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Let's stop focusing on hitting a meaningless 100% C&D waste recycling target

2014-08-15T10:49:00.002+01:00

Insanity is…

Doing the same thing over and over again and expecting a different result. Every year yet another report is produced highlighting the crisis that is facing the UK construction materials industry as a result of dwindling reserves.

The latest report from BDS Marketing Research now says this situation “is now having a serious impact on the industry.” The report goes on to say that over 100 existing pits could close over the next five years unless extensions to extraction licences are granted. The report’s author, Julian Clapp goes on to say “aggregate companies need to get their planning applications submitted soon to ensure continuous aggregate supply.”

Despite this annual warning of impending doom the opportunity that it represents for the C&D waste recycling sector is not being fully exploited. Given the obvious supply gap that exists with virgin sand and gravel and crushed rock for construction applications why hasn’t there been more investment in advanced processing systems that offer specifiers a real alternative?

It’s an issue of positioning – and for too long recycled sand and aggregates have been positioned as a low value, lower quality option. “If there really is no other option then I suppose we could use recycled material.”

So how do we change this? First of all we need an acceptance within the C&D waste recycling sector that if we persist with the most basic processing of this material we will never be able to achieve the full potential offered by recycled sand and aggregates.

The advanced processing systems that will help to move recycled sand and aggregates up the value chain are out there – and many within the industry are already using them. These companies are enjoying the benefits of their foresight and are seeing recycled materials used in high value construction applications as a viable alternative to virgin materials.

While the success of these companies is to be applauded they are the exception rather than the rule. Let’s stop patting ourselves on the back about how good we’ve got at C&Dwaste recycling. Let’s face it – the definition of recycling is so broad that it’s not hard to hit. If we’re being honest with ourselves a lot of what is happening is simply dumping under another name.

The only way we’ll succeed in moving recycled sand and aggregates up the value chain is to stop focusing on hitting a meaningless “100% recycling” target for C&D waste and instead start focusing on increasing the volumes of this material that are used in high value construction applications.

By doing this we’ll not only be ensuring that we are extracting maximum value from this valuable resource but we’ll be in a great position to take advantage of the opportunity presented by the lethargy of the construction materials industry and the inadequate planning system that combine to create the opportunity in the first place.

Co-Creation as a means of delivering efficient plant design

2014-07-03T09:16:00.001+01:00

In recent years the issues of productivity and efficiency have risen to the top of the agenda in the global materials processing industry. There has been a shift in emphasis from one founded on the principal of ‘more capacity’ to one which seeks to ensure that every individual operation is extracting maximum value from the material being processed.

This presents a new challenge for most equipment manufacturers who will now have to go beyond their previously self-imposed boundaries and get closer to the end user to ensure that the equipment they provide will meet the productivity and efficiency requirements that are now driving investment decisions.

Every application has its own unique challenges and in order for equipment manufacturers to provide fit for purpose processing systems they need to ensure they are at the very centre of the discussion. This is especially true in the wet processing and classification market where understanding the specifics of the feed material is a critical factor in the delivery of a successful project.

The change in emphasis from ‘capacity’ to ‘productivity’ has sharpened the focus on every processing phase within the complete system as operators seek to identify where the inefficiencies lie and put a plan in place to address these. This increased focus can reveal an array of process issues that previously went unnoticed – unnecessary material spillage, inefficient separation systems which result in poor quality final products and good quality material being lost to the water treatment or waste management phase.

Any processing plant including several different processing phases must be much more than a number of individual equipment items in sequence. In order to deliver on the productivity and efficiency requirements of the industry a robust plant design process is required which requires a considerable level of consultation between manufacturer and end-user. It is only by adopting this approach that a full understanding will exist of the requirements of the project.

This process should take account of a number of issues and ensure that the plant is configured to ensure delivery of the most efficient processing system. These include material testing and analysis, space restrictions, civils design, proximity to waste storage areas, transfer point technology, water management and maintenance access.

Our experience over the last two decades in the design and delivery of successful materials washing projects has been built on the theory of co-creation – a partnership between us and you, the end-user to understand your objectives, address the issues you are facing and ensure that the processing system is designed with the in-built flexibility to ensure that any future changes in your requirements can be accommodated with the least amount of disruption.

A successful materials washing plant is built on a detailed understanding of your project as something unique and the design and specification of the appropriate technologies to ensure your objectives are met. To try and achieve this with a limited range of standardised, mass produced equipment is not possible – and the success we have enjoyed in the materials washing arena over the last 20 years is testament to this.

By conducting extensive material testing and analysis in our own laboratory a full understanding of the nature of the feed material is gained. While testing will indicate whether the final product specifications desired by the end-user are able to be achieved it is the further detailed analysis of these results that will potentially reveal opportunities to maximise product yield from the feed material. It may be possible to look at production of additional sand specifications which will not only reduce waste volumes but provide an additional revenue stream. This will often require the introduction of more complex processing systems if a specialist sand can be produced - sports sands, filter sands, foundry sands for example. While this will require additional investment the return on investment argument is a compelling one given the potential to produce a product for one of these high value applications.

By conducting a process audit on existing sites we can focus in on the areas where specific actions are required in order to improve efficiencies. This will help us to identify what the important issues are to you in that specific situation and ensure that any new processing system is built to tackle these and deliver on your requirements for increased process efficiency, productivity and plant availability.

A key element of the co-creation process is the design workshops that we undertake. These workshops typically involve a number of representatives from the customer – operations personnel as well as senior management – as well as an extensive project team from CDE. This will include a senior Technical Engineer who will be involved to discuss plant specification in detail with you and ensure that there is clarity around the site infrastructure (civils design, water requirements, power requirements).

As well as dealing with these pre-sales elements our design workshops will also introduce you to the delivery processes we have in place to ensure project delivery goes to plan. This is an area which is often overlooked and the costs of poor delivery underestimated. Our washing centric ProMan system has been proven to deliver hundreds of materials washing projects successfully and the design workshop will involve meeting with the individual Project Manager who will take ultimate responsibility for the delivery of your project and act as a single point of contact until project completion. You will also be introduced to all of the other elements of our project delivery process and meet the team of people involved in your project – logistics, design, install & commissioning, post commissioning support, training.

In summary, mass produced and standardised equipment is designed around the principle of making a production facility efficient rather than delivering successful materials washing projects. The success we have enjoyed in the global washing sector is evidence that successful plant design and delivery involves a huge level of direct contact between us as equipment manufacturers and you as end users of the equipment. Each and every plant we build is co-created with our customers and this applies whether we’re delivering a single item of equipment or a full turnkey processing system integrating many different processing phases. Our M2500 is the perfect example – almost 100 machines sold in the last 3 years and no two machines are the same.

It is this ability and our agility in regard to the plant design process that ensures we are in a position to help you deliver on your requirements for the most efficient, most productive processing system available.

Mining in remote locations - how equipment manufacturers can continue to deliver fit for purpose systems

2014-06-09T14:57:00.000+01:00

Our experience in the delivery of mining projects across the world in recent years has revealed a number of challenges for us and other equipment manufacturers if we are to continue to provide processing systems that are fit for purpose.

A major challenge for equipment manufacturers in the years ahead will be to provide materials processing systems that are able to be efficiently deployed in increasingly remote locations. There will also be a requirement to process increasingly difficult materials that have been overlooked until now. As our demand for steel, aluminium, copper and silica sands and other industrial minerals continues to increase mining companies are constantly looking for new and improved processing technologies that will allow them to process lower grade ores and industrial sands and produce final products suitable for use in downstream processes.

Another development we have witnessed is an increased focus on staged investment as a means of delivery for new mining projects – designing your plant in such a way as to allow for production to begin in the shortest possible timeframe while planning for further plant and process development. To use the age old adage ‘the customer is always right’, if mining companies are looking for equipment that can be more efficiently deployed, that can process increasingly difficult materials and that are is suitable for staged investment then it is the responsibility of equipment manufacturers to meet these requirements.

In looking at how we can do this I will look at a number of issues which can be categorised under these headings:

1. Built with the application in mind
2. Modularity
3. Intelligent Process Integration
4. A phased approach to design & delivery
5. System adaptability
6. Mobility – without compromise
7. A turnkey approach

1 - Built with the application in mind

Every project presents its own unique challenges. When we look at the raw material there are a several factors which will influence the selection of the appropriate processing system. The quality of the ore is the first issue to consider. In addition to this we need to analyse the level of contamination within the material that needs to be removed. This could be sticky plastic clay that requires a logwasher to provide the necessary attrition. In the case of iron ore processing we will also have to consider the levels of silica and alumina contamination which if they are not removed will lead to inefficiencies in downstream steel production processes. The presence of all of these materials necessitates that every project is considered as a stand-alone system and designed, specified and constructed individually with a full understanding of the requirements of the project.

If we take this to its logical conclusion the response from equipment manufacturers to this scenario should be to produce tailored processing systems for every individual project in order to maximise process efficiency. This represents a major shift from the typical business model for equipment manufacturers – which is to produce a limited range of standard machines that can be applied across a wide range of applications. Using standard machines presents a problem, and requires end users of the equipment to accept that they will have to compromise on performance , if they do not intend to run the equipment within the designed operating parameters. .

While the vast majority of equipment manufacturers will tell you that tailoring each individual project is not possible – the reality is that it is entirely possible. Our experience in the mining sector has shown that there are a number of individual considerations that need to be made in order to maximise the efficiency of the final processing system.

The selection of the appropriate screening media is very important – polyurethane is almost always the best match for mining projects but not all polyurethane is equal. Due consideration must be given to the abrasiveness & specific gravity of the material to ensure that the most suitable product is specified.

The choice of lining for any hydrocyclones also requires individual consideration – rubber lining may well be suitable on some materials but others will demand ceramic linings when dealing with highly abrasive mineral ores.

Consideration should also be given to the requirement for additional wear liners at specific points in the system. Easily replaceable wear liners at the feed point will have a positive impact on plant availability by minimising the time required for maintenance.

The appropriate conveyor belt specification will also require individual treatment based on the nature of the material to be processed. Enhanced top cover thickness will enhance wear resistance, maximise plant productivity and reduce costs of operation through a reduction in the spare parts requirement. Staying with conveyors, the inclusion of belt cleaning systems such as tungsten tipped scraper blades will also offer enhanced wear resistance.

The specification of appropriate pumps is also critical in an effort to ensure they will stand up to the rigours of the material to be processed.

2 – Modularity

A rise in the popularity of modular processing systems on mining projects has been evident over the last number of years. One of the major motivations for a move in this direction from our own perspective was a focus on Transfer Point Technology – ensuring the efficient transition of material from one stage of processing to another. The direct result of this approach is to maximise material retention within the circuit and avoid bottlenecks within the system where the discharge point from one processing phase is not optimised for seamless delivery to the next stage.

There are numerous advantages to this approach – greater process efficiency and reduced installation and commissioning time being the most obvious. All of this works together to ensure you are able to start extracting value from your material as quickly as possible.

In most, if not all mining projects there will be a requirement to integrate third party equipment within the processing system so it is also important that designers are aware of the likely connections that will need to be made and consider this very early on in the design process. This will streamline the project design process and ensure that once the system is up and running it operates at maximum efficiency.

The third party equipment that CDE has most experience with when designing processing systems for mining projects are attrition cells, spiral classifiers, decanter centrifuges and filter presses. Through the development of partnerships with suppliers of these systems we can ensure that our focus on Transfer Point Technology does not stop at our own products but extends to this 3rd party equipment as well. As a result of our focus on tailoring each system we are also able to manage the introduction of new equipment to our systems as and when required.

3 – Intelligent Process Integration

Intelligent Process Integration involves the introduction of several different processing phases onto a single chassis. Aligned with the previous point on modularity this allows for transfer point efficiency to be maximised. Additional advantages are a reduced plant footprint which results in a reduced civils requirement. These factors combine to reduce both the time required and the final cost of the project.

When feed systems, screening plant, fines processing, scrubbing systems are all provided as individual stand-alone units there will be a large amount of design time spent on designing civils and support structures to accommodate all of this equipment. Once the equipment reaches site the time taken to mechanically install the plant will be longer than necessary as a result of having to put all of the individual components together.

The reduction in mechanical install time is delivered because all equipment undergoes a complete pre-build to its working position in a factory environment. This is a final quality control step that allows for any fabrication issues to be addressed before equipment is dispatched. Our focus on the delivery of wet processing systems means that this approach extends to ensuring all pipework connections are already established prior to dispatch – eliminating the requirement for cutting or preparation work on site, reducing install time and eliminating the requirement to source this pipework locally either because it has been damaged in transit or is missing from the items delivered to site.

Another significant advantage of integrating several processes onto a single chassis is that all equipment can be pre-wired and tested in a factory environment. Adding to the reduction in time taken for mechanical install, the electrical installation time is also reduced. It also has the advantage of making the electrical connections a design feature of the plant – cable runs and housings are part of the design process which not only improves the aesthetics of the plant but also enhances health and safety on site.

This approach also reduces the requirement to try and find local suppliers of cables and other electrical items – particularly relevant in any discussion concerning how to approach mining projects in remote locations.

4 – A phased approach to project delivery

Through a phased approach to project delivery it is possible to show a return on your investment much more quickly. The start of this process will be detailed discussions with your mining engineers to understand the specifics of the reserve – capacity requirements, likely requirements for future upgrades. This will also involve a detailed analysis of your material in an attempt to understand whether it is possible to kick start a project with a simple processing system which can then be added to as and when required.

For example, a detailed material analysis throughout the reserve will reveal whether there is a seam of relatively clean, uncontaminated material that requires minimal processing. Following this it can be determined at what stage additional equipment may be required – for example a logwasher may need to be introduced to tackle claybound material or to help in the removal of other contaminants. Following this a third phase may be the introduction of primary stage water treatment and tailings management systems.

From an operational perspective the main advantage of adopting a phased approach is that rather than waiting for months on the delivery of a complex processing system, most of which will be under-utilised for a period of time you are able to take delivery of your first phase equipment in as little as 12 weeks. This allows you to begin to show a return on the investment very quickly which helps fund the future expansion of the plant when conditions dictate that it is necessary.

5 – System Adaptability

We have touched on the variability that is inevitable within mining projects and what is required at the outset may change over time. Future developments with your business may require a capacity upgrade to meet a rise in demand for the material you are producing. We may come across an area of your reserve with particularly challenging material that will require the introduction of a new process. Space restrictions on site or future environmental legislation may require the introduction of a tailings management system.

Given this potential for circumstances to change, it is essential that your processing system has the in-built flexibility to respond to these changes. We can’t predict the future but through a comprehensive analysis of your material we can identify whether for example there is likely to be a requirement for an additional process to be introduced and when this is likely to happen given your extraction plan for the reserve.

If we have established that your business plan indicates a likely requirement for additional capacity as extraction progresses we will design the civils on site to take this into account – minimising disruption to your operation. We will also bear this in mind when considering the location of the processing plant in the first instance to ensure that once any upgrade is required the original location is still suitable. Another step that we will take is to ensure that the original conveyor specification is fit to cope with the forecasted additional capacity both in terms of belt specification and stockpile capacity.

Similarly, if additional processing equipment is likely to be required this can be considered during the design of the original plant civils. We will also conduct a detailed analysis of the likely future water and power requirement once the additional equipment has been added to make sure that this infrastructure is in place.

6 – Mobility without compromise

Mobile makes sense. As your extraction progresses it makes sense that your processing plant should be able to be moved within the deposit to ensure maximum operational efficiencies are delivered. With a static processing plant this is not possible. As your extraction progresses your operational efficiency is reduced – increased transport movements on site as vehicles have to haul material greater distances to the processing plant, unnecessary double handling of your material as it is stockpiled at the extraction point before being delivered to the processing plant. By opting for modular equipment which integrates several processes on a single, easily transportable chassis you ensure that your processing plant can be moved quickly and easily within the deposit – or to another processing location – in order to maximise operational efficiencies.

This should be done without compromising on the specification of the screens, fines washing plants or logwashers that are included. The creation of a modular product range fit for purpose in mining projects should involve the same specification of equipment as would be included on a static plant.

One of the major areas of compromise on mobile plant is with the walkways – ladders leading to very narrow walkways are the norm on most mobile machines. This makes plant maintenance very awkward, – increasing the time and therefore the cost of carrying out plant maintenance. Site health and safety rules may also be compromised.

This is why we believe that even on mobile or portable plant the walkways for access and maintenance should be of the same specification as would be found on a static plant. This ensures that you continue to enjoy all the benefits of a static plant in relation to maintenance access – ease of visual inspection, access to change screen media ,media, replace spray bars, and carryand carry out hydrocyclone maintenance.

The issue of maintenance access is often overlooked when a processing plant is being specified but it is a very important consideration as it is a factor which will have considerable influence on plant availability and delivering the highest standards of health and safety on site.

7 – A turnkey approach
It is evident from the analysis of all the aspects that make up a successful mining project in the 21st century that a much greater level of interaction between equipment manufacturer and the end user is required in order to deliver successful projects. With the many considerations that need to be made there is potential for a huge number of vendors to be involved on each and every project and this requires that a robust Project Management system is in place.

Our own process is split into three distinct phases:

1. Technical Pre-Sales
2. ProMan
3. CustomCare

Each of these phases include large amount of work. In Technical Pre-Sales the elements include process design, equipment selection, mechanical design, civil design and 3rd party equipment integration. As we move into the delivery phase of the project ProMan takes over and includes factory testing, power distribution, risk management, scheduling, budget management, construction management and quality control. Once your plant has been successfully installed and commissioned our range of After-Sales services are activated including our MasterClass training programmes, service visits, recommended spare parts lists and on-going maintenance contracts.

The effect of being able to offer this complete range of services in addition to the equipment that we provide is to significantly reduce the number of vendors involved in the project, the result of which is a more streamlined project timeline which costs less to deliver. Effective communication is crucial to the delivery of successful materials processing projects and our process provides you with a dedicated single point of contact throughout the project lifecycle to ensure you remain fully informed at every stage of the project. Another advantage of this approach is that it helps to develop both our knowledge of your business and your knowledge of our capability which will allow both parties to explore the potential for further co-operation in the future.

In Conclusion

It is clear to all involved in the delivery of mining projects in the 21st century that there are many complex issues to overcome. The demands of the industry are constantly evolving and it is essential that the products offered by equipment manufacturers continue to evolve. It is equally important that equipment manufacturers develop their processes and approach to project delivery in order to continue to meet the demands of the industry.

In summary, I believe there are 3 main considerations in this analysis of how equipment manufacturers can continue to supply mineral processing systems that are fit for purpose.

1. The individual components that make up a complete processing plant cannot be looked at in isolation and should instead be made up of modular systems with the in-built flexibility to cope with shifts and changes in individual project circumstances.

2. Off the shelf processing systems from a collection of different manufacturers will not deliver the efficiency required of 21st century mining projects. A tailored approach is required with each individual project being built according to the specific requirements of the project – capacity, feed material and potential for future development.

3. Equipment manufacturers must get closer to the project and the end-user and understand the background, the specific objectives and the plans for future development. For most equipment manufacturers this requires a huge shift in the way their business models are constructed. Our business has always been constructed on the principle that direct contact with the end-user is critical to success. We have been delivering projects in this manner for over 20 years and our project portfolio across all the sectors in which we operate is evidence of its success.

This article was developed to accompany a presentation by CDE Mining at the Bulk 2014 conference in England organised by the Materials Handling Engineers Association (MHEA) on 21st May 2014. Further information on the Bulk 2014 conference and the work of the MHEA can be found at www.mhea.co.uk

ENDS

Information for Editors:

• CDE Mining offer a range of equipment which can be applied in the processing of a wide variety of materials including iron ore, bauxite, chromite, copper and gold. CDE Mining is a Division of CDE Global Ltd who operates in the Construction & Recycling sector – providing sand and aggregate processing systems across the world, and the Specialist Industrial Sands sector – with expertise in silica sands, frac sands and other industrial minerals.

• The company operates in 7 regions – Ireland & UK, Europe & Russia, Middle East & Africa, Latin America, North America, Australasia and Asia – and currently have offices in Northern Ireland, Brazil, India & the US with dedicated Technical Sales teams working throughout Europe & Russia, Australia and Middle East & Africa.

• You can find out more about the company by visiting www.cdemining,com and www.cdeglobal.com

A Better planning system - now there's a novel idea

2013-11-29T09:40:00.002+00:00

It's that time again - every few months in the UK media we hear about how our broken planning system is endangering the future supply of sand and aggregates. The latest article has appeared on the Agg-Net website following a report from the Mineral Products Association.

For how long can all the industry bodies keep producing report after report detailing this real threat before something is actually done about it? Government makes all the right noises about trying to support businesses during the recovery but if we look at the evidence - instead of the soundbites - there is nothing being done to address this issue.

With the industry on the upward curve again after a very tough period surely the very least we can expect is for those we charge with responsibility for ensuring that we all have the opportunity to prosper and grow to demonstrate some action and fix a broken planning system.

Exhibitions are fine - but demonstration events are a far better bet

2013-07-24T12:35:00.001+01:00

With the amount of construction equipment exhibitions across the world you could spend your life either visiting them or organising attendance at them. We've found that open day events at working sites are a far better way of demonstrating equipment and gaining a real understanding of the benefits of investing in a new processing system. When equipment is at a trade show and it's been polished up and cleaned to within an inch of its life you can't really tell how it's going to perform in the real world. Start throwing a few hundred tons an hour of rocks at it while you can talk to the people that own it, operate it, maintain it - now that's a far better indication of how it will really perform.

Calling all editors - Is there anybody out there?

2013-05-02T20:53:00.001+01:00

54 - that's the last count of trade magazines that land on my desk every month. All of which are producing circulation certificates boasting of their unrivalled ability to reach our customers. Which is of course how they attempt to justify their ridiculous advertising rates.

4 - that's the last count of trade magazines that land on my desk every month that are worth reading.

The only reason the other 50 even make it out of he plastic packaging is so that I can put them in the recycling bin.

Why are there so many sub-standard publications out there? I can't help feeling that it's because the art of editing the content is slowly but surely disappearing. Far too many - over 90% as far as I can make out - simply copy and paste badly written press releases from corporate marketing departments. Most of the people writing these articles have had no formal training on how to construct decent copy so it makes for painful reading.

I can't really blame the marketing people for this though - they've got a job to do which involves presenting their company in the best light possible. Why not fill the news release with boasts of how wonderful they are and how their products will change the world? It's not like there are any editors (in the truest sense of the word) checking the copy.

The blame here has to lie with the editors - a little bit of simple fact checking wouldn't hurt would it? For example, I came across an article today where the headline looked familiar. As I read on the whole article had a familiar feel to it.

I checked back through our records and found an article from over 12 months ago with the same headline and broadly similar copy published in the same magazine. Surely the editors of the magazine have a responsibility to ensure that the material they are publishing is accurate in the first instance, and original in the second?

I'm not that bothered by our material being blatantly copied by others in our industry - it displays a complete lack of imagination on their part. If this is their approach to marketing I'd be fairly sure it's replicated throughout their business which we can only take as positive.

However, I'd expect more from the trade magazines who for the most part fail to recognise that it is only by publishing genuine, interesting articles that their publications will survive in a massively competitive environment.

C&D waste recycling: Are we measuring the right thing?

2012-12-10T11:16:00.001+00:00

2013 is the first year that the UK will be required to report figures for the recycling of construction, demolition and excavation waste under the Waste Framework Directive initiative to achieve 70% recycling by 2020.

While there is no doubt that some form of measurement is needed to allow us to monitor progress I have serious doubts about whether simply looking at a 70% recycling rate allows to achieve anything meaningful. What does recovery actually mean? If we look at the figures at the minute they seem to be very impressive – 20% of aggregates used in the UK come from recycled sources. That represents somewhere close to 45 million tonnes at the minute which represents half of all the CD&E waste produced according to Government estimates.

For my money we should be looking at raising the bar in the approach we take to dealing with CD&E waste. The vast majority of the material being produced at the minute is being used on very low value applications using the most basic processing possible. Surely we should now be looking at how we can move recycled material up the value chain?

Yes, there has been good success up to now with the numerous initiatives to increase the focus on the valuable resource that CD&E waste can provide. Yes, we should celebrate the commitment from the UK industry that has seen us lead the way in the adoption of new technology.

We should not however just keep measuring the same thing – we’ve moved on from simply trying to increase the amount of recycling of this material. The opportunity exists for us to turn this waste material into a real sustainable, high value alternative to virgin sand and aggregates rather than a cheap, low quality alternative.

How can we do this? Well maybe we can learn something from our European neighbours. After achieving more than 90% recycling of C&D waste some years ago in Belgium the target switched to improving the quality of recycled materials. This to me makes much more sense that simply aiming at a number that is fairly easy to achieve providing your description of what constitutes ‘recycling’ is wide enough.

If we’re simply doing this to tick another Brussels box then by all means keep measuring the volume of waste recycled. If, on the other hand, we’re serious about movingCD&E waste up the value chain and making the most of it as a valuable resource then it’s time for the focus to change. This happens by measuring something that encourages everyone in the CD&E waste recycling sector to up their game – from equipment manufacturers to material producers, architects, specifiers and building contractors.

Does the technology exist to do this? Yes it does. Will it help protect long term aggregate supply from a sustainable source? Yes it will. In the words of a famous American sportswear manufacturer – Just Do It.

Landfill tax changes - threat or opportunity?

2012-05-25T12:24:00.003+01:00

The environmental industry web sites are all singing the same tune today with articles dealing with the general disquiet over the changes in the landfill tax regulations for fines from trommels or screens.

The dominant voice seems to be the one that talks about the 2460% rise from £2.50 per tonne to £64 per tonne as a threat to the future of the industry and the potential for increase in fly tipping that will occur as a result. There are however some dissenting voices happy that a loop-hole has been closed that allowed for what David Palmer Jones described as '"cheap landfilling".

While there no doubt be attempts in the coming weeks and months to have this decision reversed it's also important for them to know that there is an alternative to the high landfill costs. It is possible to produce high quality recycled sand and aggregates from this material if more sophisticated processing systems are employed.

Simple crushing and screening of this material will not allow production of these quality recycled sand and aggregates. Introducing a washing plant will successfully divert the vast majority of this material from landfill and allow for the increased specification of recycled products on construction projects across the country.

While the initial reaction to this development is that it poses a threat to the industry there is no doubt that there is an opportunity here for operators dealing with this material to upgrade their processing systems in a move to avoid the huge increase in landfill tax.

The UK has established a reputation as the world leader in C&D waste recycling over the last decade largely due to the development of more sophisticated systems - which has only happened as a result of increased demand in this area. It has to be said that this demand has largely been driven by Government interventions and this landfill tax rise is simply the latest of these.

The industry has responded to challenges like this previously and it will do again - if these changes are here to stay then it has to in order to survive. Even if the decision is challenged we all know the decision will not be reversed any time soon given the government's reputation for quick action.

Innovation is: Unique + Bold + Original

2012-04-05T09:53:00.000+01:00

In recent times the requirement to wash mineral reserves has become more frequent as operators tackle more difficult materials. With this upward trend set to continue equipment manufacturers have an important part to play in developing products which meet the evolving demands of the global industry.

There has always been a requirement to process difficult materials. The geology of a region plays a large part in influencing the processing system that is chosen and it is for this obvious reason that washing equipment has found its place in the market. When there is clay present in the material or high levels of -63 micron material a washing plant offers the best solution to ensure production of the highest quality sand and aggregates.

When operators are faced with reserves which have variations in material quality they will obviously process the easiest material first – the low hanging fruit. The selection of the appropriate system will be selected according to the nature of the material to be processed and the final products that are required to satisfy customer demands.

As we have moved through the decades and quantities of this ‘low hanging fruit’ have diminished the challenge for equipment manufacturers has been to continually develop and improve systems to ensure the more challenging materials can be efficiently processed.

One of the key developments of recent years has been the move to mobile equipment within the global construction materials sector. This began with the development of mobile crushing and dry screening systems which operators can easily move between different processing locations and also move around a single site in order to minimise the transport movements of other vehicles.

The unique requirements of washing plants made this move to mobile a more challenging concept. Logic tells us that washing plants are restricted in their mobility due to the requirement for connection to an external water supply. The early attempts at mobile washing provided evidence of this and these plants were moved rarely – if at all.

Another short-coming in the development of the first washing plants described as mobile was the inability to successfully integrate the sand washing element with the washing screen. This required operators to purchase two separate items of equipment to deliver on the sand and aggregate production requirements.

The result of these short-comings was that the uptake of these systems was limited and the perception in the industry was that mobile washing plants had a problem – they weren’t mobile. Simply putting hydraulic tracks onto what was essentially a dry screen with the addition of a few spray bars was not a satisfactory solution.

The term ‘Mobile washing’ had reached a point where it had become the evil that will not be spoken of due to flaws in existing systems. These systems did not fail because of limited demand or lack of promotion. They failed because of an assumption that the same design principles that apply to dry processing equipment can simply be copied when developing a mobile washing plant. This provided the motivation for the development of the M2500.

Central to the creation of the M2500 was the integration of the sand washing element with the rinsing screen. The aim was to produce a mobile washing plant which offered feeding, aggregate washing, sand washing and stockpiling on a single chassis.

Another key issue was ensuring that the rinsing screen was suitable for the application and would stand up to the rigours of an aggregate screening process. The issue with previous mobile washing screens was that more often than not the spray bars were bolted to the screen box. This meant they were subject to extremely high stress levels which would ultimately result in failure.

The M2500 eliminates this risk by offering a spray bar assembly which is completely independent of the screen box thus removing this risk of failure and ensuring the M2500 is designed for long term reliability and performance.

By successfully integrating the Prograde rinsing screen and the Evowash sand washing plant onto the M2500 mobile washing has gained new momentum in recent years. The M2500 has quickly become established as the equipment of choice for operators in variety of industry sectors and has been employed on the processing of sand and gravel, crushed rock, dust washing, scalpings and construction and demolition waste recycling. In addition to this there are specific models available for mining applications.

The success enjoyed by the M2500 since its introduction to the global market is evidence that with the correct design ethos, existing processing systems can be substantially improved to offer the industry more efficient processing systems which help to improve product quality, reduce waste and meet the requirements of a fast changing industry.

Sand production - wet or dry?

2011-05-16T17:43:00.000+01:00

Wet?

Washing is widely accepted to be the most efficient way of producing high quality sands for use in a variety of applications ranging from sands for use in concrete to specialist applications such as golf and silica sands.

This is because of limitations with traditional dry screening processes particularly in regard to the ability of these systems to effectively and consistently remove minus 75 micron material.

CDE Global have built a reputation on the delivery of efficient sand washing plants throughout the world over the last two decades and have been working in the Gulf for almost 10 years.

During this time we have completed many sand washing installations including two 1200 tonne per hour plants in Qatar. There are numerous other CDE washing plants in operation in many other regions of the Gulf and North Africa including KSA, Oman, Bahrain, Tunisia and Morocco.

Our entry into the Gulf came as the result of the demand for high quality washed sands in the region. This resulted in the two large 1200 tonne per hour projects in Qatar initially and since then there have been many other installations with capacities more in line with every day requirements – between 50 and 150 tonnes per hour.

Over the years CDE has developed a project list full of examples of replacing inefficient traditional sand washing plants such as bucket wheels and screw classifiers with the hydrocyclone based Evowash system.

Old sand washing technology has a number of issues, not least the loss of significant quantities of quality fines to the settling ponds or water treatment phase. In an effort to ensure effective removal of the minus 75 micron fraction these inefficient systems take a lot of commercial quality sand with them which has a negative impact on the profitability of the operation.

Operators using inefficient sand washing plants are taking a hit on two fronts. Not only is the final value of their sand product compromised by the presence of larger quantities of minus 75 micron material than is ideally the case but operational costs are also increased as a result of the requirement to clean out settling ponds regularly in an effort to recover the good material that has been lost.

There are various design features on the Evowash plant that prevent this problem from arising with the choice of hydrocyclone technology being one of the key factors. Hydrocyclones offer the most efficient means of delivering the required cut point thus ensuring a sand product that meets the desired specification. The effect of being able to guarantee a sand specification is to maximise the commercial value of the material and thus the profitability of the operation.

Investing in low cost, old technology is a false economy as the return on investment takes much longer than is the case when our washing system is specified.

Water recycling

The ability to offer operators water recycling equipment to accompany the sand washing plant has also been a key factor in the success that we have enjoyed in the Gulf.

Given the climate in the region and a scarcity of water when compared to the North European markets where CDE originally established a reputation the specification of the Aquacycle thickeners and GHT filter presses that we offer was very frequent as business grew.

You could say that Gulf operators led the way for the global washing industry in relation to the specification of water recycling equipment. We would now include our thickeners and filter presses on 80% of all global washing projects whereas as recently as five years ago this figure would only have been around 20%.

The scarcity of water in the Gulf was a major factor here and made the CDE water recycling and sludge management system a ‘must have’ rather than a ‘like to have’ as it was seen in some other territories. Environmental concerns and subsequent legislation in this area has driven demand for water recycling systems but there is also a growing realisation that their introduction does actually offer a more efficient way of operating.

When you factor in the costs of managing large settling ponds, the additional space required to accommodate the operation and the potential health and safety risks, water recycling systems offer operators a way to ensure a much more efficient and easily managed washing plant.

Dry?

Just as the introduction of effective water recycling systems was a response to the unique climate of the Gulf region we then introduced new air classification technology.

The introduction of our Sirocco air classification system was a move inspired by the need to offer a solution to operators not able to consider a washing plant due to water supply issues. Even with full closed circuit water recycling reducing the volume of fresh wash water required to around 5% of the total volume some operators are simply not able to ensure supply of the volumes needed to operate a wash plant.

The question that arises from this decision is how does it fit in with the previous assertion that dry screening of material is not as efficient a process as washing?

Well, although a dry process, the Sirocco air classification system is far removed from the traditional dry screening process which has been problematic for those seeking to produce high quality sand.

The key success of washing using our Evowash system is the capability to efficiently remove the minus 75 micron material. We prefer to describe the Sirocco as a dry wash system – or washing without the water as it is able to achieve the same results as washing in terms of minus 75 micron fines removal.

Previous to the introduction of the Sirocco air classifier to the Gulf operators wishing to produce quality washed sands were unable to do so because of a lack of water availability. With the introduction of Sirocco the option exists for these same operators to achieve the higher specification sand products that will allow them to diversify into new sectors of the construction market.

We have several Sirocco units operating in KSA and

Oman

which are producing concrete sands to the same specification as those being produced by our Evowash sand washing plant. With each new Sirocco unit comes a growing acceptance of the technology and a realisation that this dry wash system is a viable alternative to a washing plant.

An additional feature of the Sirocco system that has made it attractive to operators is the small amount of space required to accommodate the system. We offer the Sirocco as a stand alone unit or as part of a turnkey package. The turnkey option includes a feed system, the Sirocco air classification unit, two stockpile conveyors – one for the sand product and one for the fines – and a dust suppression system.

The fines product from the Sirocco is not a waste material but has a number of applications including its use in the manufacture of ceramic tile adhesives and grouts. This provides additional revenue for operators from what many consider to be a waste material.

The Sirocco system is available in a variety of configurations from 50 tonnes per hour to 800 tonnes per hour in a single unit. This differentiates the Sirocco from other air classification systems on the market which offer single units at 150 tonnes per hour and multiples of this system should larger capacities be required.

Our washing plants are customised to the specific requirements of each project and our Sirocco units are built according to the same principles. The specification of the right system needs to take account of the individual characteristics of the feed material, with the level of fines being the critical factor. Other systems take a ‘one size fits all’ approach which compromises final product quality.

The future

The introduction of the Evowash and Sirocco units reflects the approach we take to all the regions in which we operate. We will continue to respond to the specific requirements of the Gulf region and all of the other territories we are working in or aspire to work in as we seek to continue to offer operators the most efficient sand processing systems available.

And the winner is...

2010-12-10T11:24:00.000+00:00

Following the announcement of Russia and Qatar as the hosts of the greatest show in earth in 2018 and 2022 respectively the inbox has been filling up this week with details of lots of conferences, exhibitions, networking events promising to be able to put us in front of the people writing the cheques for the Billions of dollars of investment required to ensure a successful World Cup.

While there can be no doubt that there will be significant opportunities in both Russia and Qatar due to the nature of the work to be completed I can't help feeling that the organisers of these events are doing their best to ride on the wave on enthusiasm following last week's announcement.

A large helping of caution will be exercised with a side portion of cynicism as details of these events promising a pot of gold at the end of the rainbow continue to flow in over the coming months. As is usually the case with the vast majority of these exhibitions and similar events, the main winners are the organisers who secure massive investment from participants for what is more often than not a dissapointing return.

Water recycling top of the agenda for washing plant operators

2010-12-09T17:14:00.000+00:00

The inclusion of water recycling equipment on washing plant installations has risen dramatically in recent times as operators realise that in addition to the altruistic benefit of protecting the world’s most precious natural resource there are significant efficiency gains to be enjoyed.

The specification of equipment such as thickeners and filter presses has seemingly progressed from being seen as something that was done only at the behest of planning authorities. As awareness has grown of the real potential for these water recycling technologies to improve the efficiency of traditional quarrying and C&D waste recycling processes their introduction to existing operations and new installations has increased dramatically.

As recently as three or four years ago a thickener or filter press was only specified on around 20% of our washing plant installations. The last 12 months has seen this figure rise to around 80%.

This increase is not restricted to any specific geographical area with recent installations in Ireland, the UK, Europe, Middle East, Australia, South America and South Africa.

The key drivers behind the increased specification of this equipment differ from one installation to the next and include issues concerning:

The space available on site to accommodate large settling ponds
The availability of the volumes of water required to operate a new washing plant
Reducing health and safety risks on site
Efficiency improvements offered through significantly reduced operational costs.

We have focused on the potential efficiency gains for a number of years now when in discussion with both new and existing clients. The management of large settling ponds is a very expensive process and one which the introduction of a thickener can significantly reduce. If the full sludge management system including a filter press is specified these settling ponds can be removed completely from site.

In the UK market the specification of water recycling equipment has been most prevalent on construction and demolition waste recycling operations due to the nature of the sites where these plants are located. While it is usually the case that traditional sand and gravel or hard rock quarries are located in rural settings on large sites, the opposite is the case for recycling plants.

The nature of the material being processed means these sites are located in urban areas and as a result some degree of water recycling is essential on all of our C&D waste recycling plants. We have many plants working on sites located in built up industrial and residential areas where not only is there not the space to contemplate settling ponds but the health and safety issues surrounding these ponds rule them out of consideration at the very outset.

Outside the recycling sector the demand for equipment is coming from operators who are introducing a washing plant for the first time. Operators considering a washing plant on a site that has previously only operated a dry crushing and screening process are more focused on the volume of water required to run the plant than those already operating washing plants.

The issue of the space required for ponds is more acute for those not already operating these ponds and one of the first things they are concerned with is reducing this space requirement. The specification of a thickener and filter press is the obvious way to achieve this.

It is not exclusively the ponds issue that leads operators to specify some sort of water recycling system however. An equally pressing issue is gaining access to the volumes of fresh water required to run the washing plant should a thickener not be included.

On a recently completed project in Poland this was precisely the issue that the customer was faced with. Our customer was operating an Evowash sand washing plant after their dry screening process but had a requirement to increase sand production following the award of a new contract.

The customer chose our M2500 mobile washing plant to deliver this increased capacity but they simply did not have access to the volumes of water required to run the new plant. The introduction of an Aquacycle thickener on this upgraded washing plant ensured that the customer in this instance was able to take advantage of the increased sand and aggregate production capacity while requiring less water to do so. The introduction of the thickener on its own has allowed the customer to recycle between 85% and 90% of the water used to feed the washing plant.

It is rarely the case that operators will only have one of these issues to deal with and according to CDE it is usually a combination of factors working together that lead to the conclusion that a thickener and / or filter press is needed. In the case of a recent project in South Africa the customer had a number of concerns.

Firstly, they were spending considerable time and money cleaning out their existing ponds and reprocessing material due to the inefficiency of their existing sand washing plant so the first priority for them was more efficient sand washing. They were also adamant that they wanted to address their ponds issue and reduce not only the space they were occupying but the cost of managing them.

While thickeners are much used in the mining sector in South Africa it is believed that this is the first instance of a thickener system being installed on a traditional quarrying operation. A further consideration for this customer was the location of the washing plant adjacent to a local river. With this at the forefront of the customers’ mind the safe storage of waste material from the washing plant was of paramount importance.

We fully expect this trend towards thickeners and filter presses to continue. Given the fact that this year has seen the installation of our first water recycling systems in six new countries the expectation is that this will lead to more in the coming months and years.

The whole is greater that the sum of it's parts

2010-12-09T14:38:00.000+00:00

If I hear the word ‘challenges’ or any variation on it once more in an analysis of the state of the industry in Ireland at the minute, I swear something destructive is going to happen. I am sure this is something that many others have thought over the last twelve to eighteen months which has seen our industry change dramatically. Faced with this dramatic change everyone working in our industry is faced with having to adapt to this new world order and decide how they are to continue to grow and develop in the years to come.

The key thing here is that it is ‘our industry’ and collectively we all must take responsibility for doing our bit to ensure that it continues to be an industry where the new talent emerging from our schools and universities want to work. As is usually the case, the development of such a mindset requires a facilitator. The ‘Addressing the Challenges’ event organised by Machinery Movers magazine presented us with a great opportunity to start shaping the future of our industry in Ireland and beyond. We made our way to the Osprey Hotel in Naas positive in the knowledge that a forum had now been provided for us all to work together and exchange views and opinions that would help us enjoy future success.

I personally found the event in Naas very worthwhile and it was useful to hear the comments and experiences of people from different corporate backgrounds on what the best way forward is. What was disappointing about the event was the numbers in attendance. There are so many companies working in our industry at the minute facing the same problems and looking for solutions to these problems. Whether those problems relate to balancing quarry production with a reduced demand for product, or trying to find ways of demonstrating that investment in new equipment now will prove cost efficient in the long term the problem is essentially the same. The whole face of the industry has changed. Given the nature and extent of this change I don’t think there is one company in Ireland who is able to tackle this change on their own and come out the other side smiling. We are all interdependent – a vibrant, thriving industry is to the benefit of us all.

I left the event in Naas even more committed to working with Brian Coogan and the team at Machinery Movers to build this network of people who want to see our industry grow and prosper in the years to come. This is all of us. Everyone involved or employed with any company working in the quarrying, mining and recycling sector in Ireland has a vested interest here – be they materials producers or equipment and component suppliers.

Despite the trials and tribulations of the last twelve to eighteen months the industry in

Ireland

has a lot to be proud of. Our business takes us all over the world and there is not one country we go to where to do not meet someone from this little island working in the industry at a very senior level. The natural skill set that exists within us and our approach to work wins us a lot of friends and this continues to be the case. This reputation is borne out a strong industry at home so to continue to ensure that opportunities exist for Irish companies outside this island we must ensure a strong image is portrayed.

A strong industry at home is also essential to ensure the techniques and processes used in production, and the equipment we produce for the global market continues to improve. Without this we will lose the best young engineering talent to our competitors overseas and that does spell trouble for the industry as a whole. We must not let this country slip back to the ‘brain drain’ days where all of the top talent is lost. A huge amount of work has been done over the last 20 years to stop the flood of young people from Ireland and we must work together to ensure that this situation is not reversed.

The approach that CDE have taken as a company over this most recent period of time has been to continue to develop and innovate. Whether that be new industries that we can target, new markets we should be looking into or new products that we can develop. Only by continuing to adapt to the external factors that lie out of our immediate control and making the best that we can of the opportunities will we be able to sustain the growth that has characterised our recent history. However, we can’t do this on our own and welcome any opportunity to work as part of a group with the same collective aim. I believe that the work that Brian Coogan will continue to do through the ‘Addressing the Challenges’ initiative provides the ideal platform for us to do this.

Another thing that you notice on chance encounters with fellow Irish men and women who find themselves working in foreign lands is a fierce and unbreakable loyalty to their home. After all, it was largely here that they did their apprenticeships working in our local industry. It was this experience that gave them the tools to develop personally and professionally and find the career opportunities that exist outside this island. Let’s continue to give them an industry to be proud of and one which commands the same level of respect – even envy – that has allowed this country to punch well above its weight. Speaking from our own perspective I can safely say that no matter how many countries we may be present in, this market in Ireland is our home market and will always remain the most important. By embracing the ‘Addressing the Challenges’ initiative we can go some way to doing this because the whole is greater than the sum of its parts.

I am not in the employ of Machinery Movers magazine, nor am I receiving any financial benefit from writing this article. What I am offering here is simply my opinion on the opportunity that is presented to all of us by the ‘Addressing the Challenges’ initiative and why I think it is essential for as wide a cross section of people from our industry to get involved.