Hub-4 Wash Plant Focus

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Wash Plant Product Focus

November 2011

CDE Global www.cdeglobal.com T. +44 (0)28 8676 7900

Based in the East of EnglandFirstgrade Recycling SystemsLimited has recentlyintroduced the Zambesi WaterSeparator (ZWS) to therecycling market. Ideal for producing high qualityaggregates the first system has beeninstalled for Smith Skips in Aberdeen toclean up two fractions (10 to 50mmand 50 to 280mm) from their wastetransfer station.

Utilising water separation (undoubtedlythe best method) the ZWS hassuccessfully removed all wood, plastics,plasterboard and other waste materialsfrom the incoming feed of recycledaggregate, resulting in a high qualitysaleable product.

In operation the ZWS uses a fastmoving flume of water to separate thelight from the heavy materials andthrough a unique separation systemremoves items which are heavier thanwater, (such as rubber and plastics),along with the light fraction.

Applications for the Zambezi includeremoving light contamination fromrecycled aggregates, and removingglass and metal from woodchips ormulch.

About us:

Firstgrade specialise in the design,manufacture and installation ofmachinery for the waste processingindustry.

Ideally suited to the evolving needs ofthe skip waste, MSW, wood waste andcompost sectors, their main productportfolio includes, trommels screens,vibrating feeders, picking stations,conveyors and elevators, separatorsusing air, magnets and water andvibrating screens.

Product focus

High qualityaggregates fromthe ZambesiWater Separator

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The company also offer a consultation service involving a site visit,the preparation of a detailed drawing and a proposal to suit yourspecific needs.

Machines can be designed to make the best use of the spaceavailable, which is almost always a limiting factor in wastetransfer stations.

Further information:

Firstgrade Recycling Systems Limited. Unit 2, Crossways,Cockfield, Bury St Edmunds, Suffolk, IP30 0LN Tel: 0844 8009357 Email: [email protected] www.first-grade.co.uk

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Rapid International, haverecently started to supply mixerwashout systems into theRomanian market, in partnershipwith the Powertek Group. Thesemachines fit neatly into theirnewly launched mobile concreteplants due to their compact andself-contained design features.

Rapid International is recognised as one ofthe world's leading manufacturers ofconcrete pan, planetary and twin shaftmixers. Several years ago, having identifieda more cost-effective cleaning solution toaccompany these mixers, the company setabout designing and developing their ownwashout system to suit the requirements of

Product focus

Mixer WashoutSystem Fits Perfectlyinto Compact BatchingPlants in Romania



the batching plant owners. This has now evolved into 3 models - theRJW2 (2 pump system), RJW3 (3 pump system) and RJW4 (4 pumpsystem).

The Powertek Group are a distributor of recognised concrete, asphaltand construction equipment throughout Romania, Bulgaria andMoldavia.

An RJW2, 2 pump washout system has recently been fitted with aTwinshaft mixer on Powertek's mobile concrete batching plant (60m2/h capacity). Andrei STANCIU, in charge of the Romanian projectsays:

“We've selected the Rapid International wash-out system because thewashing heads from this wash-out system fitted perfect into ourcompact designed plant and also because we've worked closely withthe Rapid International technical team, who helped us obtain a goodsolution, somewhat custom made for our plant.”

These washout systems are proving extremely popular with batchingplant manufacturers due to their time saving features. With onewashout cycle, taking just 4 minutes, this results in an increase in themixer production time and serious reductions in downtime. It alsominimises the safety risks as the Jetwash system reduces the need foremployees cleaning inside the mixer.

Time is not the only saving with the Jetwash system. Using thispowerful system, batching plant owners can save money on having tochange mixer parts frequently. The washout system prevents a build-upof concrete and damage to the components. It also ensures overallreduced wear with the mixer, giving it a longer life span.

With the RJW2 model for Twinshaft mixers, the RJW3 model for panand planetary mixers and the RJW4 model for 4m3 mixers and above- there are several options to suit customer's requirements whenchoosing a mixer washout system.

of the highest possible quality due to the very efficient removalof silts from the feed material” says Mr Yasar Eren.

Eren Construction are one of the leading multi-disciplinaryconstruction companies in Turkey and have a portfolio of manylarge civil engineering projects including roads, viaducts,underpasses and sewage pipelines as well as experience inresidential and commercial construction.

This canal project is the first time that Eren Construction havebeen involved with the production of their own sand andaggregates for use on a project. Previous to this the companywould have used large quantities of river won aggregates butnew legislation in Turkey required that they explore otheravenues of supply. “Carrying out the washing and screening inhouse has been a big experience with a lot of learning in theprocess but other aggregates projects are inevitable now withthe new legislation so it has been a positive step for thecompany” explains Mr Yasar Eren.

The construction of the canal requires the blasting andexcavating of both limestone and basalt with an estimate thatapproximately 13m cubic metres of earth will be removed. Thelimestone will be used as backfill to create the graded slopes forthe canal while the basalt is being used in construction of thecivils. “We needed to excavate the basalt to create the canal soit made sense logistically to use it for aggregates” says Mr YasarEren. When complete the canal will measure 10 metres wide atthe bottom with graded 12 metre banks on each side allowingfor a water depth of 6 metres.

In addition to the two mobile dry crushing and screening plantsand the M2500 mobile washing plant there are also mobileconcrete plants on site with a fleet of ten mixer trucks to delivermaterial to the construction sites. The M2500 is being fed a rateof 125 tons per hour from the dry crushing and screening plantand is producing four products - 0-4mm sand and 4-15mm, 15-22mm and +22mm aggregates.

Once material has been delivered to the M2500 E4X the feedconveyor delivers the material to a double deck ProGrade P275rinsing screen fitted with wire mesh on both decks. The +22mmaterial is removed by the top deck and the 15-22mm by thebottom deck and these products are stockpiled by the integrated9m wing conveyors.

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Mobile washingemployed onmajor canalproject in TurkeyEren Construction has takendelivery of a new mobilewashing plant for use on amajor canal constructionproject in Turkey. ErenConstruction are the principalcontractors for the final 63kmsection of the 221km canalwhich will take water from theAttuturk reservoir for theirrigation of agricultural landin the east of Turkey during thehot summer months.On winning the project ErenConstruction ventured into aggregateproduction for the first time in an effortto reduce costs and increase controlover the supply chain. The initialinvestment involved the purchase oftwo mobile crushing and screeningplants.

As the project developed in becameclear that the material being blastedand excavated on site to bereintroduced to the canal constructionproject required a washing process inorder to be able to deliver the qualityof sand and aggregates required foruse in the civils. “The dry crushing andscreening process served our purposeadequately in the early stages of theproject but as time went by we soonrealised that washing was needed dueto the volume of silt and unwantedfines in the excavated material”explains Mr. Yasar Eren, Chairman ofEren Construction. “The nature of theproject required that the washing plantbe mobile as it would be moved everyfew months as the project progressestowards completion.”

It was at this stage that the M2500mobile washing plant from CDE wasintroduced to Eren Construction. “TheM2500 offered the mobility that weneeded while also ensuring that thesand and aggregates we produce are

The -15mm material is sent to theintegrated EvoWash sand washingplant where a split screen allows forproduction of a 4-15mm aggregateand 0-4mm sand, once againdischarged to stockpiles via theintegrated conveyors. It is thehydrocyclone technology employed onthe EvoWash that allows for theeffective removal of silts from within thefeed material while the high frequencydewatering of the sand ensures that it isdischarged at 12% moisture, ensuring itcan be used in the production ofconcrete very soon after production.

Commenting on the project, IainWalker, CDE sales manager for Turkeysaid “The application of the M2500 onthis project provides evidence of itsmobility as well as demonstrating thecapability of the unit to be employedby contractors on large civilengineering projects for the productionof their own sand and aggregates onsite.”

In addition to processing the newly excavated material the M2500will also be used to process some 60,000 tonnes of material that hasbeen stockpiled on site awaiting the arrival of the new washingplant. “The M2500 has been a very good solution for us” explainsMr Yasar Eren. “Not only has it allowed us to effectively deal withthe issue or excess fines in the dry screened material but the mobilityof the unit fits in with the requirements of the project perfectly. Thewhole installation and commissioning of the new washing plant wascompleted very professionally by CDE and given the quality of thefinal products this is a process that we will be using in future onother large civil projects that we are involved with.”

Product focus



The increasing requirement toreclaim and recycle a greaterproportion of primaryaggregates and the need toclean materials containing ahigh proportion of silt haveensured that the washing barrelcontinues to play a major rolein many sand and gravelprocessing plants. Barrels have been used to washaggregates since the very early days ofwashing plants, and although the basicconcept has not changed, the modernday washing barrel has become a farmore efficient and user-friendly machinethan the earlier versions. Today's barrelsincorporate modern materials, resulting inshorter downtime and easiermaintenance. This coupled with theinherently robust nature of this type ofmachine, means that the barrel remainsan important method of washingaggregates.

In essence, a barrel is incorporated withina processing plant when adhering clay orfines need to be liberated from theaggregate to produce a clean product.

Product focus

Matthew Joyce,managingdirector ofWilemanEngineers Ltd,outlines theoptions available

Two types of barrel are available:

Washing barrels: which turn at a relatively slow speed (approximately25% of critical speed) and are normally incorporated when the feedmaterial does not require intensive attrition to clean it, or where thematerial might break up due to its fragile composition and hencecreate further undesirable fines, e.g. coal washing.

Scrubber barrels: These turn at a more rapid 50% of criticalspeed. The faster speed of these barrels creates far more material-on-material attrition, causing the fines and clays to be literally scrubbedoff the aggregate.

Within these two types there also exist different concepts that allowfor flexibility in the overall design of the processing plant, dependingon the material analysis. These concepts essentially revolve around thesand content in the feed and the direction of water flow within thebarrel:

Uniflow: this concept, as the term suggests, is where all the materialthat is fed into the machine exits at the discharge end. Generally,most -5mm sand would be removed from the feed before it is fed intothe barrel, thus allowing only those fines still adhering to the stone tobe scrubbed. All of the water used in this concept enters at the feedend of the barrel and travels in the same direction as the materialflow.

Contraflow: this concept is offered where customers wish to scrub'as dug' feed, including the -5mm sand. Best results are usuallyachieved when the sand content does not exceed 50% of the feedmaterial, due to the cushioning effect of the sand. Unlike the uniflowsolution, the water is introduced into both the feed end and thedischarge end of the barrel. Perforated de-sanding meshes areincorporated in the feed end of the barrel, creating a flow of sandand water towards the feed end where the sand is removed for furtherprocessing. An addition to this concept is the incorporation of aperforated de-sanding discharge trommel to remove further sand andallow a certain amount of dewatering to take place before thecoarser material passes over the trommel for further processing.

Barrel washing offers a number of significant advantages. First, theattrition created in a high-speed barrel means that a very cleanproduct can be achieved; secondly, the incorporation of a contraflowbarrel in certain circumstances can provide flexibility in the overalldesign of the processing plant; thirdly, a barrel can handle largerfragments within the feed material; and fourthly, high-tonnages can beachieved through a barrel.

One disadvantage of barrels is that they rely on the break-up of theclays through the action of attrition, but this can cause some clay,especially those of a plastic nature, to ball up into larger lumps ofclay, and therefore such materials are not suitable for barrel washing.

Wileman Engineers Ltd are a leading supplier of scrubber barrels tothe sand and gravel and associated industries and have beensupplying machines to the major UK aggregates companies since the1970s.



Complete Utilities is a civilengineering companyestablished over 20yearsago based inGloucestershire. Whilst theirmain business is 'diggingholes in the road' in recentyears the emphasis ontreating wastes has ledthem to develop recyclingoperations so they can dealwith their own wastes.After investigating some of thecommon routes to recyclingconstruction and demolition wastesComplete Utilities commissioned awash plant from DUO. Whilst amore expensive route the wash plantdemonstrated it was able to operateeffectively in all weather conditionsproducing a consistently high qualityproduct.

The main element of the processingplant is a Powerscreen Aggwashwhich washes and grades the trenchspoil the company generates in itsutility work. The Aggwash systeminitially rinses the feed material andscreens off any oversize, anoverband magnet on the feedconveyor removes any ferrous metalfrom the material before it enters thelogwasher. Whilst in the logwasherthe material is agitated by tworotating shafts each fitted with hightensile paddles, this scrubbing actionremoves any clay and floats off lightweight contaminants onto a

dewatering screen. The scrubbedaggregate is the fed onto a secondscreen which gives a final rinse aswell as sizes the aggregate so that itcan be stockpiled as three usableproducts. The underflow from all ofthese processes goes to the built-insand plant which removes the siltcontent and dewaters to produce asingle grade of sand; the wastewater is then pumped to the watertreatment system to ultimately bereused by the Aggwash as part of aclosed circuit system.

A notable feature of CompleteUtilities wash plant operations is thatit runs from a small yarddemonstrating that you don't need abig site with lagoons to run a washplant operation.

The graded aggregate from thewash plant is blended to meet thespecification for a type 1 aggregatematerial. The whole process isquality driven and the operations arecontrolled by a factory productioncontrol process. Testing is carriedout on the recycled aggregateproducts to confirm it meets BritishStandards. This is detailed in a'Quality Protocol' the company hasdeveloped specifically for its washplant. This complies with theguidance of WRAP (Waste ActionResources Programme) and confirmsthat the recycled aggregateComplete Utilities produces meets aspecified standard and is not awaste.

The washing plant now accounts for100% of the companies requirementsfor aggregates. The residual is silt

fines which the company isinvestigating further treatments optionssuch as combining with cementatiousmaterials or composting materials togive a full diversion rate of 100%from landfill.

This is a major investment for acompany of this size and has beenrecognised with the project being afinalist in this year's NJUG (NationalJoint Utilities Group) awards in the'Sustainable' category competingwith major national companies suchas Balfour Beatty and LaingO'Rourkes.

Product focus

Utilities Company washesarising trench waste


Complete Utilities arewinners of the NJUGSustainability Award 2011with Wash Plant

Complete Utilities win the 2011Sustainability Award for it washplant recycling operations. At aCeremony at the House ofCommons Complete Utilities beatoff the tough competition toscoop the top Award. Acceptingthe award Steve Chaplin,Managing Director, said "It isgreat to get national recognitionour recycling efforts - we'recommitted to environmental issues,minimizing our waste andrecycling as much as possible.This award shows how the hardwork of my team and how ourwash plant makes a realdifference. I'm delightedparticularly given how tough thecompetition was."

Latest News


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Based in Great Blakenham nearIpswich, Suffolk, JT Few Plant HireLtd (JTFPH) is the latest company toinvest in the new award winningPowerscreen ™ Aggwash mobilewash plant.

Offering plant hire, road haulage andrecycling services in Suffolk, JTFPH alsosupply bulk aggregates and other materialsfor use in the building and constructionindustries.

Washing for the first time

Having only previously crushed and dryscreened materials the company made thedecision to invest in a wash plant whichwould enable them to add value to thematerial and provide quality materials toexisting and new customers. Additionally,this investment would also allow them toprocess material previously untouched dueto the high clay and high moisture content.

After almost 2 years of market research andsubsequent site visits to view wash plantsJTFPH made the decision to purchase thePowerscreen ™Aggwash from industryleading, specialist washing equipmentsupplier DUO (Europe) plc. of Coventry,

West Midlands. In addition to the supply of the Aggwash, DUOalso designed, installed and commissioned a plant whichincluded a full water treatment system based around a centrifugewhich was specifically selected for its compact size, lowoperational cost and ease of maintenance.

The Installation and its Financial Benefits

Working within planning regulations (max 6 metres height) thewater treatment solution supplied by DUO perfectly complementsthe Aggwash and provides a compact size plant relative torequired production levels. As JTFPH had only previouslycrushed and dry screened materials it was essential that theincoming contaminated waste feed was dealt with in compliancewith the Environmental Agency regulations which would notallow any waste water being sent to a lagoon.

To deal with this issue the DUO team specifically designed thewater treatment element to incorporate a closed circuit systemwhich not only guarantees the cleanliness of the product,reduces water usage, eliminates ingress into the ground andconsequently promotes sustainability. The end result being thatthe centrifuge consistently produces an excellent cake, the lowmoisture content of which is vital to ensure that the material willbe accepted by landfill sites.

The centrifuge is supported by a sludge tank, clarified watertank and a thickener system. All site water is collected andpumped into the plant to prevent any water going off site, withthe silt from the centrifuge (20 tph of cake) being stockpiled fordisposal off-site. This reduction in the volume of waste materialhas provided JTFPH with considerable savings on any landfillcosts. The disposal cost of the material that does go to landfill isreduced further due to the cake's greatly reduced water contentand consequently lower weight.

JT Few PlantHire invest inthe new awardwinningPowerscreen™AggwashMobile WashPlant

Product focus

A working partnership

Installed within a four week time framethe new plant is controlled by a fullyinterlocked PLC which runs the plantautomatically. Processing recycledaggregates at 55 tph the Aggwashproduces two sands, a gravel andwashed oversize. Designed to processa large variety of recycled materials,the process efficiently removes metals,trash and clay from the feed materialsubsequently providing saleablematerials for use in all buildingprojects including concrete, drainageand pipe bedding.

Jonathan Few - Director, commented,“The new plant is exceeding ourexpectations and current processingrequirements. It is proving to be anexcellent investment that will provide uswith more saleable products whilstpromoting sustainability and we canfeel secure in the fact that we have thebenefit of the DUO team and all theirexpertise behind it.”

Fintan McKeever - DUO Director, commented, “The new plant is able to process a large variety of recycledmaterials and consistently produce quality aggregates. The very latest technology available, the Aggwashcombines compact processing with excellent access and lower operation and maintenance costs than any othermachine on the market.”

Award winning

The Powerscreen® Aggwash is an award winning mobile wash plantthat brings together for the first time rinsing, screening, scrubbingand sand washing capabilities on a single transportable chassis.Primarily designed for the processing of construction & demolitionwaste but equally suited to virgin material applications it is capableof producing four grades of aggregate and a single grade of sand atup to 60 tonnes per hour.


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A Rotar 900R screener buckethas helped a Nottingham-basedcompany overcome a 17-yearold materials processingproblem, converting a tricky andsticky waste into a saleablecommodity.Nottingham-based North MidlandConstruction (NMC) is a rare find; anational civil engineering and buildingcontractor that is a jack of all trades butappears to be a master of all of them.Operating as five individual divisions andsubsidiaries, NMC undertakes constructionprojects covering water, power, utility,energy from waste, rail, road and civilprojects, urban regeneration,environmental, and infrastructure work, andwell as having its own mechanical,electrical and building companies.

Recycling Requirement

Obviously there is a huge amount of wastematerial from its construction and utilitywork that needs to be processed andrecycled as a result. Alongside thecompany's state-of-the-art headquarters,NMC has its own recycling centre, whereconstruction and demolition waste can beseparated, screened, processed, crushed,sorted and eventually reused.

However, because the majority of thegeology in the Midlands has an overlayingcover of heavy clay, the processing ofgroundwork material has proved difficult asyard supervisor Kevin Morton explained."We can remove stone and brick from thewaste easily enough. We'll bring in amuncher to deal with rebar. We can screen

Product focus

Dig A CrusherProvides MoneySpinner


and trommel the vast majority of the material whilst it is dry. Butthe moment it gets wet, the trommel blocks up and the screenersimply isn't efficient enough to warrant trying to separate thewaste,” he says. “As a result it gets stockpiled until it's dryenough to process again. Except it rarely is. As a result we hada yard full of a highly sticky waste product we simply couldn'tseparate. As a result we accumulated a 7 metre high waste

pile that was slowly enveloping the yard; onethat the Environment Agency really tookoffence to. They refused to grant a furtherlicence to hold more - although a differentcategory - waste material, until we had foundan answer to our existing waste stockpileproblem."

Rotar to the Rescue

Help came in the form of a Rotar 900Rrotating screener bucket from Middlewich-based Dig A Crusher that NMC saw in actionat last year's Hillhead exhibition where one ofthe uses demonstrated by the rotating bucketwas aggregate washing.

Suddenly realising they had stumbled on apossible solution to their muddy waste, a

demonstration machine was soon on its way to NMC's Huthwaiteyard. It proved so effective that it never left, and after a twoweek hire, it was purchased outright.

The bucket was fitted to an existing 21 tonne Komatsu excavatorand work began in earnest. “The Rotar worked through the toplayers of the stockpile quickly because it was fairly dry anduncompacted. We removed the top quarter of the stockpile,processed and washed it without problem. After this we had themoist sticky mess left, which was more akin to thick mud withstones; a totally useless material that was destined for landfill. Ithad totally compacted through years of sitting in the rain,” Mortoncontinues. “But we stuck with the bucket but, because of the highwet fine content, we started to use it in a different way. We tookto pre spinning the material before washing. This took out quitea bit of the fines. We then did a prewash, which took out themajority of the mud, before a final clean wash, this was simply toprevent having to constantly empty the skips that were used as thewashing bays. The resulting material makes an excellent Type 1product and we've since discovered that it also makes excellentclean drainage material, which the local farmers love, so we haveyet another market for the aggregate."

Quality over Productivity

Kevin Morton readily admits that the system used to process thisdifficult material is not achieving high throughput levels but, hesays, he is willing to forego productivity for the sake of qualityand to finally tackle a 17-year old problem. “Although the wayin which the bucket is used isn't going to win any productionrecords, we now get two saleable products from rubbish. Topsoilcan be separated in the wash programmes, allowed to drain insettle tanks and then used as clean backfill, whilst the real money-spinner, the clean aggregate can be recovered easily. We'veopted for quality over speed and it's paid off,” he concludes.“The original stockpile is now down to just a quarter of its originalsize. We have found the only machine capable of processingsuch a sticky product. Our operators love it for its ease of use,simple maintenance and the fact that we are starting to get ouryard back. It is a brilliant solution to a problem that has plaguedthis yard for too long.”


Aggregate Processing Solutionshas provided an uprated TerexFinlay TC 15 Sand Master toboost productivity on site atHanson Aggregates inMercaston, Derbyshire.

The machine has been brought in as part ofa 28-week contract, which will see the sandand gravel quarry produce volumes thatwould normally be achieved over an 18month period.

With a processing power of up to 120tonnes an hour of sand, the modified TC 15offers a quick and efficient way for thequarry to meet tight deadlines and productspecifications.

The TC 15 works with a chassis mounted,Terex Finlay MP300, mobile washingsystem, a Terex Finlay 390, two Terex Finlay532 conveyors for sand stockpiling and aTerex Finlay 683 producing three grades ofgravel.

Brought in to replace an older permanent static system, the TC 15 hastwo 24 inch cyclones and produces a -2mm fine sand to meetHanson's specification.

Raw material is stockpiled before being fed by the 390 to the MP300washing system.

Sand from the on-board rinsing screen then flows to the TC 15. Plus2mm gravel passes through the integral Terex Finlay 206 logwasher,which delivers onto a de-watering screen which has been configuredto produce a 2mm - 5mm grit product.

Anything above 5mm is fed through the Terex Finlay 683 Supertrak inorder to produce three grades of gravel, 10mm, 14mm and 40mm.

The TC 15 Sand Master's low level feed-in and easy to access pumpshelps keep maintenance simple.

As well as rubber lined centrifugal pumps and impellers, an electriccontrol panel is fitted as standard, which facilitates two 7.5 Kwstockpilers, enabling the sand system to be easily incorporated into anexisting washing arrangement.

Andy Bull, the quarry manager at Mercaston Quarry, said; “The TC 15Sand Master is quick and versatile, and is extremely compact andeasy to locate, even with the uneven ground we have here.

“It deals with our time, space and surface limitations really well and isa durable, fast working machine.

“Importantly, it uses under half the amount of electricity and water thatwas consumed before, saving the quarry a lot of money.”

Bob Parker, the contracts manager from Aggregate ProcessingSolutions, said: “The TC 15 is perfect for the fine sand at Mercastonand has enabled us to meet our contractual obligations in terms ofproduction and product specification.”

Hanson is part of the Heidelberg Cement Group, which is the globalleader in aggregates and has leading positions in cement, concreteand heavy building products. The UK business - Hanson UK - is aleading supplier of heavy building materials to the UK constructionindustry.

Product focus

Uprated TerexFinlay TC 15Provides HighCapacityTreatmentSolution forMercastonQuarry.



The main advantages of the BAIONI Centrifugal decanter systemsare they are small and compact compared with other methodsbeing used today , the cost of maintenance is also low , withminimal operator control needed as they are fully automatic,controlled by its own dedicated plc

BAIONI BAIDEC Centrifugal decanter come in 9 model sizescapable of producing solids from 1 tonne per hour to 20 tonneper hour

BAIONI THICKENER Come in 5 model sizes from 4000 litresper minute to 13500 litres per minute

BAIONI GRF Hydro cyclone and dewatering screens come in10 model sizes

Baioni crushing plants consider it to be more than just a supplier.It offers real help and support to every customer, with whom itdoes its best to co-operate in a reliable and genuine mannerstriving to achieve mutual satisfaction and success

Safety is a big issue with safety devices required under the EECmachinery directive 2006/42/EC

Protecting the environment andreducing the amount of sludgefrom being tipped or stored inlagoons has prompted Baioni todevelop methods of collectingand dewatering sludge’s fromaggregate washing plants.

Over the last fifteen years Baionihave followed a policy ofdeveloping the Centrifugespecifically for the aggregateand recycling industry.Many are well established in the UK andworldwide and are proving to be veryefficient at collecting and dewateringsludges from aggregate washing plants andrecycled aggregate plants.

This method of dewatering allows for thesolids to be disposed of in dry landfill or tobe used on restoration in quarry areas,more recently the use of the solids acapable of being used in hydraulicallybound materials, the water reclaimed fromthe process is clean enough to be returnedto the washing plant for immediate reuse.

The process starts by taking the flow ofsilted water after a hydrocyclon unit (BaioniGRF hydro cyclone and dewatering screen)this produce a silted water with a solidscontent of minus 63 microns, this iscollected by a thickener tank where thematerial is settled to a density of around1.3, this sludge is then pumped to aagitated buffer tank this give a constantsupply to the Centrifuge at a controlleddensity.

The next stage is to pump it to aCentrifuge, prior to entry it is dosed with asmall amount of flocculent this gives thewater a very good clarity, which can bereturned to the washing plant for reuse. Thesludge is centrifuged at high speed andgives dry solids of around 58 to 62 % dry.This is a solid that can be handled easilyfor transporting and will not release anymore water due to the high centrifugalspeed that it has been subjected to.

Product focus

Centrifugedevelopments forthe aggregateand recyclingindustry



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