addition, up to70 loads of raw material are delivered to the site everyday.

The operation also encompasses the neighbouringHindlow site and remote cement loading depots (railfed) located in the West Midlands, Yorkshire andLondon.

Tarmac required a flexible and innovative on-siteweighing and load management system that wascapable of encompassing all operations. It needed toseamlessly integrate with the driver self-loadingremote cement dispatch depots and handle more than250,000 dispatches per year.

The system also needed to provide fast and accuratemanagement reporting to monitor site performanceand efficiency, as well as replace two existingdispatch systems.

Precia-Molen designed and built a bespoke solutionthat deployed the power of GeneSYS. Utilising aweighbridge management system developed in-houseby Precia-Molen, the system has aligned Buxton Limeand Cement business processes and systems withother Tarmac operations to increase flexibility andallow for future development.

The system integrates the operation of eightweighbridges, two batch weighers for rail car loading,and a total of 18 driver consoles which enable fullyautomated dispatch operations across the site.

The installation also includes a new weighbridgeentrance comprising three weighbridges, eachincorporating a driver console, traffic barriers andtraffic lights. A special fast track weighbridge facilityenables even faster processing of Tarmac’s regularfleet of vehicles, which can arrive 24 hours a day andpass simply through the entry and exit weighbridgestation.


In operation

To accomplish seamless operation from ordering through toinvoicing, the GeneSYS system is fully integrated withTarmac’s own sales order management system. When anorder is placed, it is entered into the sales system andmatched against quotes set up in SAP. GeneSYS thenimports the order ready for collection or dispatch.

Preferred road vehicles visiting the site are pre-issued withRFID cards for identification. On arrival the vehicle drivesonto the weighbridge and the driver presents the RFID cardto the cab-height driver console and enters an order number.GeneSYS then weighs the vehicle and, if the tare weight iswithin expected tolerance, a loading slip is issued. Data forpreferred vehicles is kept permanently by the systemenabling faster verification and entry to the site.

If the vehicle is new to the site, the driver reports to theweighbridge operator, who inputs the registration details andorder number. The vehicle is then weighed, issued with aloading slip and a single use RFID card and proceeds to theloading areas.

For bulk loading the driver proceeds to one of the numerousdriver-operated loading points which feature automatedloading. GeneSYS verifies the vehicle is at the correctlocation and signals via the integrated PLC that the loadingoperation can start.

For vehicles being directed to the aggregates stock pile area,the order details are sent to the loading shovel via atelemetric link where the operator verifies that the vehicle isto be loaded with the correct product and tonnage. Onceloaded the vehicle proceeds to the check weighbridge wherethe order weight is checked against the loaded weight and ifwithin tolerance is directed to the exit weighbridge.

For bagged cement or lime products, the driver simplypresents his loading slip to an operator. Once loading iscomplete, confirmation is entered into GeneSYS and thedriver proceeds to the exit weighbridge.

All vehicles return to the exit weighbridge to receive theirdispatch documentation. The RFID card is inserted into thedriver console, allowing the driver to confirm the final weightand receive the relevant documentation. Where multipleloads are required, the RFID card is returned to the driver forfuture use – otherwise it is retained.

In addition to the continual road traffic multiple rail dispatchesof either cement or aggregates leave the site every day,delivering product either to major customers or to Tarmac’sremote dispatch depots.

Cement rail loading is managed by two Precia-Molen batchweighers with the loading details entered into GeneSYS forintegration into the site’s other operations.

Raw materials and fuel are delivered to the site by road. Aswith the sales process, a vehicle may arrive either with orwithout a pre-issued RFID card. On arrival, GeneSYScompares the load details with the purchase order on SAP toconfirm acceptance, and while the vehicle is being unloadedGeneSYS checks whether that vehicle has then beenassigned to dispatch an order. If so, a loading instruction isissued which directs the driver to the appropriate loadingpoint.

A single system

Precia-Molen has provided a powerful and flexible system,which has met or surpassed the needs of this busy anddiverse quarry operation.

Tunstead now has a single system that encompasses thecement, lime, concrete aggregate and chemical stoneoperations, enabling fast and efficient throughput for highvolumes of road and rail traffic.

The system provides integration and operation of rail-fedremote driver self loading dispatch depots, reducing roadvehicle movements by up to 70 a day. Precia-Molen hasalso built in system resilience and data replication to allowremote dispatch depots to continue operation in the event ofa communication failure.

In addition, the system is fully integrated with Tarmac’s ownSAP sales order and site systems, providing sophisticatedmanagement information.

The GeneSYS-based solution has created a stable andexpandable platform for the management of the entire site,doubling weighbridge operator capacity and providingimportant performance and management information.

The new system is one of the most advanced automatedloading operations in Europe, and with the integration of thenew remote dispatch depots in the West Midlands, Yorkshireand London, Tarmac has been able to expand into thesemarket areas.

Nick Thomas, Buxton Lime and Cement distribution managerfor Tarmac, says: “The installation of Genesys has broughtabout many benefits for Tarmac Buxton Lime & Cement. Wehave greatly improved our throughput of vehicles withoutincreased staffing and enabled our remote cement depots tofunction as driver operated units. From the standard systemoriginally purchased Precia-Molen and Tarmac havedeveloped the program to meet the needs of the businessand integrate all part of the various units. We are delightedwith the functionality and flexibility of the current version.”

33

Qua

rryi

ng



34


35

Dus

t M

anag

emen

t

ww

w.h

ub-4

.co

mD

ust

Man

agem

ent

Within quarrying operations there are two basic typesof dust: heavy dust and respirable dust. Heavy dust isa particle that can become airborne down to 50microns and because it falls at around 200mm/second, it is unlikely to make it beyond theborders of the quarry. Heavy dust is readily seen as acloud with the naked eye.Respirable Dust, which is anything below 50 microns in size,can be breathed into the lungs and may stay in the air forover 30 minutes. This type of dust causes the greaterproblem for quarry operators as it can travel beyond the siteboundaries. Even at this size, when present in large enoughquantities, it can be visible as a dust cloud. Respirable dust is most commonly seen as a fine coatingwhen it settles on machinery or other surfaces within thequarry site as well as on leaf surfaces beyond the boundary.Respiratory dust is a real problem for many quarriesbecause a cross wind can agitate the dust once it hassettled, where it again remains in the air for another 30minutes or so. Through this process, it can travel a relativelylong distance causing a serious issue for the surroundingenvironment.

Filter bag media selectionOne of the best methods of achieving effective filtration inquarry operations, that do not process finished product, ispolyester bag filters. These are particularly effective for stonedust generated through crushing and sieving operations.Polyester is one of the most widely used synthetic fibres inthe world due to its versatility, tenacity and costeffectiveness. Polyester bag filters are available in a selection of fibredeniers, which allows the quarry operator to choose a range

of felt efficiencies. Bag filter media supplied to quarryoperations range from 0.5 to 6 denier. In a dry environment,bag filters can operate continuously at over 140?C,depending on fibre type. For more demanding applications,there are chemical, mechanical and thermal treatmentsavailable. Where dry and fine dust is present in a quarry,polyester bag filters are supplied with conductive fibres suchas Steel, Epitropic and Copper Sulphide to prevent staticbuild up.For quarry operators that process finished product, such asasphalt, selection of bag filter media is crucial in achievingthe required filtration levels as well as bag life. Within thesetypes of operation, the bag filter is used on the rotary dryer

Over the last decade, air filtration requirements in the quarrying industry have becomeever more demanding, which means operators have to constantly review both the healthand safety as well as environmental aspects of their business. Here, Stuart Ainsworth,takes a look at how filter bags can become an integral part of maintaining clean air.

Instrumental inmaximisingpotential

▼

There are two types of dust in quarries: Heavy and light dust,both of which create issues for quarry operators.

Bag filters are an integral part of ensuring compliance in many quarry operations


36

Part of the Finlay Group of Companies

Finlay Hire Ltd., A member of the Finlay Group of Companies,

Lakeside House, Ladford Covert Industrial Park, Seighford, Stafford ST18 9QL

THINK Finlay

e. hire@fi nlay-group.co.uk w. fi nlaygroup.com

t. 01785 282 323

THINK Choice THINK

QualityTHINK Value

THINK Hire...Finlay Hire provides a top choice of premium-quality

materials - processing equipment, available for hire at

highly competitive prices – with no-nonsense, on-time

delivery anywhere in the UK.

We’ve more than 120 machines

in our fleet, including screens, jaws,

cones, impactors, rinsing and washing equipment,

plus trommels and tracked grids.

We offer a range of hire agreements including

spot hire, contract hire and hire with option or

commitment, all conducted under CPA model

terms and conditions.

So call Ray on 01785 282 323 - and benefi t from Finlay service, where choice, quality and value come as standard!


ww

w.h

ub-4

.co

m

37

Dus

t M

anag

emen

t

together along with various other locations within theprocess. This application requires special high temperaturebags made predominantly from Aramids. Nomex was theoriginal meta Aramid and as such is still the industrystandard, being widely recognised as technical the best.Other fibres for more demanding applications include P84and PTFE.

Issues with filter bagsMany of the issues faced by quarry operators includepremature bag failure and this is often because ofinappropriate media choice, poor cage fitting, overtemperature, poorly fitted bag or aged bag. Bags generally should last around two years, although this ishighly dependent on each application, however, it may beworth talking to your bag supplier if it is significantly less thanthis. Generally the first indication many quarry operators haveof a problem with the bags is when they have issues withtheir emissions test. In many cases it can be as simple as a very small (10mm)hole developing in one of the bags or even one poorly fittedbag. We are also finding that many bags in the market arenot manufactured to adequate quality standards, resulting ina loose fitting around the collar. In these situations air forcesits way through the hole or gap, with the result of a failure.

Stack Emission TestMany bag suppliers offer Isokinetic Stack Testing &Certification and it’s worth asking if they are also a MCERTand UKAS accredited company. Often the best method ofachieving the required standard for ongoing stack emissiontests is to implement a Managed Maintenance Programme.An effective maintenance programme should have within it aregular Filter Unit assessment repairing, where necessary, toensure the quarry operation complies with Stack Emissionrequirements. These types of programmes can help ensureplant is ready, performing efficiently and is up to standard,therefore reducing costly unplanned downtime and failures.

Managed maintenance programmesOther benefits of adopting a managed maintenanceprogramme are that it helps identify filtration issues early,which potentially avoids any large scale emissions to theoutside air. The key to achieving an effective maintenanceprogramme is to ensure the supplier offers supportingproducts and services. This means a filter bag removal andfitting service, unit assessments and reporting of potentialproblems, UV leakage testing to quickly identify damagedfilter bags and leaks, unit repairs and advice to avoid future

unplanned downtime, new filter cages, seals, diaphragms,solenoids, regular inspection as an ongoing programme,supported by Method Statements & COSSH Assessment.Offering a bag analysis service is also a key area as this canpotentially save money, particularly if it identifies issues withthe system, as well as improving filtration efficiency. Managed maintenance programmes can therefore be a hugebenefit to quarry operators and with many bag suppliescarrying out the servicing during planned downtime, annualshutdowns or weekends it can easily maintain productivitylevels. These types of programmes also mean that quarryoperators have one less thing to worry about, which in abusy and competitive environment is an invaluable benefit. Bag filter manufacturers are constantly looking for ways toincrease filtration efficiency in an effort to help quarryoperators achieve clean air targets. Achieving improvedlevels of filtration makes both the quarry operation andsurrounding areas cleaner and safer. There have been manytechnical advances in filter media in recent years and manybag suppliers are taking this a step further by offeringplanned maintenance programmes.

Footnote:Stuart Ainsworth is Business Development Manager ofTyne Tees Filtration (TTF), which has many years’experience in developing and supplying advanced filtrationsolutions for bulk crushing operations via a worldwidenetwork of end users and bag-filter OEMs.

Close up of dust particles trapped by the fibres of a bag filter

Explosion-proof controls enable dust-freeloading of dry bulk materials

A range of hazardous area electrical equipment,including terminal boxes, control stations,emergency stop controls and enclosuresmanufactured by Cooper Crouse-Hinds (CEAG), arebeing used on loading systems for handling dry,potentially-explosive bulk materials, includingcement, alumina, sugar, petroleum coke, grain andsulphur.Based in Stockton-on-Tees, Cleveland Cascadesdesigns and manufactures a range of custom-designed,retractable loading chutes for the handling of dry bulkmaterials. Using its patented Cascade system, thecompany has more than 400 systems in operationaround the world in various ship, silo, rail and roadtanker loading applications. The company is consideredto be a market leader in its field and its product theindustry standard. ▼

Hazardous area control equipment from Cooper Crouse-Hinds on a sulphur chute destined for Russia



38


ww

w.h

ub-4

.co

m

39

Dus

t M

anag

emen

t

Ray Ollis, electrical design engineer at ClevelandCascades comments: “We’ve been purchasing CEAGequipment for many years now, via Scattergood &Johnsons, our local distributor in Leeds. When it comesto offering loading chutes for hazardous environments,we provide a detailed design specification toScattergoods, who would then source the requiredcontrol stations and terminal boxes from CEAG. Up tonow, the CEAG equipment has been very reliable andwe’ve never had a single problem from the customeronce we’ve installed the system.”All other dry bulk loading systems currently available onthe market enable bulk material to freefall and in doingso, pull volumes of air down with the falling material. Thisair needs to escape at the base of the chute and whendoing so, carries the separated material particles, causinghighly visible dust emissions, which is not only a nuisanceto the local environment but which also creates apotentially explosive atmosphere. These systems wouldrequire a dust extraction to attempt to recover this dust-laden air.As Ollis explains: “Unlike free fall chutes, the Cleveland

Cascade chute gently supports the material being loaded all the way down the vertical length of the chute and in doing so,maintains a constant and low velocity, which together with the cone shape, keeps the material in mass flow form. The lowvelocity means the material does not pull air down with it and so if there is no air to escape, there is no dust generated.”The Cleveland Cascade system constrains the material to flow in a zigzag path through inclined cones to limit the flowvelocity and therefore prevent particulate separation, material degradation and segregation. In this way, dust generation isvirtually eliminated at source, without the need for expensive and energy-intensive dust extraction and filtration systems.The Cleveland Cascade system is so successful that Cleveland Cascade is the only company in the world who cancurrently guarantee dust emission levels down to less than 5 mg/m3.Ollis continues: “We normally have to retrofit our loading chute to the ship or tanker. This involves a lot of engineering effort,both mechanical and electrical. For example, if the customer needs to load 200 tph of cement to a tanker, we have todesign our chute and associated control equipment to cater for this. This means we sometimes have to use customisedcontrol stations and junction boxes.”According to Ollis, chute controls can be integrated with the customer’s existing PLC equipment or operated independentlywith a dedicated controller. The controls for the chute would normally be located in a gallery, close to the conveyor, orremotely. In either situation, especially when ATEX certification is required, CEAG control stations are used, which typicallycomprise emergency stop-start controls, reset and raise controls, stainless steel or plastic enclosures (depending on theapplication) and terminal boxes.In order to monitor the loading of dry bulk materials, a pair of level probes are located at the bottom of the loading chute,terminated to a CEAG junction box. If the job requires full installation, Cleveland Cascade would then provide full chutecontrols.“People are starting to wake up to the ATEX regulations and more jobs are now including this type of hazardous areaequipment. Out of the nine enquiries currently on my desk, three require ATEX approved control equipment. We’re currentlytendering for a contract in Spain with the oil company Repsol, which involves a lot of ATEX Zone 21 control equipment. It’sfor a loading system for filling open road wagons and we will use CEAG controls and terminal boxes for this application,”says Ollis.

A standard Chute inCasablanca


INMALO takes on DustBossdistributorship

International Marketers (London) (INMALO) has been appointed distributor for theDustBoss line of mobile dust suppression units, manufactured by Dust ControlTechnology of Illinois, USA, which offers solutions for the control and suppressionof dust from construction and demolition sites to landfill operations, quarries torecycling processors and composting facilities. The designs feature a fully automatic, oscillating ducted fan with a high pressure mistingsystem that creates a Virtual Dust Barrier - an ultrafine mist that attracts dust and drives it tothe ground. The DustBoss units can blanket an area between 511 and 1,950 m2 in size,depending on the model. They produce dust-attracting water particles ranging in size from50-200 microns – the optimum size for agglomeration of dust particles.Requiring only a water supply and generator, a DustBoss unit canbe easily set up by one person in around 30 minutes and then

requires no further attention.Commenting on his new distributorship, INMALO MD John Polak said:

“The DustBoss equipment is crucial to help maintain responsibleenvironmental controls on all types of sites throughout the UK. Healthand safety is also an issue with the huge reduction in dust and

odours for site personnel and often neighbouring premises. Furthermore we are alreadyserving the relevant markets with our range of MBI hydraulic attachments and theaddition of DustBoss to this range allows us to provide our customers with a “totalsolution” package. We are pleased to be able to offer this quality equipment in the UK.”


DustBoss DB30

DustBoss DB60


40

The Plant And Waste Recycling Show

15/16/17 June 2009 at Torbay Devon

A special message to Skip

Hire Companies and Waste

Transfer Operators, a show

not to be missed.

Put the 15/16/17 June 2009

in your diary and why not

bring the family and have a

break at the same time.

Our friends at The Skip

Magazine will have a nice

surprise during the show for

you and your Industry!!

e. [email protected] t. 01962 870355 f. 01962 870956 w. www.pawrs.com

The Best Show For Networking Business and Family

BOOK NOWwww.pawrs.com

International event for Plant and Waste Recycling with new organisers,

new ideas, international exhibitors but the same location and same space

P L A N T A N D W A S T E R E C Y C L I N G S H O WPaignton, Devon, UK15, 16, 17 June 2009


Blue show at RWM Exhibiting its new brand, Blue Group showed aDoppstadt AK-430K mobile high-speed shredder and aKiverco mobile picking station was displayed outside inaddition to the introduction of the Nihot SDS 500 Drum– Blue is the non-exclusive partner of Nihot and isintroducing this company’s range to its portfolio ofwaste products. With this compact version of the SingleDrum Separator type SDS 500-C, Nihot is anticipating agrowing need for customers for a semi-mobile single drumseparator, which can be operational on site in the shortestpossible time.

The SDS 500-C is a compact unit on a base frame, and fitsin a 20 ft container. It’s a plug and play concept, whichmeans that it is equipped with the necessary product inputconveyor and subsequent output conveyors for theseparated light and heavy fraction. All motor drives areconnected and an Electrical cabinet is controlling theoperation of the machine. It also includes a compact FilterUnit. Depending on the specific client and site situation, theunit can be operational within 4 hours after delivery to thesite. Applications include sorting, recycling and up grading ofa variety of waste types.

41

New

s fr

om

RW

M 0

8

New

s fr

om

RW

M 0

8Biggest ever Rocket launchAccelerated Compost launched its largestRocket. The A1200 can recyce 2.5 tonnes of cookedand uncooked food waste every week. Five A1200sare already in use at Aardvark Recycling and arehelping to divert around 650 tonnes of food waste fromlandfill each year. Huw Crampton, general manager atACL, commented: “With more food waste beingdiverted from landfill than ever before the A1200Rocket has an increased capacity to effectively reducethis further. The combined capacity of all the Rocketscurrently out ‘in the field’ means organic waste tolandfill reductions are in the region of 3,700 tonnes peryear...and growing.” A sixth A1200 Rocket® is currentlyin production ready for exporting at the beginning ofOctober to the Exxon Mobil site in Chad.

Joined to separate Eriez and Toratec exhibited their combined metalseparation system for the first time. Thisarrangement achieves several separation objectives.The primary separation stage is aimed at separatingstainless steel using a new, ultra high strength EriezRare Earth Magnetic Drum. Material then passesdown into the Eriez RevX Eddy Current Separatorwhere the majority of aluminium is separated. The finalstage is the Toratec Air Metal Sensor system wherematerial such as wires and smaller metals arerecovered. This enables maximum metal recovery withlimited loss.

Visitors to the Eriez stand were able to see thecombined module in operation and witness itsseparation capabilities. The system is the result of an alliance betweeen EriezMagnetics and Toratec, which provides a single sourcefor companies processing and recycling metals seekingthe latest technology for magnetic separation, EddyCurrent separation and sensor based sorting witheither air or paddle metal rejection methods. Eriez, which has developed many systems for therecycling industry including Eddy Current Separators, aspecialist range of Metal Detectors and high intensitymagnetic separators. Toratec has 15 years ofexperience in recycling technologies for bulk materialseparation. Its equipment uses sensor-basedtechnology for different kinds of sorting tasks. For the recovery and sorting of non-ferrous metals, themetal sensor sorting machines are a perfect match inexisting as well as new recycling plants to separate allmetals from post shredder material. As well asoperating in the automobile recycling and electronicrecycling markets, Toratec’s equipment is an idealcomplement to standard solutions such as EddyCurrent separators and magnets, to recover all metalsin demolition waste, incineration and steel slag,woodchips or even household waste sorting plants.




Tracked DOPPSTADT AK-430K

Metso Lindemann mobilises recycle crushingMetso unveiled a new recycling crusher that combinesrecycling efficiency with manoeuvrability. The CR 225 LTcombines the waste recycling capability of the MetsoLindemann CR 225 crusher with the mobility of the track-mounted rock crushers manufactured by fellow Metso groupcompany, Metso Minerals.Weighing in at 39 tonnes, the new CR 225 LT is powered by a415 kW Caterpillar C15 ACERT diesel engine and carried on atrak-mounted chassis based upon the LT106 rock crusher,which allows the machine to manoeuvre under its own power.At the machine’s heart is a CR 225 crushing unit that featurestwo counter-rotating rotor blades, which revolve at up to 40times per minute. The geometry and combination of rotor andstator tools results in a sturdy anchorage and selectivecrushing of abrasive parts up to a length of 150 mm, whiledelivering a throughput of 30-50 tph.


www.hub-4.com


Software forweight deriveddataAvery Weigh-Tronixlaunched a softwarepackage for the wasteindustry that it claims isthe simplest to install,use, maintain and

upgrade for the management of weight deriveddata. Called MI PAYLOAD, the new software package isa set of software applications for distribution,transportation and supply chain managementprocesses.Able to link to both new and existing weighbridgeinstallations, it enables customers to identify and weighvehicles and trailers, manage customer and suppliercontracts, and invoice and receive payments. Simon Hallam, global software solutions director atAvery-Weigh-Tronix said: “Our MeasurementIntelligence software focuses on ease of use. It has afriendly and attractive interface; familiar and logicalscreen layouts; and predictable function keys that areeasy to use for both basic and advanced use. Newmodules will be released on an ongoing basis that willfurther increase its application and depth of function.”

42

New

s fr

om

RW

M 0

8

ww

w.hub

-4.com




Compositeweighbridgeconceptbringsimportantcost savingsWeightron Bilanciai introduced its steel-concretecomposite weighbridge. The SPB-MC is available in 50 tonne capacity with lengthsup to 18 m and installation can be carried out quickly andexpediently without the need for heavy craneage. The design uses close-coupled longitudinal beams and outerframe to provide exceptional strength and durability,especially in harsh operating conditions. The modular steelframe, together with the integral floor pan and reinforcingmesh, is fitted in place on dummy load supports and thenthe concrete infill is poured directly on site. Once the deckhas hardened the load cells can be fitted. The SPB-MC iscompatible with standard analogue load cells or BilanciaiCPD digital units. If digital load cells are chosen, operatorscan make full use of Weightron Bilanciai’s optionalTelemaintenance remote support package.

Crushingpower forSMEsSo new wasBaughans’ 21 x21 Jobber, beingshown on thecompany’soutside stand, that the paint was barely dry. Thisnew small mobile crusher launched at RWM is aimed atSMEs and has a 21 x 21 in. jaw with single toggleaction. The steel tracked unit derives power from its 3cylinder Deutz air-cooled engine. It has a hydraulicallydriven folding conveyor, with an optional magnet, and asteel work platform. Output is 10-130 tph.

Toyota Material Handling was discussing on itsstand how the company has worked with a newrecycling plant to provide a greener materialhandling solution.The Closed Loop recycling plant in Dagenham is a worldfirst – the first plant to take in both PET and HDPE wastebottles and return them to food grade raw material foruse in manufacturing new bottles. With the capacity to process over 35,000 tonnes ofwaste plastic each year, Closed Loop’s recycled productsare already in demand by large packaging producers likeCoca Cola and Nampac, keen to manage theirenvironmental impact. Five lorry loads of baled waste that would otherwise bedestined for landfill are delivered to the site each day togo through an eight stage process of sorting cleaning andsterilisation. A fleet of new Tonero forklifts from Toyota areused to unload the lorries and transport bales of flattenedbottles to the conveyors for processing and to load thefinished product in bags for delivery to the customer. Fitted with bale clamps, the Toneros compress the balesto allow easy handling even when the strapping isremoved. Bryan Barnes, production manager explains why theTonero is so suited to the work on site: “Unloading thelorries and bringing the bales into the plant requires thedrivers to make frequent changes of direction. The Tonerois very easy to handle and the operators enjoy using it.The design of the instrument panel and overhead guardgives good all round visibility and the SAS system helpsus feel confident that we are putting our drivers in one ofthe safest trucks around.” Toyota’s System of Active Stability (SAS) helps to supportthe driver by “stepping in” to stabilise the truck if apotentially dangerous situation is detected. Sensorsmonitor the load, speed and turning rate of the truck,causing the swing lock cylinder to temporarily lock thesteering axle, improving stability at critical moments,reducing the likelihood of a side tip-over. The instrument panel, overhead guard and mast havebeen redesigned to give good visibility in all directions,helping operators to manoeuvre safely and productively. Active steering synchronisation ensures that the positionof the wheels is always inline with the steering wheel.This supports drivers making frequent changes ofdirection as they can easily tell the position of the wheelsand the expected direction of travel when they begin tomove.To further improve safety Closed Loop specified theSafety+ Package. This allowed the company to tailor theTonero to their needs with a package of competitivelypriced factory fitted options. A speed limiter ensures sitespeed limits are adhered to and controls accelerationwhen the truck is carrying a load. A load weight indicatorallows operators to asses the weight of each bale beforeit is lifted to helping to ensure the truck is not overloaded. Dave Brown, from the Toyota sales team has worked withClosed Loop from the outset to specify a fleet that metthe needs of the plant: “Toyota can offer a wide range ofoptions to help recycling plants like Closed Loop be asproductive as possible, from additional safety features, tospecialised radiators and filters to protect against debrisbeing drawn into the engine. We can also advise on awide range of specialist options and attachments such asclamps and rotators to assist the safe handling of bulkmaterial.” For operations director Colin Jackson, it was alsoimportant that the company supplying the forklifts fittedwith the ethos of Closed Loop: “It goes without sayingthat as a recycling company, we examine every area ofour business to reduce the environmental impact. Solarand wind power help to reduce our energy use and wetake great care to clean the water used in our processesto allow it to be returned to the water system.” Colin concludes: “With the truck itself being 99%recyclable – it’s perfect for Closed Loop”

Part of theprocess atClosed LoopRecycling



43


DUSTSUPPRESSIONUNITSfull range of tractors,water tankersand applicators.

www.. co.uk

NATIONWIDE GENUINE 24 HOUR/7 DAYS A WEEK SERVICE

Tel:: 019088 5621911 Fax:: 019088 260461e:: [email protected] www.bundiebowser.co.uk

BUNDED FUEL BOWSERSextreme duty, all-steel construction,welded inside and out for double protectionwidest range on the marketincluding UN IBCs.

400 – 36,000 litres capacity(100 to 8000 gallons)

The ORIGINAL andSTILL the BEST

MADE IN ENGLAND

Leaders in specialisthire & sales

Tel : 01132 739400 w w w.danthermfi ltration.co.uk

Sole manufacturers: AIRMASTER, BMD GARANT

NORDFAB CLIPPED DUCTING

ATEX QA EN13980

ISO9001:2000

DUST EX TR AC TIONFor mineral processing, bulk handling and conveying

Design & installation or supply only

Planned maintenance

Service and Spares

All you need - from one reliable source!

44


Fin

es S

cree

ning

45

ww

w.h

ub-4

.co

mF

ines

Scr

eeni

ngRed head solvesa stickyscreeningproblemThe widespread difficulties experienced in screeningminerals <6 mm and exhibited as blinding and peggingof the screen surface can affect not only sticky or‘difficult’ products but many normally straightforwardmaterials also with consequent production losses,inaccurate gradings and increased maintenance costs.Brian MacKenzie told the BULK 08 conference thatwhile the orthodox view sees evolution towardsmodular systems as being inevitable, there remainsignificant benefits to be achieved by furtherdevelopment of conventional tensioned systems.Despite continuous development over several decades theproblems of pegging and blinding, associated withscreening fines and sticky materials, continue to be aprimary cause of low efficiency and high maintenance inminerals processing plants. Although several products havebeen developed to address the problem, with varyingdegrees of success and cost, there remains a majorproblem to be solved. Typically screens will become blinded by adhered andagglomerated fines which attach, initially, to the more staticparts of the screen media such as side borders andreinforcement areas, subsequently extending over thesurface of the apertures until, in some cases, throughput isreduced to zero. Mechanical devices have been designed inan attempt to clear this material but always run a risk ofdamaging the screen media itself, which, by definition, isfragile at this separation size (<6 mm). Frequently manual‘de-pegging’ is required which obviously impact onproduction, is extremely time consuming, can raise Healthand Safety issues as access is often confined and/orexposed and very dusty and can. Itself, lead to screenmembrane damage.

ObservationsIt has long been established that softer screen media has agreater resistance to material build up owing to the effect ofsurface flexibility dislodging adhered material. This is alsotrue of fines minerals handling in general, including chuteand hopper lining. One of the original benefits of syntheticrubber screen surfaces over metallic plate screens was thereduction of build up on the screen surface. When polyurethane screening systems where firstintroduced they were confined to wet screening owing tothe greater tendency to peg and blind with dry aggregate.Subsequently, softer materials with the required mechanicalproperties have been developed that can be used moresuccessfully, however it remains the case that soft rubberoffers better ultimate blinding resistance and remains thepredominant medium with several propriatery systems onthe market.At Materials Handling Products (MHP) we initially observedthat this phenomenon of better performance of softermaterial was not restricted to difficult screened materials.Surprisingly even on easy to process, wet, round, alluvialgravel there is a significant improvement in the volume ofmaterial passing through the screen apertures when a softerscreen media is used. In one test a screen handling suchalluvial material was equipped with 90 Shore hardnessmodules on one side and 65 Shore hardness modules downthe other, both with the same aperture size. Approximately5% of the material remained rejected by the 90 Shoremodules wheras no material was rejected on the softermodules. It would be possible to measure this quantitativelyhowever the result would be very dependent on aperture

size, material and a number of other paramaters making it oflittle practical value. It is therefore sufficient simply toobserve that the phenomenon exists.Open area is vitally important in fines screening especially ifthis is compromised by some of the problems above.Modular systems usually reduce the effective open areaowing to the additional structural members and thistherefore favours the use of traditional tensioned media. Attypical aperture sizes of 4-6 mm the open area is likely to beless than 20% so any pegging or blinding has a verysignificant effect on the overall throughput and screeningefficiency. Furthermore modular systems tend by their natureto be more rigid in the support areas, which encourages theinitiation of material build up.Damage resistance is always a problem on fragile screenmedia and conventional soft rubber surfaces sufferparticularly in this respect. To address this several proprietrysystems use bonded on reinforcing members toaccommodate the transverse tensioning forces and controlelongation. These tensioning members generate severaldifficulties: the finished screen is made difficult to manipulatein the confined space of a screen machine, there is risk ofdetachment and limitation of the screening panel size andproportions.

Development of the Testa Rossa solutionGiven the situation described above MHP began a designprocess in 2005 to design a progressive development whichwould use existing technology as a base and build on thatusing our expertise and experience as a screen mediamanufacturer to address the problems of fines screening.Much of the expertise in screen media tends to be shroudedin ‘black art’ terms, which is often an excuse for lack ofunderstanding of the processes involved. It is true that as arandom process with so many variables precisemathematical modelling can be difficult and is not alwaysjustified as designs frequently need to address local issues,particularly the nature and condition of the mineral beinghandled. Consequently it was decided to develop theconcepts in a live production situation and this took placewith the cooperation of Aggregate Industries and LafargeAggregates in two sites handling granite fines in the UK.The development had several specific objectives :• to use a soft rubber-based screening media to maximise

self cleaning• to develop a means of support that offered enhanced

structural strength and hence damage resistance CFexisting solutions.

• to make use of internal, rather that external,reinforcement

• to include some reinforcement in the screening panelsthemselves, between apertures to increase strength.

• to manufacture by punching rather than moulding tocontrol cost

• to allow complete freedom of panel size to allow this tobe adjusted to affect performance.

MHP Testa Rossa on -6mm granite

▼


46

Fin

es S

cree

ning

Costs would be minimised by the use of conventionallymanufactured corded rubber screencloth, however, MHPlaminated a specially compounded soft layer with very highabrasion resistance onto a conventional carcass containingthe polyester tension cords by hot vulcanisation. Previouslythis process had been tried with different rubbers and coldbonding which was inherently less secure and could failowing to the stresses involved in the punching process.The reinforcement component was therefore distributed overthe entire area of the screen allowing complete freedom forsubsequent manufacturing and reducing the mechanicalstress on the softer part to the minimum.As a result of the homogeneous reinforcement system somecords would be present in the transverse bridges betweenapertures, enhancing both their strength and damageresistance.Having developed a suitable base material MHP thenfocussed on the punching process to produce an apertureof such a shape that the only part of the screen involved inthe sizing was the softer part with the harder and stifferreinforcement clear of the process. In effect this involvedproducing a more eggagerated “cooling tower” profile in therubber than normal. This was achieved by tooling designand punching procedures.The crucial area of flexibility was addressed in two ways.Firstly the punching pattern was designed such that most ofthe reinforcement was cut in the screening areas, increasingflexibility and this could be varied as required, that isbecame a new control parameter available to the screendesigner. Secondly owing to the method of reinforcementMHP could adjust the size of the panel, punched as abovewhich effectively controlled the natural resonance of thatarea of the screen, which was a further new, additionalparameter available to the designer. This latter propertycontrols the fluidisation of the material being screened andalso the motion of the screen media itself, which has animpact on surface build up.

OutcomesIn addition to optimising the anti blinding/pegging nature ofthe screen medium by the use of the new material MHPhad created two useful new control parameters, in additionto aperture size and pitch, of differential strength ofreinforcement in the screening area and its naturalfrequency.In practice some test and experimentation was necessary tolearn how to use these new controls and after an 18 monthdevelopment period MHP commissioned a series of screensfor Lafarge Mountsorrel quarry, the largest granite quarry inEurope that virtually eliminated pegging and blinding on aline of 10 m x 3 m GEC screens handling -6 mm in an areawhich had suffered 50% plus blinding and required regularmanual cleaning.Subsequently MHP has successfully tackled otherapplications including limestone fines with similar successand larger aperture applications up to 14 mm.

Footnote:This article is based on the paper ‘Recent Developments inFines Screening’ delivered at BULK08 by Brian Mackenzie,FMHEA, Managing Director, Materials Handling ProductsLtd., Vice Chairman Materials Handling EngineersAssociation (UK).Copyright © Brian Mackenzie and Materials HandlingProducts Ltd 01/07/2008

www.hub-4.com/whatson

ww

w.hub

-4.com

Introducing the VTS200 WeighbridgeHigh quality steel deck• Extra wide, low profile design• Accurate and secure weighing• Superior strength with corrosion resistance• Compliant to EC 96/53/EEC • Easy to maintain with long service life• Fully inclusive 5 year warranty*

� www.mt.com/vts200

Mettler-Toledo Ltd Tel: 0116 234 5005Email: [email protected]* Terms & conditions apply.

NEWExceptional Value



ww

w.h

ub-4

.co

mM

ater

ials

Han

dlin

g

47

Mat

eria

ls H

and

ling

World leading casual tableware company DenbyPottery Co, a torchbearer for the UK ceramic industryover recent decades and with a manufacturingtradition dating back 200 years, is drawing addedstrength from its decision to commit heavyinvestment to new glaze and body quality controlplant. In a deal worth over £100,000, Denby has purchased twopowerful High Intensity (HI) Magnetic Filter units from EriezMagnetics Europe. A serious player on the branded tableware scene – andnow employing around 600 people and producing over fivemillion pieces per year – Denby visited the Ceramitecexhibition in Munich in May 2006 and met with the EriezMagnetics team. After evaluating the new plantrequirements, Eriez sought to demonstrate that substantialimprovements in material processing quality could beachieved with the use of its HI filter magnetic technology. The first step was a test programme to be conducted in theEriez laboratory on the Bedwas, UK site, this being the bestequipped facility of its kind in Europe. Trials took place onboth the glaze and ceramic body from Denby. Satisfiedwith results at this point, Denby took a trial unit – a HI25-50six-valve automatic filter unit – up to the Derbyshireproduction site and ran it for just over a month on the glazeline. Throughputs on this line are around 1 m3/hr. First impressions were encouraging, though not fullyconclusive, and the unit was subsequently trialled for anextended period. The HI Magnetic Filter’s performance inremoving potentially harmful contamination from theceramic glaze was subsequently proven and Denby placeda firm order. The Denby team had begun with a veryspecific capital expenditure in mind and the production andtechnical managers piloted the entire project through thefactory. There was close collaboration between the two companies’technical teams and the time and effort that Eriez is knownto dedicate to these projects once again paid dividends.Shortly afterwards, Denby Pottery ordered the much largerHI200-50 six-valve automatic filter unit to treat ceramicbody. This unit is required to handle throughputs of 11m3/hr and, like its glaze counterpart, has performedexceptionally and fully justified the substantial investment. “The new glaze and body treatment systems from Eriez

Magnetics have run at full production levels since themiddle of last year,” said Technical Manager, Dean Barlow.“They have proven to be significant contributors to ourprocess quality improvement – both our through and finalproduct yields have increased and we therefore create lesswaste/rework at final inspection, amongst other benefits”. An array of magnetic systems is on offer across Europe andit is seen as significant that after much careful considerationand in-depth testing, Denby chose Eriez to be the supplierof what needed to be high performance, technically soundand fully reliable systems. However, despite the size of therequired investment, Eriez was confident at calculating thepayback period at around just eight months, by anystandards a timescale that is well within industry acceptedlimits. “We have definitely seen the benefits of this sizableinvestment,” confirmed Dean Barlow, “and I am happy tosay that the Eriez Magnetics plant that has been installedhere at Denby Pottery has not only met, but exceeded allour expectations.”HI Magnetic Filters are fully automatic, self-cleaningmagnetic systems, developed by Eriez. The automationprevents any need for manual cleaning and thus matchesthe vigorous ferrous removal requirements, which are afeature of the range. In this configuration the magnetics areflushed out of the matrix on a timed cycle, a vital featurewhen processing ceramic slip or glaze. The models installed at Denby have been configured with abackground field of 5,000 Gauss which, when intensified inthe matrix, increases to a peak of around 15,000 Gauss(1.5 Tesla). Tests have demonstrated that only this highlevel of magnetic intensity is sufficient to eliminate defectsand sufficiently increase the material quality, as it is morethan powerful enough (unlike competitive systems) to drawand capture wet paramagnetic particles at the required flowrate. John Curwen, sales director at Eriez Magnetics, says: “Thisis a great success story for Eriez in the field of qualityceramics manufacture and one that has involved the wholeteam here. We are intensely proud to have worked closely,and with such success, alongside a world tableware leadersuch as The Denby Pottery Company.”

Denbymeetstringentqualitystandardswithmagneticfilters


48

www.hub-4.com

conv

eyo

r fo

cus Beaufort Conveyors

Beaufort Conveyors has been manufacturing theirunique range of modular conveyor systems for over20 years. Originally based in Bristol, they moved totheir present larger premises in Swansea five yearsago.

Their Easikit® trough belt conveyor has become a staplepiece of equipment for a multitude of applications acrossthe UK. The versatility, flexibility and reliability of theseconveyors have become bywords throughout industry.Standard belt widths of 300, 450, 600, 900 and 1200 areavailable from stock; a recently introduced 1500mm wideconveyor is also available but currently only built to order.

As the range of conveyors is modular, the overall length ofconveyor can be varied to suit the application simply byadding, or subtracting, one or more of the intermediatesections and the appropriate amount of belt which can beclip jointed. A variety of rubber belting including Plain,Chevron, Cleated and Nitrile can be specified.

The Easikit® can be supplied in a static, fixed form or as aMobile or Radial with undercarriage. The undercarriage isfitted with a hydraulic ram which enables the conveyor tohave a variable discharge height. In addition, the Radial hasan electrically powered motor on the undercarriage to givea 30º arc – essential when stockpiling. The Mobile andRadial are only available with the 600 to 1500 range ofconveyors.

Beaufort also manufacture Easibelt®, a range of flat bedmaterial handling conveyors and Eastrak™ gravity rollertrack.

Whatever your handling requirements, Beaufort will be morethan happy to help and advise.

Beaufort Conveyors E: [email protected]

Tel: +44(0)1792 310080


conv

eyo

r fo

cus

Not just another Belt Cleaner company!Founded in 1944 Martin Engineering is the leading globalsupplier of systems to make the conveying of bulk materialscleaner, safer, and more productive. The large portfolio ofproducts on offer range from simple Belt Cleaners through tocomplete Conveyors and Advanced ‘Dust Free’ Transfer Points.

Reacently a new Research and Development Center has been openedand features a three-conveyor system that can carry material in acontinuous loop.

This recirculating conveyor system is the key feature in the ProcessSimulation Area at the company’s new Center for Bulk MaterialsHandling Innovation (CFI). The process simulation “loop” is composedof three belt conveyors arranged in a triangle to carry material fromone conveyor to the next in a continuous, recirculating stream.

“This recirculating conveyor system will let Martin Engineering productengineers and material scientists test product prototypes and thehandling characteristics of real bulk material cargoes on full-scalematerial handling equipment,” said R. Todd Swinderman, MartinEngineering’s Chief Technology Officer. “We will be able to work withthe specific materials of a customer to develop solutions to theirunique material handling problems.”

Two of the conveyors are 750 mm wide; the long leg of the triangle is1200 mm wide.

One of the conveyors is an airsupported belt conveyor; the other twoincorporate conventional idlers.

The recirculating belt conveyor system, combines with the CFI’s industry-leading material testing and component analysislaboratories to position Martin Engineering to make bulk material handling cleaner, safer, and more productive throughoutthe world.

The Center for Innovation is housed at Martin Engineering’s world headquarters in Illinois (USA). From here the centreworks locally with its bases throughout the world.

The UK market is served from its Nottingham base, and from here it can supply, install, service, train and consultcustomers who have specific requirements in conveying materials.

‘Foundations 3 The Practical Resource for Total Dust and Material Control’ is the backbone of how the company appliesits knowledge and experience in bulk material conveying. This Hardback book is avaible to all, and provides an invaluableresource on solving problems and sharing best practice ideas with conveyors. A copy can be obtained by contactingMartin Engineering at the UK office.

Martin Engineering Ltd Tel: +44 (0)115 946 4746 E.mail [email protected]



49

conv

eyo

r fo

cus

ww

w.h

ub-4

.co

m

About BMSBeltCleanersBMS Belt Cleanersis one of the leadingsuppliers of conveyorbelt primary scrapers,secondary scrapers and‘V’ ploughs and ancillaryequipment relating to a beltconveyor in many countriesaround the world. BMS has it’s owncompanies in the U.K, Canada and USAand worldwide distribution throughoutEurope, Far East, Czech Republic, Slovakia,Russia and East and West Africa.

Since 1994, BMS Belt Cleaners has supplied conveyor beltscrapers supported by professional and technical back-up tothe bulk handling and mineral extractive industries includingquarrying, in mining; copper, zinc, gold, diamond etc,cement, fertiliser, power stations, agricultural, as well as fineand delicate material such as powders, vegetable oils,tobacco. BMS also provide product to original equipmentmanufacturers (OEM’s) and include in the package freescraper selection, Cad drawing for all products and fulltechnical support both at the drawing stage and prior tocommissioning the plant. BMS also offer on line productsupport plus service contracts to ensure that customersretain the long-term performance of BMS products.

The BMS Belt Cleaners ‘E’ range of metal-bladed scrapersare an improved design based on the original ‘paint scraperprinciple’ which has a 20 year track record for efficient beltcleaning recovering even the last 1/10mm of carry-backmaterial from the belt cover maximizing conveyor belt uptime,productivity, safety and lower cost of scraper ownership.

BMS offers three versions of their belt scraper for light,medium and heavy-duty applications, there is also a stainlesssteel option ideally suited for industries where high standardsof hygiene and frequent wash-downs are essential, such asfood processing, confectionary, plastics and pharmaceuticals.

BMS Belt Cleaners works closely with every customer toprovide practical solutions to their cleaning problems in orderto achieve long-term savings whilst realising that combatingcarry-back is a constant problem for the management(Managers/Engineers) of a bulk material handling plant.

For more information on our products and services pleasecontact us on: BMS Belt Cleaners LtdTel: +44 (0) 01325 483 916 Email: [email protected]

Polyurethane wear resistantitems to the quarryingindustry.

Scandura, a division of PPL PolyurethaneProducts Ltd., has been an established supplier ofpolyurethane wear resistant items to the quarryingindustry for over 40 years. Amongst the itemsproduced are a range of conveyor belt scraperblades to fit most proprietory units, starting withthe simple polyurethane strip, to mouldedelements, some with bonded-in metal re-inforcement.

Skirting is also available, soft enough to not cause beltdamage but hard enough to withstand the rigors ofcontainment. Available in a thickness to suit theapplication, in lengths up to 3 metre (longer possible)

Also in the conveyor range are dual hardness, mouldedimpact bars, mounted in a frame, these allow the beltto slide easily, without suffering the problems of rollersbending, bearings damage on impact etc. They helpcut wear on belts and reduce spillage at feed points.

We offer a roller coating service to extend the life oftroughing and return rollers and a re-lining service inpolyurethane or rubber with diamond/chevron cutprofile for drive drums.

Why not contact PPL for a solution to your wearproblems on conveyors, screen surfaces, cyclones,pump linings, rollers, chutes, hoppers etc.

Polyurethane Products Ltd. Tel: 01777 712500 E: [email protected]



Specialised Belting Supplies have relocated.

In order to enable the company to accommodate the requirements that theirincreased level of business for their range of sidewall belting has brought, SBS hasrecently completed the move to their new 30,000 ft2 premises, overcoming theconsiderable task of transferring all the manufacturing equipment in a short timeperiod, whilst maintaining a heavy production schedule.

A significant additional investment has followed with new equipment to aidmanufacture, consisting of full factory length 40 tonne overhead cranes, automatedpreparation machinery including fully computerised belt and profile rougheningequipment, as well as increased bonding and pressing capacity.

It is believed that SBS has now probably one of the best production facilities at leastin Europe, for the manufacture of their trademarked S-WALL sidewall conveyor belt,and these new and larger capacities will enable the company to react to their clientsneeds, with even the largest belts being produced on short delivery times with inexcess of 80% of the company's production being exported.

Further equipment is planned to allow the company to enter into other areas of fabricated belt assembly.

Also, additional services are now provided, including conveyor maintenance, primarily in the East Anglian area with a24hr x 7 days fully compliant site vulcanising and repair capability, as well as general belt distribution throughout the UKmarket."

For further information please contact SBS Ltd Tel: 01842 754392 E-mail: [email protected]



50

EngineeredSolutions

for Materials Handling

• Elevators• Conveyors

BeltChainScrewAirglideScraper

• Push Floors• Vibro-feeders & screens• Buildings & transfer towers

• Structural & support steelwork• Material batch dosing & weighing• Storage silos & supply equipment• Gantries, access walkway & stair steelwork• Inspection,separation,crushing & mixing

Geo. Robson & Co. (Conveyors) LtdColeford Road, Sheffield S9 5PA

Tel: +44 (0)114 2444221Fax: +44 (0)114 2433066

[email protected]

www.robson.co.uk

From Sheffield providing the world withMaterial Handling Solutions.

JCC107 Main Street

Darvel

Ayrshire

KA17 0JQ

Tel 01560 320320Fax 01560 322030

Email [email protected]

WestWeigh Controls Limited Beckford House

87 Hollies Avenue,West Byfleet

Surrey KT14 6AN England

Tel: +44 (0) 1932 344443 Fax: +44 (0) 1932 344775

E-mail: [email protected]

www.westweigh.com

Sandy Lane Industrial Estate Worksop Nottinghamshire S80 1TN

Telephone 01909 486166Facsimile 01909 500638 [email protected] www.canningconveyor.co.uk

Tota

l Con

veyo

r Con

fiden

ce

Design, manufacture, installation, commissioningEngineering & bulk materials handlingSingle roller to complete handling systemsQuarry plant and equipmentCannoflex beltingVulcanising and fastenersConveyor componentsTroughing idlers, return and replacement rollers

Canning Conveyor Co. Ltd

Home of the SuperDriveTM



52

www.hub-4.com

The biggest cause of complaint from residents livingnear mines is often noise nuisance, with the biggestoffenders being tonal reversing alarms and conveyerstart up alarms. Both devices are essential safetyrequirements, but how can safety be achievedwithout disturbing the peace of local communities?

Memphis Stone and Gravel Company is an aggregatesupplier to West Tennessee and North Mississippi.Established in 1910 the company processes about fivemillion tons of raw material each year. Until recently, therewere few options for noise source reduction, then theaggregate supplier discovered Brigade Electronic’s whitesound reversing alarms (bbs-tek). The alarms, nowconsidered to be the safest on the market are an effectiveway of reducing noise nuisance and are even approved bythe Noise Abatement Society in the UK and the bbs-tek isthe only alarm approved for use in NY on constructionvehicles, in all areas of the city. In 2005 Memphis Stoneand Gravel Company ran an aggressive campaign toretrofit much of its mobile equipment with broadbanddirectional backup alarms.

The problem remained however, of the conveyer start upalarms, which sound similar to an emergency siren.Together with Brigade Electronics, the company completeda successful pilot project using the white sound alarms onits conveyer systems. Memphis Stone and Gravel now fitbbs-tek start up warning technology.

The directional nature of the white sound alarmaccompanies the linear structure of the conveyors. Brigadedeveloped an alarm with a 117 dB(A) rated output in orderto optimize the distance along the conveyor line.

The white sound technology is much safer thanconventional ‘beeping’ alarms because the sound islocatable, this makes it ideal for blind and partially sightedpeople who are still able to source the danger. Multifrequency sound provides a massive safety advantage forthe hearing impaired, who may not be able to hear thenarrow tones created by conventional alarms, but canusually pick up some sound created by the wide range offrequencies created by white sound.

The sound is localised to the danger area and is a hugesafety advantage over conventional ‘bleeping’ alarms,whose sound is so pervasive that it can be heard welloutside the danger area, with the result that people canbecome desensitised and ignore them. The unique ‘sshssh’ sound emitted is less irritating than the shrill sound ofconventional alarms, therefore causing less of a nuisanceto residents.

Brigade’s white sound, warning start-up alarms can helpovercome planning objections and eliminate noisecomplaints, whilst retaining a distinct and urgent sound toprovide maximum safety protection for site workers.

Brigade Electronics plc Tel: +44 (0)1322 420300

E: [email protected]


conv

eyo

r fo

cus

Do Your Start Up Sirens Annoy Your Neighbours?White-Sound Solves Noise Nuisance Problems.


53

HOSCH - Belt Cleaning Solutions

HOSCH Carryback Measurement

A service by HOSCH for assessing the efficiency of beltcleaning systems

Belt conveyors tend to accumulate dirt on the return strandas a result of conveyed material sticking to the belt. As aresult of cost pressure in the bulk handling industry, thenumber of conveyor maintenance staff is falling. Thereforethe economic and safe operation of belt conveyors dependsmore and more on the efficiency of the belt cleaningsystems.

HOSCH developed a simple and practical method formeasuring the cleaning efficiency and economy of beltcleaners. This method allows:

• To easily measure and record the cleaning efficiency ofbelt cleaners,

• To analyse the measuring results on an IT-basis,

• To illustrate the results in the form of a profitability survey.

HOSCH Carryback Measurement

The measuring method consists of installation of a 120mmwide steel blade on the return strand of the belt, behind theexisting belt cleaning system for a limited period of time. Theremoved material is collected in a container and weighed.

The comparison of several measurements carried out ondifferent conveyors allows an assessment of the efficiency ofthe surveyed cleaners.

Analysis

The analysis of the measuring result is carried out onHOSCH’s own programme, based on Microsoft Excel.

Starting from specific conveyor data, for example belt width,belt speed, operating time per day etc., the programmeautomatically calculates further installation data that isrelevant for analysing the efficiency of the cleaning systems.

By extrapolating the results obtained by a carrybackmeasurement and under consideration of the technical dataof the conveyor belt, the quantity of material that enters theconveyor line can be estimated.

The calculated results are illustrated in graphics.

Analysis of the economy of belt cleaning

The analysis is based on the investment and operating costs- for example the costs for removing fallen material underthe conveyor belt, costs for the purchase, the installationand the maintenance of the belts cleaners - calculated overan operating period of 3 years.

As a rule, the measuring process and the analysis of theresults requires very little time and manpower. They arealways carried out on site in close co-operation with thecustomer.

Ask our sales team!

Hosch (GB) LtdTel: +44 (0)1642 751100 E: [email protected]





Quarrying operations have always been recognisedas the testing ground for plant equipment. The nononsense approach, the heavy loads and long hourscertainly separates the men from the boys in thematerials handling industry. Reliability and robustdesign is the defining rule, a rule in which Geo.Robson & Co (Conveyors) Ltd has engrained in toevery product it produces.

For over one hundred years Robson has producedMaterials Handling Conveyor Equipment design especiallyfor the harsh environments of the quarrying operation.Robson know that tight production deadlines and tightermaintenance budgets mean downtime is not an option forthe quarrying industry.

Geo. Robson & Co (Conveyors) Ltd has designed, built andinstalled robust, reliable bulk material handling conveyorequipment into quarrying operations around the globe.Bespoke designed conveyor systems suited to the materialenvironment and climate of the operation. Multipleinstallations into quarrying industries such as: Oil, Cement,Chalk, Flint Potash, Gold, Coal, Gypsum, Iron Ore andAggregates.

Modern 3 Dimensional computer aided design packagescombined with traditional heavy engineering experience,Robson engineers design and build the conveyor systemsfor the robust operation needed and expected by thecustomer.

The Backbone of the QuarryBelt conveyors are the backbone of any mining or quarryingoperation. Systems that ensure the bulk movement ofmaterial in excess of 1000 Tonnes per hour arecommonplace within the industry, with the carrying length ofthe conveyor system virtually unlimited, the system canconvey material from the quarry to the processing plantwithout the need for heavy transport.

Combinations of conveyors Weighers, Crushers, Magnetsand Screens ensure the end product is sized and free fromtramp metal ready or the next process. The belt conveyorhas the flexibility of design to accommodate inclines anddeclines, enabling the structure to follow hillsides or tobridge over obstacles.

21st Century Belt Technology Heavy material ripping or damaging the belt, when loadedvia bucket loader, used to be common occurrences, but themulti plied state of the art belt compounds and materialsutilised by Robson ensure a rigid, durable belt less likely tostretch and give. The conveyors integral impact rollers andor boards ensure the impact of the material is cushioned,absorbing the shock protecting the belt.

Other options of loading belts include loading bunkers orchutes, which enhance the loading operation by softeningthe loads impact and with the added benefit of reducingdust clouds with dry materials.

Belt tension is critical to the conveyor. If the tension of theconveyor belt is not set correctly the belt will slip whenunder load, at start up or in wet conditions and certainly inthe UK the wet conditions are a factor but Robson haveexperience not only with rain posing problems but also withhumid conditions with installations in the Far East and Southand Central America humidity showed to be just as bad asrain.

That’s why Robson recommends ceramic lagged pulleys, asthe extra grip achieved ensures a smooth start up and, thegrooves on the ceramic pulley, similar to a car tyre, displacethe water from the belt, giving optimum grip and conveyingcontinuity without slip. Also the extra grip can compensatefor slight differences in the belt tension.

At the Trough Robson belt conveyors use carrying idlers that havemaintenance free, sealed for life bearings. Used in groups ofthree for troughed conveyors, the idlers create a troughedshape to hold the material in place while conveyed. Thismethod works well with either wet or dry materials.

The options of open or enclosed conveyors much dependupon the material that is quarried, rough wet spoil isnormally open whereas dry dusty material is enclosed toprotect from the elements. The covers themselves havemany options depending upon use and environment. Insome cases fully enclosed gantries are used incorporatingwalkways or maintenance access routes.

Critical conveyor components such as drive’s andgearboxes within the system have to be reliable, with sparesor replacements accessible worldwide. Robson chose thedrives only from manufacturers with proven track records ofreliability and with international names for the motors andgearboxes such as SEW, David Brown, ABB spares andservice are just a phone call away, no matter where in theworld. As for bearings; again recognisable names such asCooper or SKF are used for their reputation for reliability andthe worldwide availability.

Clocking Up the Air MilesOne of the everyday required items for Robson engineers isbecoming their passport, with exports of conveyor systemsbooming, recent installations including: Egypt, Hong Kongand Saudi Arabia, shows that Robson’s reputation forreliability is certainly reaching the global market.

Same Reliable Components Different Products A variation of the belt conveyor is the Tripper conveyor,which is used to evenly distribute granular materials evenlyinto warehouse facilities. An inclined conveyor elevates thegranular material to the tripper conveyor, situated in the roofspace of the warehouse. The train of the tripper conveyorruns on tracks the full length of the warehouse, feeding theconveyed material in to the bays or compartments below.Programming and switching allows the tripper to feed acertain area or length to suit warehousing needs.

Other belt conveyor products include loading and slewingconveyors, which are commonplace within the quarryingindustry. Robson has manufactured these for many years,using the same proven components as the belt conveyors,and with export sales to Europe, the Middle East and FarEast, the Slewing Conveyors design and reliability is provenbeyond doubt.

56

www.hub-4.com

conv

eyo

r fo

cus


57

conv

eyo

r fo

cus

ww

w.h

ub-4

.co

m

The Job LotRobson has often been called upon to build not only the ConveyorSystem but to design and build the building or warehouse facilities inwhich it is housed. Often the main contractor on site, Robson isfamiliar with all CDM regulations, which is shown by their exemplarysafety record.

Repeat business is commonplace at Robson and relationships withcustomers span decades in all industries. The expert team of in-houseProject Managers and Project Engineers at Robson ensure thespecification budget and deadlines are met.

Not just a one-trip ponyRobson has a team of dedicated Vibration technology engineers oftendesigning systems that complement the belt conveyors, working inunison with the belt, or performing other processes on the same plantor site. Many standalone Vibration systems have been supplied to thequarrying industry for the Feeding, Dosing, and Measuring,Transferring, Screening, Scalping, Drying, Grading and De-watering ofmaterial.

Remote ControlLow maintenance is often the number one customer requirement, withsystems purchased for installation in remote areas reliability is crucial.Vibratory Systems are often used in quarrying, as the robust designand lack of moving parts are well suited to the harsh environments.The application of screening and scalping is widely used throughout alltypes of quarrying and opencast mining.

Continuity and purity of product is key within the power generation andkiln feed operations these systems have significant uses for VibratoryFeeders and Screens. The screens ensure the correct sized filteredparticle is fed to the furnace or kiln; regulated feeders ensure acontinual dosed feed.

Size Does MatterEspecially useful in the aggregates and food industry, grading andsizing is a major use for the vibratory system and using a number ofdecreasing sized grids, the system can grade sizes, or separate theoversize / undersize of the product. The vibratory system enableschutes to divert the graded products either to reject for furtherprocessing.

Developing the ShakesRobson’s team of Vibro engineers developed Vibration products thatmeet the ATEX regulations for use in explosive atmospheres, mainlyused in the dry foods industry but can be configured for use anyproduction environment. Other developments include a reversible Vibro feeder giving theoptions of central feed in with twin feed out at opposite ends of thetrough, ideal for measuring and dosing.

No Screw loose here Conveying material using Screw Conveyors gives options for a varietyof uses. Variations in the flight design allow Screws conveyors toConvey, Mix, Feed or Elevate material, wet or dry.Each Conveyor is bespoke to the customer's requirements givingInfinite choices for Size, Speed, Material or Application.

The type of material the screw is manufactured from depends uponthe process and material being conveyed. Wet or foodstuffs normallyare stainless steel while others are mild steel.

Using the same tried and tested motor and bearing manufacturers asthe belt conveyors, the reliability of performance and robustconstruction of the Robson screw conveyors is guaranteed. Used inmany industries, the screw conveyor’s versatility and low maintenanceare the key benefits.

A recent project undertaken by Robson was to reconfigure fifteenScrew Conveyors from three different plants to make up a singlesystem in a new location. The screw conveyors originally supplied byRobson, some up to 10 years old, were brought back to the factory.The condition of the drives, bearings and screw were still very goodand required little work to refurbish, which is a fitting tribute for acompany that has produced conveyor systems and solutions for overone hundred years.

Geo Robson & Co (Conveyors) Ltd Tel: +44 (0) 114 2444221E: [email protected]

The WestWeigh Belt Weighing systemhas always offered management reportsin addition to the “standard” beltweigher features. However, earlier thisyear one major customer asked if wecould extend the features to provide aneconomical Data Logging facilitybecause due to the economic climatethey wanted to analyse plantperformance and productivity.

There are of course many data loggingsystems in the market but generally they aremore suited to multi-channel input andcustom software is required. For thesereasons it has been expensive to apply thetechnology to small installations and difficultto send the data to other offices that do nothave the required software.

WestWeigh have developed a system thatwill record a broad range of production data(Period Start/Stop Times and Dates, - ShiftTotals and Grand Totals – Average Ratesand Maximum Rates – Productive HoursWorked – Report Numbers etc.) and this isthen written directly to a USB Flash Drive.

The “Flash Drive” can be inserted into theUSB port of any P.C. running Microsoft Exceland the data can be transferred directly to aworksheet. Excel can then be used toanalyse/manipulate the data in any form theuser requires. If required, the finished reportcan simply be e-mailed to an Area Manager/ Head Office etc. and no additional softwareis required to open (or work with) thedocument.

The Data Logger can be set up to record atpre-determined intervals via the internal realtime clock, or a report can be generatedmanually by pushing a button.

Interest in this Belt Weighing / Data LoggingSystem has been so strong that it hasalready been bought by four of the majorquarrying groups in the U.K.. We have alsosupplied it to the Re-cycling industry, a largeproduction company, a train loading facilityand it has been exported to Ireland, TheUnited Arab Emirates and Spain.

Although the system was originally designedfor static plants an IP65 protected device isnow available for mobile applications andthis has already been purchased by twoleading manufacturers. For more informationcall:

Westweigh Controls Ltd Tel: +44 (0) 1932 344 443E:[email protected]

The WestWeighBelt Weighingsystem

www.hub-4.com/directory/5926 www.hub-4.com/directory/2264


58

conv

eyo

r fo

cus

Irelands GrowingIrelands – ‘Conveyor Component Specialists’ is expandingto service the UK & Ireland. The company has been tradingas H. Ireland & Son for over 50 years but has recentlychanged ownership; resulting in substantial investment intothe expansion of the conveyor specialists. One majorinvestment has been the refurbishment of the company’soffice and manufacturing facilities at its head office inBallynure, based 10 minutes outside of Belfast.

Irelands has created a new online presence to match with abrand new website. The website is designed to tailorIrelands’ service to suit both existing and new customers.The company’s products and services can be viewed onwww.irelandsconveyors.com.

The company prides itself on its 50 years of experience andthe valued relationships it has built with its customers. Thewealth of technical knowledge has resulted in Irelandsbeing equally well equipped to cater for both small locallyowned operators as well as the major players in theengineering and quarry industries.

Irelands are keen not to simply dwell on their past achievements, instead they are benefiting from being able to adapt toindustry challenges. The ability to service a company quickly is core to its adaptability; so it has established a depot inGalway. The Company has established a partnership with Galway based firm: Western Vulcanising, allowing Irelands tocover all conveyor belting needs throughout Ireland.

Irelands’ attitude to quality is also reflected in the products it supplies. Tecniflex is Irelands own brand of premium grade beltwhich is manufactured in Germany to the highest quality standards. Irelands has also secured good relationships with itssuppliers of component parts such as rollers and screening surfaces. This results in Irelands having a high quantity of stockallowing them to react to customer’s needs quickly.

Irelands prides itself on being able to offer the right product, service and advice needed by each individual customer. Thecompany is keen to attract new customers to maximise its potential and build Irelands’ reputation as the leading conveyorbelting and component supplier.

Further information:Irelands Tel: +44 (0) 28 9335 2844 E: [email protected]


ww

w.hub

-4.com


59

conv

eyo

r fo

cus

ww

w.h

ub-4

.co

m

Magfern Recycling recently purchased a newSPS8 4 bay static picking station from JCCEngcon Group for a new site in Derby.

The company had visited the JCC Engcon stand atScotplant and had been impressed by theworkmanship and quality of the mobile pickingstations that were at the exhibition, and theknowledge and assistance that JCC Engcon wereable to provide.

After detailed discussions, Magfern Recycling optedfor a bespoke picking station that was designed inconjunction with the clients specific requirements andfor maximum efficiency and flexibility.

Product is discharged onto the 12m heavy dutyincline conveyor with chevron belting and impactsection & large feed hopper which is then transferredto the picking station which has 3.5m high supportframe and 3.2m wide bays for 40 yard skips. Accessto the picking station is via the two access stairwayson the side of the incline conveyor which are not onlydesigned for safety but also for any maintenanceworks required on the incline conveyor. The pickingstation is covered with insulated cladding & rooflightsand also comes with double glazed doors & windowsfor operator comfort. The 4 bay picking station has

three bays for commingled product and a split fourthbay for the internal ferrous overband magnet and alsonon-ferrous collection. The picking station is fullyguarded to BS:7300, CE approved, and has acombination of pull wire and push button emergencystops. The conveyors are powered by heavy dutyvariable speed electric drive motors.

Magfern Recycling were delighted at the initialdiscussions with JCC Engcon Group and the ease ofdiscussions their requirements. Each individual itemwas discussed at length and the appropriate designfeatures incorporated. After the specification & designwas agreed, JCC Engcon Group manufactured thepicking station system within 4 weeks as per thetimescale required by Magfern Recycling.

JCC Engcon manufacture a range of picking stationsfrom the PT6 hooklift mobile picking table to theMPS4 fully mobile picking station to the STPS24 twinline static picking station for 24 operatives, with twinblowers & 4 ferrous overband magnets.

For further information: John Craig Contracting Engcon Group Tel: +44 (0) 1560 320320 e: [email protected]


Magfern Recycling choose JCCEngcon Group for new recyclinginstallation


60

Polyurethane ProductsStirling Road

West Carr Road Ind.Estate Retford Notts

DN22 7SN

Tel 01777 712500 Fax 01777 707001

Email [email protected]

SSppeecciiaalliisseeddBBeellttiinngg SSuupppplliieess LLttdd

UUnniitt 2266--3322

BBrruunneell WWaayy

TThheettffoorrdd

NNoorrffoollkk

IIPP2244 11HHPP

TTeell:: ++4444((00))11884422 775544339922

FFaaxx:: ++4444((00))11884422 776655226644

EEmmaaiill:: ssaalleess@@ssbbssbbeellttiinngg..ccoomm

Sandy Lane Industrial Estate Worksop Nottinghamshire S80 1TN

Telephone 01909 486166Facsimile 01909 500638 [email protected] www.canningconveyor.co.uk

Tota

l Con

veyo

r Con

fiden

ce

Design, manufacture, installation, commissioningEngineering & bulk materials handlingSingle roller to complete handling systemsQuarry plant and equipmentCannoflex beltingVulcanising and fastenersConveyor componentsTroughing idlers, return and replacement rollers

Canning Conveyor Co. Ltd

Home of the SuperDriveTM


61

conv

eyo

r fo

cus

ww

w.h

ub-4

.co

m

Kinegar Quarryincreases productionwith a little helpfrom CanningConveyor.Kinegar Quarries Ltd supplies bulk andbagged aggregates and is located on theeast coast of the Scottish Borderssupplying materials from Northumberlandto Edinburgh and the Lothian’s, and alsothroughout the Scottish Borders.

Recently they have upgraded their operationsat their Glenfin hard rock quarry and installed anew cantilevered stockpile conveyor for theirface operation.

Extracting material from the quarry benches and transporting to the process plant was originally performed by tipper trucksthe new conveyor working in tandem with a Powerscreen Chieftain has considerably improved the production process.

Supplied by Canning Conveyor of Worksop, a new 900mm wide x 45m long troughed belt radial stockpile conveyor hasbeen installed. Designed to accept 500 tph of -200mm aggregate from the discharge conveyor of the PowerscreenChieftain the conveyor transports material horizontally for 20 metres to the edge of the cliff before cantilevering out for afurther 25 metres and discharging to a conical stockpile below.

The conveyor is constructed with heavy duty lattice frame construction and is designed with a pivot point at the tail endand a powered slewing bogie 20 metres from the pivot. A fabricated trestle fitted to the wheel bogie extends up past thelattice frame with raker supports from the top of the trestle down to the gantry to support the cantilever.

The conveyor is driven by a 500mm diameter, 15kw ceramic lagged Canning ‘SuperDrive’™ motorized drive drum and isalso fitted with a 400mm diameter Rulmeca non drive drum.

The feed hopper was fabricated from 6mm mild steel complete with 20mm thick Linatex Linard lining on all sloping impactsurfaces, a slewing drive is driven by a 3.0kW low speed high torque geared motor via chain and sprockets to one of thewheel shafts, fitted with two wheels these run on a radiused concrete beam.

Designed, detailed and manufactured by Canning Conveyor the installation has been a total success.

Arnot Findlay, Director, commented,”To resolve possible safety issues this installation has eliminated any possible risk ofoperators and maintenance personnel having to work over a 40 metre face. The new conveyor can be radialled in, ensuringthat all necessary maintenance can be carried out at ground level. This is the first phase of our continuing upgrade for theproduction of high PSV stone at Glenfin Quarry and Canning have produced a working solution that will stand the test oftime”.

Further information: Canning Conveyor Co Ltd, Tel: 01909 486166 Email: [email protected]

Tailor madeequipmentCDE specialise in the design and manufactureof tailor made equipment and with officesestablished in Ireland, England, throughoutEurope and the Middle East. We are globalmarket leaders for high-quality, innovative hi-tech plant and offer a service level second tonone.

Static Conveyors

• Static conveyors designed using 3Dmodeling software

• Complies with H&S standards

• High quality design and fabrication

• High performance belt cleaning

• Walkways designed to suit customerneeds

• Conveyors carefully designed for easymaintenance and aesthetics as well asfunctionality.

A recent project for John A Woods Ltd in thesouth of Ireland involved the supply of a 150tph sand and gravel washing plant.Processing 150 tph of ‘as dug’ material toproduce a washed oversize, 20mm, 10mmand concrete sand the project included thesupply of static feed and mobile stockpileconveyors.




5462

Pro

duc

tsP

rod

ucts

Terex has unveiled three new PT-SeriesCompact Rubber Track Loaders that rangefrom 25.1 to 74 kW and are availablethrough a network of Terex dealershipsthroughout the UK and Ireland. The largestloader in the series is the PT-80 features anexclusive independent and multi-suspension undercarriage as well as acomfortable cab interior. The 60 kW PT-80is equipped with an advanced and durablerubber track. Featuring a patented multi-level suspension system it uses 16 bogiewheels per track, which flex independentlyto maximize ground contact. As a result,the machine’s 2812 kg operating weight isdistributed down to 24.1 kPa of groundpressure. That is less ground pressure thanthat of a person on foot. With such lowground pressure, the PT-80 can workproductively in soft or wet groundconditions where skid steer loaders andother track loaders cannot work at all.

Standard tracks on the PT-80 are 381 mm,which provides faster manoeuvrability in moreconfined spaces, but the PT-80 can also beoutfitted with optional 508 mm wide tracks foreven more flotation. This also lowers theground pressure to 21.7 kPa. The loader’s auxiliary hydraulic system comeswith bi-directional high flow for brush cutting,snow blowing and more. Low flow hydraulicsfeature variable speed operation for precisecontrol of attachment functions. The PT-80 isoutfitted with pilot-operated joystick controlsthat give precise control of all machinefunctions. Quick-connect hydraulic fittings arestandard along with a supplemental electricalconnection for attachments. The PT-80’s two-speed direct drive allows the operator to selectlow for maximum torque or high for faster travel speeds up to 11mph. Conveniences such as a standard 12 v DC power port and multiplestorage areas. It can be customized with a choice of cabenclosures, an adjustable suspension seat, hydraulic quick-attach,bucket positioning and more. Other refinements taken into accountinclude a convenient ignition key location, sliding side windows, a stiffdoor frame, durable seal on the door, and a fill rate on the 68 litrefuel tank and a new steel fuel line. In addition, Idler wheels usepremium metal face seals for exceptional durability. The PT-60 Compact Track Loader is a mid-sized 44.7 kW loader thatruns on a patented rubber track undercarriage. This loader can beused on a range of ground conditions – including wet, soft orslippery conditions where other equipment cannot work at all. Ahigh-performance two-speed drive system offers the choice of highertorque for digging in tough materials or higher top-end travel speed.In low speed, the PT-60 can travel up to 6 mph; in high speed, thePT-60 runs as fast as 11 mph. Only Terex’s largest, most powerfulrubber track loader, the PT-100 (to be launched late 2009), is ratedfaster with an 11.5 mph maximum speed.

The unit’s patented undercarriagesuspension system uses ruggedtorsion axles to maximise themachine’s contact with the ground- even when travelling over objectsor rough terrain to enhance tractionand performance. The PT-60 uses 24 wheels in itsundercarriage to spread themachine’s weight over the entirelength and width of its tracks. As aresult, the machine’s 2880 kgoperating weight is distributeddown to only 21.8 kPa of groundpressure – that’s less groundpressure than that of a person onfoot. This enables the loader towork productively in soft or wetground conditions where skid steerloaders and other track loaderscannot. With the PT-60, ASV alsointroduces some new, exclusivetrack options. The machine’sstandard track is a 381 mm widegeneral purpose track withmoderate treads for optimumoperation and traction in the widestrange of ground conditions. Aspecial smooth Turf Track is alsoavailable. The Turf Track offersexceptionally low-impactperformance when on the mostsensitive or fragile surfaces. Foruse in very wet or snowyconditions, when extra traction isneeded, the new Extreme TerrainTrack is now available. This newtrack is 419 mm wide so it offerseven more flotation than thestandard track. In addition, it offersextra deep treads for self-cleaningand added traction over the worstground conditions.The PT-60 has a new heavy-gaugesteel hood protects the enginecompartment. Steel mesh panelson top and the rear of the hoodprovide ample airflow to themachine’s turbocharged dieselengine and cooling system. Undercarriage enhancements alsoimprove durability. Included aresteel rear idler wheels that readilyshed dirt and foreign materialswhile providing longer service life.Other wheels in the PT-60 arerubber-coated to maximise thecushion and protection of therubber tracks. In addition, idlerwheel bearings now use premium

metal face seals. These seals provide longer, morereliable protection of wheel bearings for years oftrouble-free operation. The loader’s overall width of 1676 mm helps withmanoeuvrability. At 1219 mm wide, the PT-30 is Terex’s mostcompact rubber track loader – indeed the mostcompact on the market, according to Terex –enabling it to work in more confined spaces, yetproductive enough to replace an entire crew ofhand labour.The 25.1 kW engine powers the 1500 kg operatingweight, which is distributed down to 19.2 kPa ofground pressure.


A new level for acompact track loader

www.hub-4.com


ww

w.h

ub-4

.co

m

63

Pro

duc

ts

Move easily whileseparating material frommetals

Cogelme has combined Eddy CurrentSeparator with a Worm Screw to a smallsystem that can separate non-ferrousmetals from grinded plastic and downloaddirectly into big bags. Aimed not only at customers in the wasterecycling market, but increasingly also atplastic recyclers, the main advantage of thesystem includes separation purity: it can reachup to 95% of non-ferrous metals extraction, assmall as 2 mm in size; four wheels allow thesystem to be moved to where it is requiredand the system is compact, occupying lessspace than comparable conveyor installations


Towablecompost andwoodchipscreenerArbor Eater hasdeveloped what itdescribes as anefficient, affordable andeasily towable compostand woodchip screenerto add to its existingrange of high capacitytrommel screeners.The ARBOR SIFT 1500can be towed behind a4x4 car, loaded with asmall bucket or a chipperor shredder output can be directed straight intothe drum to produce an evenly sized product.Customers are using the Arbor Sift to screenwoodchip for biomass and to screen out debrissuch as plastics and stones from compostproducing a superb product ready for resale.Rejects are easily ejected from the drum and theproduct is discharged onto the output conveyorfor distribution.The machine is built in the UK and priced at£15,200 plus VAT.

www.hub-4.com/directory/6118 www.hub-4.com/directory/488

‘Green for go’ onsolar poweredweighbridgesWeightron believes it is thefirst UK weighbridgemanufacturer to develop agreen weighbridge, whichis powered completely bysolar energy. The company’sSolarWeigh solar powersystem provides a zero carbonfootprint solution for poweringweighbridge installations in

areas where mains power is not readily available. This should providea flexible solution for a range of remote applications in the quarrying,and waste and recycling industries.The latest solar panel technology, combined with Weightron’s lowenergy consumption weighbridge electronics and digital load cells,provides a high level of power generation and storage. SolarWeigh isavailable in two versions: Energy-3 and Energy-12, the choice beingdetermined by the operational requirements for the weighbridge. SolarWeigh comprises four fundamental elements: one or more solarpanels, a mounting support post, a battery pack for storing theaccumulated energy and an adjustable solar panel mounting bracket. During sunlight exposure, the energy produced is made available forboth the operation of the equipment and for recharging the batteries.During the hours of low light/darkness the weighbridge system ispowered directly from the batteries. Based on a normal 8 hour working day, the Energy-3 version providesthree days power for the weighbridge system, without the need forsunlight to recharge the battery, whilst the Energy-12 provides 12days usage under similar conditions. Battery recharge time is less thanfive hours in direct sunlight.

Highest power-to-weight ratio inclass?

Driven by a 67.6 kW KubotaV3800-DI-T turbo-charged,liquid-cooled diesel engine, thenew T320 compact trackedloader from Bobcat has thehighest power-to-weight ratio inits class. The T320 is designed tomeet a market demand forincreased productivity (more enginepower, more pushing force andmore hydraulic power to givedecreased cycle times) and anenhanced capability to run a wider

range of attachments, including the most demanding high flowattachments. As well as the best power-to-weight ratio, the newT320 also has the highest rated operating capacity yet, and isamong the most compact machines in its class. The 4401 kg T320 model is a vertical lift path loader offering arated operating capacity of 1461 kg, making it the largestcompact tracked loader manufactured by Bobcat, and extendingthe range of compact tracked loaders currently available from thecompany to five models. The T320 will appeal to a wide range ofcustomers in construction, demolition, landscaping, agriculture,horticulture, equipment rental, recycling and general industry.The engine of the T320 offers 18% more power than that of theT300, the next smaller model in the Bobcat range. The T320 has a lift height of 3261 mm that follows a vertical liftpath, allowing it to load trucks easily. The design of the low-profile lift arms gives the operator an excellent view of theattachment and work area.



64

ww

w.hub

-4.com

Pro

duc

tsA first for Flip Screen and JCB Midi CXEdwards Machinery has recently sold a S30 Flip Screen to beattached to a JCB Midi CX. This is the first time an S30 FlipScreen has been attached to a Midi CX. As it turned out, this wasalso one of the very first units, if not the first, off the line. Thestandard skid steer type hitch made the hook up very easy and theCX handled the attachment very well. The Flip Screen did a goodjob screening topsoil from rubble. Roger Codling from RTC BuildingDevelopments near Norwich was delighted with the ease ofinstallation, the speed of the machine and quality of the screenedmaterial. The savings in raw material, transport and dumpingcharges will soon pay for the unit.

CMB International Ltd

CMB International Limitedcontinue to develop strongly andhave a growing reputation as amanufacturer of a range ofrugged, reliable, high performanceCrushing & Screening machinery,supplying many Quarryingoperations in both the home andoverseas markets. These include;CMB Rockmonster Jaw Crusherswhich are modern cast-steel, all-rollerbearing machines. Designed to copewith the Worldís toughestmineral/aggregate applications,specifically developed with heavyquarrying operations in mind.CMB 150 Rockstar Cone Crushersagain based on modern cast-steel,all-roller bearing construction,hydraulic adjustment enables the

operator to rapidly change dischargesettings, if necessary during thecrushing operation. The hydraulicsystem also incorporates automatictramp metal release, setting reset andan unblocking feature clearing thecrushing chamber quickly to resumeefficient operations. Design improvement philosophywhich is incorporated throughout thecrusher range, serving to optimiseboth operation performance include;Large unobstructed Feed Opening.High and consistent throughputs.Good particle density and productshape.Unattended operation.Rapidand simple adjustment. Minimalmaintenance.

CMB DB Range Vibratory ScreensHave an all-bolted constructionincorporating lazercut side-plates and



reinforcing plate round the vibratingmechanism. The substantial stressrelieved box construction mesh frameswhich are able to be adapted to suit awide range of screening media. Bolt onwear plates are fitted to the feed boxand discharge lips.


www.miningworld-events.com

14th International Exhibition for Mining and Processing of Metals and Minerals

www.miningworld.kz

17 – 19 September 2008 Atakent Centre, Almaty, Kazakhstan


www.primexpo.ru/mining

15 – 17 April 2009 Crocus Expo, Moscow, Russia


www.miningworld.kz

16 – 18 September 2009 Atakent Centre, Almaty, Kazakhstan

2008-9


www.miningworld-uzbekistan.com

6 – 8 October 2009 Uzexpocentre, Tashkent, Uzbekistan

For more information, contact us!

Anna Aleinikova, MiningWorld Events

ITE Group plc., 105 Salusbury Road, London SW6 6RG, United Kingdom

T: +44 (0) 20 7596 5186 F: +44 (0) 20 7596 5096

E: [email protected]

3rd International Exhibition for Mining and Processing of Metals and Minerals

www.miningworld-uzbekistan.com

2 – 4 October 2008 Uzexpocentre, Tashkent, Uzbekistan



Date post:	02-Dec-2023
Category:	Documents
Upload:	khangminh22
View:	0 times
Download:	0 times

Materials Handling | Recycling | Quarrying

Documents