hub magazine issue 23

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Global News &Information on the BulkMaterials Handling,Recycling & Quarryingindustries

Issue 23

Hub issue-23 - Oct 2012 16/10/12 14:31

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Welcome improvement inready mixed concretemarketsReady mixed concrete markets in Great Britain increased by anestimated 8% during 2011. This is a welcome improvement on the fallthat exceeded 30% which occurred over the three previous years.

However, the concrete industry has not been able to sustain these highervolumes in 2012. Industry marketing consultancy, BDS MarketingResearch Ltd, expects that ready mixed concrete volumes will fall back totheir 2010 level in the current year.

These are some of the conclusions of BDS Marketing's annual report onthe industry entitled: 'Estimated market shares of ready mixed concretecompanies in Great Britain'. This estimates the market shares of allcompanies in the industry, by county, regionally and nationally. As wellas a three year forecast, the BDS report identifies plants and companiesthat have both closed and opened over the past 12 months.

Although nationally, markets were higher during 2011, BDS did not findthis across all regions. Much of the growth centred on the south eastwhere the market increased by more than twice the national average.However, the ready mixed concrete market in Wales and northernEngland actually fell last year.

The industry has seen rapid growth in on-site batched concrete in recentyears. If the sector is taken as a whole, it now supplies more concretethan the fifth largest supplier of batched concrete. However, BDSbelieves that the sector has now begun to mature and the rate of marketpenetration has slowed.

The industry awaits the outcome of the formation of a joint venturebetween two of the top five concrete companies - Tarmac and Lafarge.To satisfy Competition Commission requirements, these companies haveto sell off a number of ready mixed concrete plants, as well as interestsin cement, aggregates and asphalt. The Commission has indicated apreference for one company to acquire all of the concrete plants. BDSbelieves that this would create a business which will become the thirdlargest ready mixed concrete supplier in the industry.

Although the market is subdued currently, BDS is cautiously optimistic thatprospects will turn for the better in the second half of 2013

www.bdsmarketing.co.uk

Autumn 2012Jane Layberry Editorial & Operations ManagerEmail: [email protected]

Debbie HodgettsSales & Admin AssistantEmail: [email protected]

Sarah OldfieldSales & Admin AssistantEmail: [email protected]

Hub Digital Media Limited27 OLD GLOUCESTER STREET, LONDON WC1N 3AX

Cover Story 4News 6

New Standards Setting Organisation

CMS Cepcor launch new website

Hi-Force ToughLift jacking system

Largest C&I MRF

MHEA BULK 2013

20 years of recycling across the borough

Product Focus 11Canning ConveyorTECDOS Conveyor Technology New Transfer Chutes VEGA measure biomass levels The Fenner QD InverterAccurate, Simple Batch Control SystemsVibratory conveyors and feeders Pack your bags and goProtecting people and productivitySaxlund innovations deliver Flexible storage for bulk materialsSchenck Process expertisePhase 3 completed at Grain Storage FacilityGuttridge conveyors

Recycling 31MB Crusher BucketFirst Bell loaders The MAX X Tract treatmentWaste no time with the PODFatherInnovative separating from EdgeRecovered fibre loses up to 90% liquidGlen Creston - The star of the show!First Volvo D series Ultra High Reach New jcb wastemaster backhoe loaderBulk Materials Handling 44Precia-Molen provides an I400 Kingfisher wear protectionReplacing Wear Liners; there are new alternative solutionsQuarrying 50NEW Terex® Finlay J-1170 UK's Leading Hirer of Long Reach New drying plant for Anglia LimeScreening Technology from Weir Minerals™New Warrior Screen to Reduce LandfillNew Fully Weighed Continuous Mixing Plant New R90 Mobile Impact Crusher Attachments Aid Dockside Demolition

In this issue

Tel: 0845 680 0024

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Peter O'Connor reports that the company'sinvolvement in demolition and quarrying has beenfacilitated - at least in part - by the flexibility of thecompany's Sandvik track mounted mobile crushers,screens and hydraulic breakers. When the companypurchased its Sandvik crushers and breakersO'Connor says it did so with the knowledge that theywere ideally suited for both applications. "The factthat the crushing kit can be taken to a demolition siteto process construction and demolition waste and canthen be easily moved back to the quarry to produceaggregate, greatly appealed to us.” says O'Connorwhose relationship with Sandvik began with thepurchase of some Fintec crushing and screeningequipment some six years ago. "It makes perfectsense. All our demolition equipment is guarded foreither application, and is suitably tough to work ineither industry. We originally purchased a 51 tonneSandvik QJ340 as the primary jaw crusher to producea variety of products which can be reduced to make a6F5 product for construction and demolition work.This has now been superseded by a QJ341, with theQJ340 moved to just demolition work.”

The QJ341 is a heavy duty, mobile jaw crusherpurpose built for the quarrying and constructionindustries where high performance is required.Compact and fully mobile with hydraulic adjustment,reversible jaw and automatic central lubrication, thelatest model is powered by a 261 kW emissions-compliant Caterpillar C9 Acert diesel and has beendesigned for low operator cost and maximumproductivity in applications from recycling toaggregate production. “In the quarry, the new QJ341feeds a Sandvik QH330 cone crusher that in turnfeeds a QA450,” O'Connor continues. “The four-waysplit on the QA450 allows us to produce a variety ofhigh quality, single-sized products.”

A sandstone quarry is not the first place youwould expect to find a respected demolitioncompany, but some lateral thinking by Irlam-based PP O'Connor has utilised the company'sequipment fleet in two quite unrelated fields, toconsiderable benefit.

At the massive 190 hectare Whitworth quarry at Tonge,near Rochdale, operated by Fairhurst Stone, sandstone isbeing excavated for use as decorative building materialand paving. Underlying the sandstone is a hard millstonegrit rock, which reputed demolition company PP O'Connoris responsible for extracting. This joint project involves thesandstone being removed mechanically in blocks ratherthan by blasting, prior to sawing, with this in turn allowingthe gritstone to be removed by excavator and breakerready for crushing.

Joint Project

"Although we recycle all our demolition material and havea ready market for it, it doesn't fulfil all our needs foraggregate material on civil engineering projects," says PPO'Connor managing director Peter O'Connor. "We havesites that require a clean drainage material that can'tinclude recycled concrete, so it made sense to see if wecould produce the material to our specifications rather thanbuy it in; hence our joint project with Fairhurst Stone.Although the sandstone can be broken out in blocks, thereis some waste, which we can process and use, along withthe gritstone underneath. It's a very good symbioticrelationship between the two companies."

Cover Story

Chip off the old block


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Cover Story

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Dual-Purpose Breaker

Also used in the quarry as a primary breaker is a 3.4 tonne SandvikBR4099 mounted on a Doosan 340LC hydraulic excavator purchasedespecially for the purpose. Although purchased primarily fordemolition duties, O'Connor reports that the Sandvik BR4099 hasproved equally at home in the quarry, breaking oversized material forfurther processing by the Sandvik jaw crusher.

Quarry supervisor Steve Brierley is suitably impressed with the entireSandvik set up, and has particular praise for the BR4099 breaker.“All the Sandvik machinery is very sturdily built, especially the jawcrusher. It has all performed extremely efficiently and we areproducing quality end products,” he concludes - “But the breaker hasproved a real eye-opener. It deals with the oversized materialeffortlessly and hasn't given us a moment's trouble. It really isextremely impressive."

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News




MPQC becomethe newStandardsSettingOrganisationFollowing the withdrawal ofgovernment funding, Proskills hasceased as a Sector Skills Council.While it will still function in certainindustries it has been agreed thatMPQC is best placed to become thenew Standards Setting Organisationfor the Extractives, Minerals andrelated manufacturing industries.

MPQC will represent their industries' interests in relation to education, training and qualifications to government andother key agencies. As accredited training providers Mentor is committed to delivering quality, relevant training andwill continue to work closely with MPQC Awarding Body on all aspects of operator training and the MPQCOperator Competency Scheme.

Mentor's mobile plant training team has spent the last 9 months ensuring that all courses are mapped to the relevantunits of the National Occupational Standards thus ensuring the most suitable and specific operator training coursesare delivered to site operators.

For more information on training courses available under the MPQC Operator Competency Scheme click here.

CMS Cepcor launchnew websiteCMS Cepcor™ have launched a new websitewww.crushers.co.uk dedicated to the sale of newand rebuilt approved used crushers, screens andfeeders originally manufactured by GoodwinBarsby, Kue Ken, Nordberg, Parker, Pegson,Svedala, Sandvik™, Symons + more.

CMS Cepcor has supplied hundreds of new and pre-usedfactory reconditioned crushers and screens over the last 20years establishing a worldwide reputation for the supply ofquality re-manufactured crushing equipment.

As CMS Cepcor is Europe's largest supplier of aftermarketspares we can ensure that each approved crusher, screen or feeder is reconditioned by our own engineers observingoriginal factory tolerances using any new parts where required.

Quality assured UK re-manufactured crushers

Unlike many normal machine dealers, all CMS Cepcor approved used crushers and screens that undergo reconditioningcan be seen test run in our crusher workshops prior to despatch, giving you complete peace of mind.

Importantly all crushers, screens and feeders offered for sale are wholly owned by CMS Cepcor and free of any third partyinterest. All can be inspected at our Coalville headquarters subject to prior sale and a current plant list is available onrequest.

The new website will also list the current stock of new UK manufactured Goodwin Barsby crushers and feeders.

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http://www.crushers.co.uk

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Following the launch of Hi-Force'spowerful jacking system in 2010, aptlynamed ToughLift, this 12 model range hasproved to be an invaluable addition to Hi-Force's extensive product portfolio. Thisnew generation jacking system offers theeasiest and safest method of liftingmaterial haulers in the mining andconstruction industry and locomotives inthe railway industry, which is essential forminimal maintenance and repairdowntime of capital intensive equipment.

With lifting capacities ranging from 50 tonnes to 200 tonnes, and achoice of hydraulic lift height options on the 100 tonne and 150 tonneversions, the ToughLift is the strongest and most versatile lifting jack inthe market. All models are powered by an integrated electric driven orair driven hydraulic pump unit and feature a remote, push button handpendant control unit with a 5 metre control cable for safe operationremotely from the jacking point. The Hi-Force ToughLift jacking systemincorporates a number of patented features, including a multi-positionaltransport and lifting handle and a swivel jacking base to guaranteesafe and correct positioning of the lifting cylinder under the vehicle,prior to lifting it up.

Fitted with large diameter wheels and solid rubber tyres, all models arenarrow in width, enabling them to fit into confined spaces, and havethe smallest footprint size compared to other competitor brand models.There is also a variety of optional extras available to complement therange including mechanical load holding blocks, flat saddles, as analternative to the factory fitted swivel load cap, mechanical locking andslip lock extensions all of which add further features and safety benefitsfor the user.

Hi-Force also offers a range of hydraulic tyre bead breakers, these timesaving tools compliment the ToughLift range, reduce the risk of accidentsand the amount of effort required to change tyres on large trucks,tractors and earthmovers. The GTB Giant Bead Breaker is suitable foruse on 5 piece rims 25” to 51” (635 to 1295 mm) and with thismodel you can remove larger tyres with ease using a powerful 14tonnes capacity, 700 Bar hydraulic cylinder which has a nett weight of12.5kgs. The PTB1 Combi Bead Breaker is suitable for use on single,two and three - piece 2-5-10 hole budd, 7.50 x 16s and all tubelesstruck tyres and rims. The PTB1 model can break beads using apowerful 11 tonnes capacity, 700 bar hydraulic cylinder leaving no rimdamage. Both models of bead breakers are simple to operate withoutthe need of bolts, screws or attachments and are compatible for usewith a range of Hi-Force 700 Bar rated hand and powered pumps.

As the fastest growing manufacturer of hydraulic tools in the worldtoday, Hi-Force continues to invest heavily in its manufacturing facilities,whilst also placing a major emphasis on the research and developmentof new innovative products such as the ToughLift. Since its launch, in2010, the ToughLift range has proven to be highly sought after, as thepremier choice, for lifting some of the largest earth material haulers inthe world during routine maintenance, service and repair.

For more information on the ToughLift range, please visit www.hi-force.com or contact: Hi-Force Limited, Prospect Way, Daventry, NN11 8PLNorthamptonshire, England. Tel: +44 1327 301000Fax: +44 1327 706555 - Email: [email protected]

News

Hi-ForceToughLiftjackingsystem liftsup to 200tonnes!



Hi-Force PTB1 Combi Tyre beadbreaker suitable foruse on smaller trucks

Pictured is a Hi-Force ToughLift TL100A405 beingused to lift a Komatsu hauling truck

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http://www.hi-force.com




News


WeirsannounceUK's largestC&I MRF


Weir Waste Services Ltd are delighted toannounce the next stage of development fortheir Trinity Street Materials Recycling Facilityin Oldbury, West Midlands. From April 2013the site will operate one of the largestautomated C&I waste recovery facilities in theUK, processing at 25 tonnes per hour. The newmulti million pound facility will feed into theexisting Trinity Street RDF processing plant andis part of the company's long term growthstrategy to maximise recovery of recyclablesfrom waste, in accordance with the WasteHierarchy.

The MRF has been designed and supplied by BlueGroup and will contain a range of equipment fromDoppstadt, Kiverco and Titech's new auto sort 4 NIRtechnology. The project is part funded by EDRF,managed by WRAP.

Based in Birmingham, waste management specialistsWeir Waste Services are one of the largestindependent waste companies operating in the WestMidlands. Managing Director Daniel Weircommented on the purchase, "We are incrediblyexcited that Trinity Street MRF will be bringing newand innovative technology to help us and ourcustomers in our commitments to the environment andsustainability.

Daniel added, "Weir Waste Services enjoy afantastic relationship with Blue Group which is crucialwith such a large scale project. We have 3 existingplants from Blue and we are confident that theimplementation and operation of the MRF will beanother success story"

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News

Milton Keynes Councilmarks 20 years of recyclingacross the boroughMilton Keynes Council and its recycling contractors aresending out a huge thank you to all its residents formaking its recycling service so successful over the past 20years, saving over 550,000 tonnes of waste from goinginto landfill.

When it was launched in September 1992, the council's recycling schemewas the first in the country to offer door to door recycling services for allresidents across the borough. It came about following a successful pilotscheme, set up two years previously, which required residents to use blueand red boxes to sort their recyclable waste.

Newspaper and magazines were collected in the red box, while foodand drink cans, plastic bottles and glass went in to the blue box. Thesewere then collected by a separate recycling vehicle and hand sorted byrecycling operatives on the kerbside into a number of compartments - andnot on the same collection day as the refuse. While it may seem crude bytoday's standards, at the time it was considered ground-breaking.

From such humble beginnings which saw around 4% of waste recycled,Milton Keynes' recycling rate currently stands at almost 56%. Theintroduction of pink sacks, with a blue box for glass, ten years ago vastlyimproved the scheme, with organic waste and additional materials addedin 2009 and batteries in 2011. All waste is collected weekly by Sercoand taken to the council's own Materials Recycling Facility, operated byViridor.

Cllr David Hopkins, Milton Keynes Council's Cabinet Member forEnvironment and Waste, said: “We would like to express our thanks to theresidents of Milton Keynes for embracing recycling so enthusiastically overthe past 20 years, saving both the environment and costs to the taxpayer.With their cooperation we've achieved a fantastic recycling rate and havea number of plans in the pipeline to increase this further in the future.”

Paul Rowland, Regional Operations Manager for Viridor, said: “MiltonKeynes Council has been a pioneer in developing effective householdrecycling services and their long-term environmental vision, together withlocal residents' enthusiasm for recycling, have made it such a successstory. We're proud of being part of these achievements by transforming theborough's commingled recyclables into high quality materials ready to bereprocessed into new products and packaging.”

Serco's Contract Manager Mark Sturgeon added: “We are delighted towork in genuine partnership with Milton Keynes Council, assisting them inmaximising the potential for recycling.”



MHEA BULK2013Conferenceconfirmed- Makea note in yourdiary!

15 - 16 MAY 2013Forest Pines Hotel& Country Club

Exhibition Space At Bulk2012 a total of 23companies took exhibitionspace, the feedback fromexhibitors was excellent, forBulk2013 we intend to build onthe exhibitions success and I amtherefore offering previousexhibitors first refusal on a spacefor next year's event - please letthe Secretary know if you wouldlike to make an advancedreservation - there's no financialcommitment at this time.

It will be popular - Call NOWbefore they all go

Materials Handling EngineersAssociation [email protected] +44 (0)1353 666298


Hub issue-23 - Oct 2012 16/10/12 14:44



http://www.mhea.co.uk



For more information or to book an advertisement in thenext feature please contact: Tel: 0845 680 0024

www.hub-4.com Product focus

Sandy Lane Industrial Estate Worksop Nottinghamshire S80 1TN T. 01909 486166

www.canningconveyor.co.uk

Conveyors,Elevators & Drives/Bulk MaterialsHandling & Storage

Part of the FuelHandlingConveyor Systemof one of theUK’s largestBiomass PowerStation’s beingbuilt in the UK

October 2012

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http://www.canningconveyor.co.uk

Canning Conveyor has recentlysupplied an aggregate conveyingsystem for construction work on theredevelopment of Guernsey Airport.

With planning approval granted in October2011 the £80 million contract, which is part ofthe Guernsey Airport Redevelopment Project,predominately includes the rehabilitation andreconstruction of the existing airfield pavementsincluding the runway, apron and taxiways andthe installation of a new surface waterdrainage system.

Commenced in January 2012 the project willtake approximately 2 years to complete.

Bespoke System

The bespoke system which has been suppliedon hire was designed and manufactured byCanning Conveyor for the sole purpose ofconveying incoming aggregates from ships atGuernsey Docks.

Designed to accept 200tph of -20mmaggregates the system includes a conveyormounted receiving hopper fed from a bargemounted 360° grab. Mounted centrally thishopper feeds material onto a 16 metre long,ship to shore conveyor.

This conveyor incorporates many uniquefeatures that deal with the rise and fall of thetide. The tail end of the conveyor is fitted with apneumatic tyred wheel bogie which runs on thehatch cover of the ship; the head section beingmounted on a support trestle para-bolted to anew concrete pad on the sea wall. This supporttrestle is fitted with a slewing and pivotingarrangement which allows the conveyor to riseand fall at the tail end with the tide. A furtherfeature allows the tail to be lifted by the shipmounted grab and slewed around to rest onthe sea wall at times of high wind or gales.

All aggregate is delivered from this conveyor onto a 50 metre long groundconveyor which runs horizontally on the quay side which then feeds into areceiving hopper on a 12 metre long stockpile conveyor. This stockpile conveyorwhich elevates to a height of 4 metres discharges into waiting dump trucks, oralternatively stockpiling material onto the ground.

Canning SuperDrive™

The ground conveyor is powered by a Canning SuperDrive™ motorized 22kWsingle drive drum which is designed specifically to power ground conveyorsoperating in these applications, having the motor, gearbox and bearings totallyenclosed and hermetically sealed inside a steel shell drum.

With an impressive track record the Canning SuperDrive™ offers many benefitswhich include extremely low maintenance costs - (none, other than recommendedsynthetic oil change after 30,000 running hours) and a higher efficiency (97%)compared to approximately 85% on conventional drives.

The Canning SuperDrive™ single drive drum which provides a belt speed of 1.6metres/sec to the ground conveyor is fitted with ceramic lagging and includes ahigh tension bend pulley, jib discharge drum, loop bend drum and a primary andsecondary belt scraper. Complete with a discharge chute with integral crash boxand hinged inspection hatch the entire unit is mounted on a substantial skidmounted frame with cantilevered jib discharge.

Along with a loop take up unit, heavy duty tail end loading section the conveyorstructure is made up of Canning intermediate bays and Cannoflex beltingthroughout.

Designed and manufactured in the Canning workshops the system is providing aneffective and reliable system for the construction of the airport in the handling ofthe incoming aggregate for this huge project.

Product focus

Canning Conveyor lend ahand with the redevelopmentat Guernsey Airport


Coming SoonCanning Conveyor are currently involved in thedesign, delivery and commissioning of bulkhandling equipment for part of the Fuel HandlingConveyor System of one of the UK’s largestBiomass Power Station’s being built in the UK.The project in Fife, Scotland which commencedin 2011, will be commissioned in March 2013.The new biomass energy plant will be the largestof its kind so far in Scotland and will reduce theannual carbon emissions of Tullis RussellPapermakers by some 250,000 tonnes.

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Product focus


Impact BarsThe new Canning Heavy-Duty Impact Bars feature a solid design that preventsbelt damage. Manufactured with our highest quality materials these provideexceptional impact and wear resistance, ensuring our impact bars offersuperior belt support, significantly longer life, and lower impact bedmaintenance requirements.Featuring a new innovative design with 'increased shock absorptivity' thisallows them to absorb more impact through the high tensile low frictionUHMW Polyethylene.The solid construction absorbs and cushions the impact load, whilst providinga contact surface that allows the belt to slide freely, resulting in less wear andtear on your conveyor belt.• Available ex-stock• 2 sizesYou will benefit from lower belt and bed maintenance costs.

V6 Chevron BeltingV6 Chevron belting is a special oil resistant belt. The patterns are designed toconvey materials at inclined angles. The V-shaped 6” width chevron cleatshave integrally molded cleats - overlapping 6” width cleats which maintain asmooth travel over return idlers.• For handling materials containing light oil (MOR), heavy oil (FULL OIL),

flame, heat,etc.• Applications include aggregate, grains, sand, bark and wood chip.Avaliable now - 1600mm, EP400/2 3+1.5 200mtr V6 MOR

Baler BeltingCanning Conveyor offers a comprehensive, top grade range of baler beltingspecifically manufactured to suit all makes and models of round balers.• Bamfords Model Nos - 1000/1000HD/1100-1100HD• John Deere Model Nos - 550/590 - 540/545/570 - 580• Farmhand Model Nos - 540E/804• Gehl Model Nos - 1460TDC• Hesston Model Nos - 5640/5650• Greenland Model Nos -

RV136/136L/156/156L/156LOC/186/186L/186LOC• Massey Model Nos - 1440/1450/1455 - 822/828• New Holland Model Nos - 640/650• Vermeer Model Nos - 5031/504 Super I/504 Silage I/505 Super I/604

Super J/604K/605 Super J/605K• Vicon Model Nos - RP1201/1250/1281• Welger Model Nos - RP400/150/150S• John Deere Diamond profile belting - supplied in roll form or pre-clipped to

suit exact size requirement.• Baler Belting - our general purpose baler belt with textured profile

top on a heavy duty 3 Ply construction, suitable for all other balers.• Class• Vicon• Massey Ferguson• WelgaAll ranges available from stock - immediate delivery

Canning Conveyor introduce newproducts to their current ranges….


www.canningconveyor.co.uk

Impact Bars

Impact Bars

V6 Chevron Belting

Baler Belting

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http://www.canningconveyor.co.uk



Product focus


TECDOS conveyortechnology forthe transport ofpackaged goods& bulk materialsRUD Chains ltd is a leading manufacturerof high quality round steel chains,systems and components. For over 140years the RUD group has beenproducing top quality chains andapplications in accordance with theirgroup wide slogan “Tradition inDynamic Innovation”.

Experience, diligence, ambition and passionare the virtues RUD manifest in order toremain the best. RUD is ISO 9001 certifiedand is renowned for its expertise in heattreatment methods - delivering highperformance chain products to suit the mostdemanding applications.

RUD offers an extensive range of conveyorand elevator systems for the transport ofpackaged goods and bulk materials. TheTrough chain conveyors offer a completesystem for the smooth transport of yourmaterials. Equipped with round steel chains orforked chains, RUD trough chain conveyorsprovide the ideal conveyor solution for bothhorizontal and inclined conveyor sections.

The RUD drag conveyors offers maximumdurability in feeding and ash removal for coalfired power plants and bio-mass plants. Thestrength and versatility of the drag conveyorsare remarkable especially when used in harshconditions.

The Apron conveyor uses round steel linkchain as a pulling element which is driven bypocket wheels. The apron conveyor possessesmany advantages from its robust simpleconstruction to its lower construction heightdue to smaller diameter wheels. The roundlink chain system used is self-cleaning andworks well in wet, corrosive and dirtyenvironments. RUD Apron feeders are idealfor the transport of bulk and unit bulk loads inapplications such as power stations, recyclingand construction.

RUD'S product portfolio offers conveyingsolutions for conveying projects in anydirection, horizontal, inclined or vertical.Screw conveyors are an example ofconveyors that can be used in any directionand are suited for conveying abrasive hightemperature materials. Bucket elevators areused for conveying at heights and under highperformance conditions, an area where RUDhas a lot of experience and extensive productrange.


RUD retains a high level of technical experience in conveyor and elevatorsystems for the handling of bulk materials. Supplying standard andspecialised solutions across all conveyors, drive and elevator applications,RUD have the expertise and engineering capability to help in even themost demanding of projects.

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Hub issue-23 - Oct 2012 16/10/12 14:32

New transferchutes clampdown on coaldust at WestarEnergyThe largest electric utility in Kansas hasannounced completion of an upgradeprogram to redesign transfer chutes andload zones on the coal handlingconveyors at its biggest coal-fired facility,drastically reducing dust and spillage.Worn chutes and skirtboards at WestarEnergy's Jeffrey Energy Center (JEC)were replaced with custom-designedcomponents from Martin Engineering,employing special geometries thatcapture and concentrate the materialstream as it travels. The result is acleaner working environment, lessmaintenance and reduced waste, asmaterial is better contained.

Westar currently has 19 energy centers inKansas, providing 7,100 MW of generatingcapacity to serve more than 689,000customers. The firm employs about 2,400people and operates approximately 35,000miles of transmission and distribution lines.Situated on 10,500 acres of land, JEC is thelargest coal-fired power plant in the state, withthree generating units producing 1,857 MW.All three burn low-sulfur coal (as much as33,000 tons per day between them) and takeadvantage of some of the most advancedemission control technologies available.

Fugitive Material Challenge

Over time, operators at JEC began to noticeincreased dust and spillage around transferpoints on four of its 42-inch conveyors. Theproblem was traced to worn chutes andskirtboard liners, which no longer containedthe coal fines as they did when new. A worn-out skirtboard liner plate was found to beexacerbating the problem.

“We have two transfer buildings where theyard feeders deliver incoming material tosupply the boilers,” explained Coal HandlingEngineer Josh Olson. “They were wearing out,and we knew we needed to take action. Butrather than patching the existing chutes andliners, we wanted to see if we could find abetter design solution.”

The 1/2 inch thick belts on conveyors 101A,101B, 301A and 310B travel 550 FPM andhave a capacity of approximately 1,000 tonsper hour. The load is 4" minus PRB coal, withmoisture content around 28-30% and bulkdensity of 45-55 pounds per cubic foot.

Westar contacted Martin Engineering to investigate its options, andtechnicians came out to assess the situation. “Chute design has evolvedsince this system was first installed,” observed Martin EngineeringTerritory Manager Jason Illum. “Today's transfer point chutes capture andconcentrate the material stream as it travels through the chute. Each oneof our designs is tailored to suit the specific material characteristics andconveyor systems of the individual customer, rather than using stockproducts and attempting to make them work,” he explained.

Before proceeding, Westar engineers visited a nearby facility in whichMartin Engineering had installed a similar system. “We were veryimpressed by what we saw,” Olson continued. “The conveyors deliveredexcellent belt support, and the material flow was directed to minimizeturbulence and maximize dust containment.” Transfer Chutes from MartinEngineering provide the dual benefits of minimizing aeration andpreventing buildup within the chute, particularly important when dealingwith combustible materials.

To achieve the optimum chute, spoon and settling area, engineers used3-D computer-based flow and modeling to define the geometry. MartinEngineering included detailed information about the specific materialcharacteristics and the physical parameters of the conveyor itself, such asthe feed system, belt properties, support structure and transfer distances.

Product focus


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Product focus



The transfer chutes built for the Westar facilityemploy a “chute and spoon” design, with thehead discharge chute at the top of the systemand a spoon receiving chute to place materialwith minimal impact onto the belt beingloaded. “The head chute design allowed forexternal mounting of the head pulley bearings,replacing the old design,” Illum said. “Thespoon provides a curved loading chute for asmooth line of descent, consistently feeding thematerial at a specific speed and direction tominimize impact in the loading zone.” All fourtransfer points also received MartinEngineering belt cleaners to minimizecarryback.

“One of the features that our operators and mechanics really like is theadjustable skirtboard,” Olson said. “We can get very precise sealing,and the reversible design of the apron seal gives us double the servicelife. When one side wears out, we can just flip it over. It may seem likea simple idea, but it shows that Martin is ahead of the curve with itsproducts.”

Martin® ApronSeal™ Skirting was the first dual-sealing system on themarket, incorporating a primary seal clamped to the steel skirtboard tokeep lumps on the belt and a secondary or “outrigger” strip to captureany fines or dust particles that pass beneath the primary seal. Thesecondary seal lies gently on the belt and self-adjusts to maintainconsistent strip-to-belt pressure, despite high-speed material movementand fluctuations in the belt's line of travel.

“Another deciding factor for us was the no-excuses guarantee,” Olsonadded. “We didn't want to have to spend a lot of time tweaking thesystem. The Martin Engineering guys are extremely knowledgeable, andthey've been out several times to make sure everything is running at itsoptimum level.”

Since the transfer chute overhaul was completed in 2011, results havebeen excellent. “We don't take specific measurements or airborne dustreadings, but we can definitely tell that the load is centered, spillage issignificantly reduced and dust is being contained,” Olson concluded.Quarterly inspections and reports are provided by Martin Engineering forone year at no cost to JEC.

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Product focus

VEGA measurebiomass levels atDrax PowerDrax Power Station in North Yorkshireis already the largest, cleanest and mostefficient coal-fired power station in thecountry.

Already home to the largest biomass co-firing facility in the world commissioned in2010, in which sustainable biomass isburnt alongside coal to produce electricity,Drax has ambitions to become apredominantly biomass fuelled generator.Not only does their investment in biomassco-firing strengthen their environmentalleadership position, but it further enhancestheir reputation to stay at the forefront ofdevelopments to establish effectivealternative fuel technologies for electricitygeneration in the UK. Electricity generationfrom biomass is a low carbon technologydelivering significant carbon dioxidesavings compared to fossil fuel generation.

The biomass co-firing facility enables thepower station to receive, handle, store andprocess a variety of biomass materials.These are directly injected into Drax's coal-fired boilers where they are burnt alongsidecoal. The storage facility for the biomass isa key part of this process, to ensure it iskept at optimum condition before beingused.

When compared to coal, biomass is lighter,it has fluctuating handling properties andgenerally much lower, variable bulk density.It therefore requires larger storage facilitiesand offers some different processchallenges. The feedstock products varyfrom forestry residues, or cultivatedproducts such as Miscanthus and Willow, toagricultural by-products like straw. Thestorage capacities for these products needto be large and stock rotation/retentiontime requires careful management, as theproducts need regular 'rotation' to avoidany degradation. The construction of thesilos can also differ greatly, with tallernarrower and shorter wider designs,depending on material behaviour andmaterials handling schemes.

However, even with large silo sizes, the biomass typically only has aretention time of only 24-48hrs, before being sent to electricityproduction.

An important area of this fuel stock management is the levelmeasurement. A non-contact technology is preferred on site, tomitigate the potential for fouling and wear. VEGA have installedmany non-contact radar level transmitters on biomass levelmeasurement around the world, where they have a provenperformance dealing with dust and filling noise. At Drax, there aretwo 12,000m3 storage silos, around 27m high and 30m indiameter, and the biomass is brought in by rail. These are centrallyfilled by conveyor and emptied via rotary screw discharger at thebottom. The size and throughput means the silos are being frequentlyfed into and discharged from giving an uneven product surface andthe need for long range measurement.

VEGA have installed non-contact VEGAPULS 68 level radars forsolids, working over a range of approximately 27m. Two units areinstalled on each of these large silos, to give an average reading, aswell as for dual redundancy level measurement of the biomassmaterial. They are mounted towards the centre of the silo, aimeddown and slightly outwards, this is to measure at a pointapproximately at half the radius, to deliver a good average levelreading over the surface profile. Although the conveyor fills point isquite close-by, the units work reliably, regardless of the filling stream.There are no cross-talk issues with VEGAPULS radars, even withmultiple units in the same silo. This is achieved using dedicated pulsesampling filters, which means there can be many in the same areawith no danger of them picking up each other's signals. The unitshave worked reliably ever since their installation over two yearsago, providing information to facilitate the available filling capacityfor the rail transport department and feed stock supply data to thepower station control room, optimising the biomass supply to Drax.

The multi million pound co-firing facility provides Drax with thecapability to produce 12.5% of power generation from biomass co-firing and it is a key element of their goal to reduce carbon dioxide(CO2) emissions.



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Product focus

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www.hub-4.com | p19|

Achieving energy efficiency from motors and drive systems for conveyors andelevators requires the specification of gearboxes, drive motors, couplings andchains that are capable of withstanding extreme loads, shock, andcontamination from dust, debris and glass, plus widely varying temperatures.The quest to maximise efficiency is more than worthwhile; by focussing uponefficiency and cost reduction, the quarrying, mining and constructionindustries will be far better placed to survive the tough economy and maintaina strong competitive advantage.

To extract raw materials from the ground in the most cost effective wayrequires an awareness of the most up-to-date methods of production, state-of-the-art products and new technologies. Companies such as ERIKS, that offera deep and broad experience across the engineering industry, understandthe challenges presented by harsh environments and work constantly todeliver solutions that meets those needs, with energy-saving features built in asstandard.

The addition of one particular component offers not only the potential to saveenergy but reduces shock loading to machinery, and provides continuousmotor protection, minimising both maintenance and operating costs.

That component is the Fenner QD Inverter.

This capability of this device to vary the speed of an electric motor deliverssignificant energy- and cost-savings, especially in industries where machinerycan be required to work more or less around the clock. When inverters arefitted to heavy duty machinery, the resulting elimination of shock loads cansignificantly limit wear and tear as well as reduce energy consumption.

Efficiency is also enhanced by upgrading to an IE3 motor, which offers evengreater energy efficiency than the IE2-rated motor now required within theEU. The ERIKS Online TCO Calculator provides a simple method ofevaluating a motor upgrade, enabling the user to view the total cost ofownership for the year, or for fifteen years, or any period of years inbetween. The results provided by the calculator will list and compare thecost of repairing and running the existing motor, replacing it with a standardIE2 motor, or replacing it with an energy-efficient IE3 motor.

Plant reliability is vitally important in minimising downtime and maximisinguptime - even a couple of hours' downtime can result in huge losses - but arange of simple but highly effective tools are now available that can reinforcethat reliability.

The Fenner QD Inverter

Accurate,simple batchcontrolsystems

Minimise material wastage,ensure legislativecompliance and increasebatch quality andprofitability by reducingunder and overfilling.METTLER TOLEDO's online video“Expert Guidance on Batching ControlSystems” demonstrates how to eliminateunnecessary cost during production andimprove productivity.

Discover how the new checklist forDesigning Batching Control Systemshelps you improve your processexplaining what should be consideredwith a new batching control system. Youwill also gain batching knowledge tomaximise productivity and minimisecosts in your operation.

The rugged industrial batch controllerIND780 can distribute to multiplecontrollers via ethernet connection froma single batch tool, easily managingchanges to the batch process. Built inreports provide critical batch historyinformation to help track and traceevery step of your results.

The error-free recipe guides assistoperators through the process reducingmaterial wastage and optimisingconsistency, speed and accuracy.

To discover more watch the onlinebatching video and download the freechecklist.

Visit: www.mt.com/uk-ind-batching-webinar

Hub issue-23 - Oct 2012 16/10/12 14:32




http://www.mt.com/uk-ind-batching-webinar

Vibratory conveyorsand feeders fromMogensenMogensen manufactures an extensive range ofvibratory conveyors and feeders.

The designs, based on more than 60 years ofexperience in the field of vibration engineering, extendfrom light-duty, stainless steel units for use in theprocessing of foodstuffs and pharmaceuticals up to theheavy-duty, heat-resistant machines used, for instance, infoundries and incinerator plants. Trough conveyors areusually custom-made to suit individual applications andare powered by twin Invicta rotary electric vibrators.They are available in either open or fully dust-proofedversions with or without wear-or heatresistant liners.The company also offers tubular, vibratory conveyors ineither mild- or stainless-steel execution. Internaldiameters range from 200mm to 609mm; lengths varyfrom 2 to 6 metres between inlet and outlet centres.These versatile, inherently dust-tight machines may belinked together using flexible, dust-proof connectors,either in a straight line or angled to fit plant layoutneeds. They are also driven by twin Invicta vibratormotors, and, together with Invicta electronic variablespeed controllers, can deliver easily adjustable feedrates. Throughput capacities extend from a fewkilograms per hour up to 300tph (based on a bulkdensity of 1.6 tonnes/m3).

The Mogensen vibratory feeder range starts with thesimple, inexpensive Type SR1 machine, which is drivenby a single, rear-mounted Invicta vibrator motor. Troughwidths up to 1000mm are available and offercapacities up to 160tph depending on the bulk densityof the feed material. The heavier Type TR1 feeders aredriven by twin rear-mounted Invicta vibrators and aresuitable for variable speed control. Trough widthsextend up to 1000mm; throughput capacities reachabout 300tph depending on the size of machine andthe feed bulk density. The feeder range also includesthe heavy-duty Type TS machines, which are availablein three different construction weights and trough widthsup to 2.5m. Capacities are up to about 800tph. Thesemachines are driven by two side-mounted Invictavibrators, and are also suitable for variable speedoperation. Of particular note are Mogensen's spreaderfeeders, which accept a flow of material from arelatively narrow source and distribute it evenly across awider item of process equipment. Spreads of up to 3metres are possible. Machines, which spread a narrowfeed efficiently and evenly across two or more followingmachines, are also available.

Replaceable stainless-steel, rubber, hard metal, ceramicand adhesion-resistant liners are available for allfeeders and conveyors. Some models of machine areavailable with heated bases for the non-stick handlingof damp clays and damp, fine stone.

Product focus



Hub issue-23 - Oct 2012 16/10/12 14:32



Hub issue-23 - Oct 2012 16/10/12 14:32

Pack your bagsand goThe number of industrial processesthat ultimately dispense an endproduct into a receptacle (sachet,stick pack, bag, sack, or big bags) isextremely large and the spread ofapplications span virtually allindustrial sectors. The diversity ofproducts (ranging from very finecohesive powders to free-flowinggraded aggregates) being packedprior to shipment to end users isenormous, and consequently therange of dispensing equipment hasgrown over the years to meet thisseemingly ever expanding industrialrequirement.

One of the prime requirements for anydispensing equipment is that the fillingoperation should be undertaken withminimum overfill, maximum consistency(between filling operations), and of coursewith as little spillage or fugitive particlesgenerated as possible. Modern controlsystems have proven invaluable for the co-ordination and operation of high speedfilling operations, but even the bestinstrumentation or supervisory control anddata acquisition (SCADA) control can onlygive optimal results if the bulk particulatebeing handled can be brought to thepoint of entry into the receptacle in acontrolled bulk condition and at acontrollable flow rate. Failure to achievethese seemingly basic requirements forparticulate delivery can bringconsiderable inefficiency and degradationto local environmental working conditions,through poor filling efficiency and spillagedue to powders “flooding” from handlingequipment.

For some companies (often thoseprocessing easily aeratable - or more tothe point air retentive powders),maintaining shift output levels can be analmost daily battle. In many cases thecause of the problems can be traced backeither to the use of buffer hoppers thatafford minimal residence time for powderto densify before reaching the meteringapparatus or to an overly exuberantapplication of aeration to obtain a“consistent” feed of material (the onlyconsistent thing about some of thesesystems being their inherent inconsistency)!

Approaches to resolve such fill variationproblems should invariably focus on anevaluation of the flow properties of thepowders being handled. As a generalobservation most concessions to the need

Product focus


for a standard piece of equipment to handle cohesive powders invariableinvolve the attachment of additional aeration points or vibrators (usuallypositioned in the most convenient point for access - rather than for optimalassistance to flow). Such air introduction points can be of benefit, butshould be considered as an augmentation to best practice for reliableflow, taking second place to a consideration of bin geometry and flowcontrol operation. The latter two aspects of equipment should bedesigned in accordance to the flow behaviour of the powder - withaeration (in very small quantities) being used to assist flow. The control ofair usage to initiate flow is an aspect of operation that can bring veryrapid and tangible benefits to plant optimization where packing problemsoccur with fine powders.

In summary, although control systems and automated operations haveadvanced considerably over the last decade it is often the case that thepotential for realizing the full potential of such systems is often hamperedby poor flow performance when fine powders enter the equation. Themain reason for this under-performance is invariably a lack ofunderstanding of the importance of correct bin and interface design forthe powders being handled.


Hub issue-23 - Oct 2012 16/10/12 14:32



Unprotected conveyors can bedangerous to workers around the belt -especially around the rollers and pulleys.The safety and well-being of sitepersonnel is priority one and everyinvestment in improving the workplaceenvironment is a smart one.

Metso have recently launched a new productrange focusing on the safety around theconveyors. With the Metso Hisafe products,your people will be able to work safer andyour operation will work smarter.

Metso HiSafe Roller Guard

Metso HiSafe Roller Guards reflect yourcommitment by making it impossible forclothing and fingers to be caught between thebelt and roller. Metso HiSafe Roller Guardsare designed to perfectly fit the curve of anymedium rollers available on the market. Theirhigh adaptability makes prioritizing workplacesafety even easier.

Metso HiSafe Head Pulley Guard

Made of two rigid polyurethane blocks thatadjust to the shape of the belt, the HiSafeHead Pulley Guard eliminates the spacebetween the belt and pulley. Its qualitymaterial ensures the on-going, long-lastingprotection you and your co-workers dependon for a safer and more productive workenvironment.

Metso HiSafe Tail Pulley Guard

The HiSafe Tail Pulley Guard eliminates thespace between the tail pulley and belt wherethe risk of pinching is greatest. Because of itsfit and plow-styled deflectors, the HiSafe TailPulley Guard also prevents stones and debrisfrom wedging between the belt and pulley -extending the belt lifespan and minimizing therisk for costly downtime.

Product focus

Protectingpeople andproductivity


Other products included in thenew HiSafe product range are: Metso Belt Turner

Material build-up in the returnidlers and under your conveyormeans more safety risks anddowntime for cleanup, andlowers the belt's throughput. TheMetso Belt Turner is a clogprevention belt turning systemthat solves the issue in onehassle-free installation. Its dual-action antifouling system twiststhe belt to keep the drive sideclean and dry, improving itsgrip on the pulley. The MetsoBelt Turner is a cost effectiveway to keep the conveyorrolling, extend the life of yourequipment, and minimizeunnecessary risky interventions by personnel.

Metso Chain Cradle

The Metso Chain Cradle is an all-in-one feed point system providingimpact absorption and sealing at the same time. Impact force prevention,spillage minimization, pinch protection and belt life optimization - all froma single, standardized unit that is fast and easy to install onsite.

Metso Troughing Cradle

Optimizing the loading point of your conveyor is a simple tactic forimproving productivity and lowering cost-per-tonne. The Metso TroughingCradle helps you do just that, working as a secondary loading pointsystem to better distribute the material on the belt and prevent spillage. Asimple adjustment lets you raise the belt edges to create up to a 75°trough, preparing the load for problem-free conveyance with no spillingfrom the start.


Hub issue-23 - Oct 2012 16/10/12 14:32



Product focus

Saxlundinnovationsdeliver on RWEnpower plantcontract


Scotland's mega renewable plantbiomass combined heat and powerplant (CHP) at Markinch incorporatesSaxlund efficiency know-how andequipment in turnkey projectmanagement and supply contract

Evidence of Saxlund International'scapability to tackle large scale projectsand deliver innovative solutions isspotlighted by its prestigious contract forthe RWE npower renewables biomasscombined heat and power plant (CHP) atMarkinch in Fife. The bulk handling andbiomass experts were tasked with projectmanaging the Biomass Fuel HandlingSystem for the £200 million build in 2010which, when finished in 2013, will be thelargest of its kind in Scotland.

The Biomass CHP, which lies on thegrounds of Tullis Russell Paper Makers, willreplace their existing coal fired powerplant and reinforces the company'sposition as one of the world's leadingenvironmentally-focused papermakers.Using a mixture of reclaimed and virginwoods, the 49.9 megawatt plant willsupply both steam and electricity to TullisRussell. Moreover, the company alsosigned a 20 year energy supply contractwith RWE npower renewables, with anyexcess electricity created being supplied tothe National Grid, equating to around25MW an hour, compared with the17MW actually used.

View of the three

concrete storage silos

Hub issue-23 - Oct 2012 16/10/12 14:32


To help complete this massive project,Saxlund had to choose and develop keysubcontractors, as its managing directorMatt Drew explains: “One of the largestchallenges to overcome was the removal ofoversized materials. Our solution was to usetwo large disc screen separators, which arecapable of screening up to 780m3/hr ofwaste or virgin wood before conveyingthem to our storage silos. We then had toerect three 20m diameter, 26m highconcrete storage silos, complete withexplosion protection. Each Silo is fed bytwo overhead conveyors from the receptionsystem.

“The process of discharging the wood fromthe silos is completed with the use of aSaxlund TubeFeeder®. Each TubeFeeder sitson the bottom of the Silo and sweeps itsfloors discharging the wood at a rate of upto 285m3/hr. The patented TubeFeeder®

consists of a screw conveyor housed insidea rotating tube. The tube is perforated witha regular slot pattern permitting 'activated'material to fall onto the screw conveyor,thereby eliminating the external staticmaterial pressure on the screw andpresenting a uniform feed to the screw.”

Here Saxlund has been able to aid TullisRussell's eco drive, with this system needingjust 25% of the power needed for traditionalexposed screw reclaimers. The biomassmaterials collected by the TubeFeeders aretransported by chain conveyors back abovethe ground where they discharge into thedownstream conveying system.

Other innovations to support the substantiallogistics operation at the plant includespecification of Lorry Reception units. Eachof the four units is capable of receiving upto 380m3/hr from either Walking FloorTrailers or Tipping Trucks. The units aresupplied complete with reverse jet bag filtersto minimise dust emissions and fully mobileenabling a simple robust method ofproviding redundancy.

Working with Canning Conveyors to deliverthis project, due to the large size of the FuelHandling System, Saxlund and CanningConveyors negotiated separate contractswith the client for their respective scope ofsupply, with Saxlund taking the overallProject Manager role.

“This is a challenging project, whichdemands innovation and creative solutionsat every stage. Ultimately its projects of thistype, not just because of the scale, thatallow us to demonstrate how we can addreal value to the project; we believe thatTullis Russell is a prime example,” concludesMatt.

Product focus



Saxlund Specification:

• Four x B&W Lorry Reception units.

• Two Disc Screen Separators for the removal of oversizematerial.

• Three 20m Diameter, 26m Height Concrete Storage Silos.

• Three Saxlund Radial TubeFeeders® for the discharge of wasteor virgin wood

• Three Saxlund Elevating Twin Strand Chain Conveyors

• Two GEFA Enmass Elevating Chain Conveyors

View of the belt conveyors from the

screens to the storage silos

Enmass Conveyors feeding

the METSO day bins

Hub issue-23 - Oct 2012 16/10/12 16:40



Hub issue-23 - Oct 2012 16/10/12 14:32

To build storage bays for bulkmaterials that can be removed,replaced or expanded at any time.Quickly but solid, without diggingfoundations. That, in short, is theessence of the Legioblock®

construction system.

The flexibility of the Legioblock®

construction system is a valuable feature,since it allows their owner to adjust thewalls to their changing needs for storagecapacity. Need more capacity? Simply callJansen to extend the height of your existingwalls or to add more storage boxes.Moving to another site? You can moveyour blocks with you and construct themagain at the new site. With Legioblock®, itis all possible. Also, while many localauthorities regard a Legioblock®

construction as 'temporary structures',planning consent is much easier to acquire,in some cases not even needed at all.

The standard size of a Legioblock® is 160x 80 x 80 cm with a weight of 2.400 kg.Thanks to the interlocking principle, theblocks are easily stacked an placed,without the need of any fixing material.

This way, walls can be built in minutes andhours as opposed to days or weeks.Legioblocks® are delivered directly fromstock, which means very short deliverylead times. They arrive on the back oftrucks and are then lifted into place with atruck mounted crane very similar to a brick-grab.

Product focus

Flexiblestorage forbulk materials



Main applications of Legioblocks® are storage bays, retaining walls,partition walls, soundproof walls, fire resistant walls and industrialworkspaces. Especially for waste recyclers and other companies that dealwith bulk materials, it is the ideal solution to - temporarily or permanently -optimize storage capacity. Legioblock® walls also have excellent sound-proofing and fire resistant properties.

Legioblock® is a product of A. Jansen B.V., a Dutch based company withover 15 years of experience with concrete building blocks. Over the years,the Legioblock® has developed as a high quality product and has become avery popular solution in Northern Europe for all kind of constructions. Theultimate flexibility and the sheer durability of blocks, make it a highly cost-effective construction system.

Hub issue-23 - Oct 2012 16/10/12 14:32



Schenck Processexpertise inpneumaticconveyingThe combined product andprocess technologies fromSchenck Process areable to handle awide variety ofraw andprocessedmaterials fromdelivery todespatch.

The market-leadingpneumaticconveyingtechnologyprovidessystems that efficientlyhandle bulk materialswithin a productionplant with very high levels of reliabilityand minimal plant downtime.

By using Dense Phase pneumaticconveying, difficult materials that areabrasive or friable are transported in aplug form at very low velocities whichensures minimal wear on the pipes andbends and a long life of the installation.Standard Schenck Process systems areavailable for material temperatures up to450° C, flow rates of over 300 tonnes perhour and for distances up to 2.4km,depending upon the material, all in asingle pipeline.

Central to the operating efficiency of allSchenck Process pneumatic conveyingsystems is the Dome Valve® whichincorporates a unique and highly reliableinflatable sealing arrangement. Theinherent simplicity of the Dome Valve®,the only moving part in system, ensures theoverall system's reliability and lowmaintenance operation. The originalDome Valve® was developed by ClydeMaterials Handling in 1974 and theCompany was purchased by SchenckProcess in 2011 and the Dome Valve® ispart of the extensive range of SchenckProcess technologies.

Schenck Process pneumatic conveyingtechnology ensure that materials aremoved without creating any dust tomaintain a clean working environmentboth internally and externally to the plantwhich has significant operating benefitscompared to alternative conveyingmethods.

www.hub-4.com/directory/758 www.hub-4.com/directory/328


Product focus

Phase 3 completed atGrain Storage FacilityGAME Engineering has been working with WoldGrain since2010 completing Phase 1, Phase 2 and now Phase 3 of theirplant development programme at their grain storage facilityin Hemswell, Lincolnshire.

As part of WoldGrain's planned programme of works which includeda plant upgrade and throughputs in 2012, they installed new in-feedconveyors to their original storage silos.

The new conveyors have increased the transfer capacity from 50 t.p.hto 100 t.p.h to match the equipment installed during phase 1 & 2.

This investment will not only increase the transfer throughout but alsoeliminate the untimely breakdown which can happen due to thepressure put on the old equipment by the earlier phase improvements.

It is hoped that during 2013 further improvements can be made to theold silo discharge arrangement so that their routes become morereliable and faster.

GAME Engineering Ltd has been working in the Grain & Seed sectorsince its formation in 1986, originally focussing on the design,manufacture and installation of milling equipment.

Specialising in these sectors, GAME has amassed a wealth ofknowledge, experience and capabilities which have beenimplemented into a variety of projects already undertaken.

The expertise that GAME hold in turnkey solutions and CAD Design,means they can offer services to design, construct, upgrade, refurbish,extend or improve processing facilities

Hub issue-23 - Oct 2012 16/10/12 14:32




Hub issue-23 - Oct 2012 16/10/12 14:32

Guttridgeconveyorsdeliver highreliability forabrasive dutiesin new Lafargeaggregateblending unitGuttridge Ltd, a leadingmanufacturer of materials handlingsolutions, has supplied a suite ofconveying equipment to the LafargeBarnstone Works (NottinghamshireUK) for feed and product transportthrough a new aggregate blendingunit. Specified to ensure maximumreliability for highly abrasive processstreams, the six Hi-Load bucketelevators and the Kleenbelt beltconveyor incorporate sensors forupset detection as well as a numberof features that streamlinemaintenance. Lafarge is a globalleader in the production of buildingmaterials and has installed the newplant to makesand/cement/aggregate blends forspecific applications within theconstruction industry.

“We already had Guttridge machinesworking reliably on site,” explainsAdam Elmes, Project Manager forLafarge, “so we were well aware thatthe company could provide us withquality systems at an acceptable price.Beyond that, though, we wereimpressed with the company'swillingness to innovate new solutionsthat would help us to achieve the veryhighest levels of reliability - a majorgoal for our site. The Guttridgeengineers are both responsive andknowledgeable and this was animportant factor in ensuring the successof the project.”

The six bucket elevators are used tovertically lift different streams - cement,aggregate, sand and associatedmixtures - at various points in the

Product focus


process. The belt conveyor is a completely enclosed system thattransports a cement and sand mixture some distance, from avibratory screen to the elevator feeding the mixer. All equipmentwas supplied with a host of carefully engineered features designedto ensure reliable long-term abrasives handling with minimalmanual attention, as well as to ease maintenance.

“All the systems came on stream quickly and easily and areworking well,” continues Mr Elmes, “but we're especiallyimpressed with the Kleenbelt. It's a really robust design with anexcellent sealing system. All of the incoming material is fed cleanlyonto the belt without spillage and we have complete productcontainment even though the stream is very dusty. This is a majorimprovement compared with our previous experience of aconventional belt conveyor.”

The Kleenbelt conveyor is a unique but well-proven solution forapplications where it is especially important to avoid productspillage or emission. Capable of handling flow rate up to 800cu.m/hr it is suitable for the widest range of materials - from rolledoats to rubber crumb, coal to cement.

To find out more visit the Guttridge website: www.guttridge.co.uk


Hub issue-23 - Oct 2012 16/10/12 14:32

http://www.guttridge.co.uk



Recycling


MB products are being used forimportant constructions in Brazilahead of the 2014 World CupAn all-Brazilian challenge for the ItalianCompany MB, leader in the earth movingand construction industry: its products havebeen in use for several months at varioussites across the country. Thanks to apartnership with Grupo Monte SinaiLocação Ltda, MB's Crusher Buckets andScreening Buckets have been used for theconstruction of the Arena Pernambucostadium ahead of the 2014 BrazilianWorld Cup.It all began in 2009 with initial contactbetween the Group owners, AbinaelManoel and Enoque Manoel De Souzaand MB Area Manager for Brazil,Carlotta Mettifogo.“We purchased the first BF90.3 in May2011 - the De Souzas explained - andused it for recycling demolished materialat the “Atlantico Sul” shipyard in the Portof Suape (Pernambuco). We then took theMB Crusher Bucket to the “Shopping RioMar” site to crush inert material from thedemolition of an old factory, and thismaterial was subsequently reused at thesame site”.

“We are really pleased with the purchase - the owners confirmed - so muchthat in January 2012 we bought another model from the range, theBF120.4, and then in March 2012, the Screening Bucket MBS-18, one ofthe company's newest products”.Once again, MB Crusher Buckets and products have become importantassets in worldwide events. Back in 2010, MB Crusher Buckets were usedto build the Soccer City Stadium ahead of the South African World Cup.After South Africa came Brazil and its Arena Pernambuco, the constructionof which was entrusted to the national giant “Construtora NorbertoOdebrecht”. It was Odebrecht to contact Grupo Monte Sinai for the hire ofits MB Crusher Buckets.Significant investment in research has allowed the Vicenza-based company,world leader of its sector, to produce indispensable and cutting-edgebuckets with unparalleled performance. It is precisely for this reason thatMB products are chosen by companies from across the globe who areworking on projects on an international scale. These projects confirm theenormous flexibility of MB Buckets, which have become ruler of this marketin just a few years These customers confirm the versatility of MB products. “With the MBCrusher Bucket - Mr De Souza of Brazil said - the great advantage hasbeen that of saving on the cost of material: instead of buying it from thirdparties, we used material that came straight from the site, from thedemolished construction or from the site ground itself. This has allowed us tomake significant savings in terms of material, resources, our time and thetime of the customer who commissioned the work. This show of “significantsavings” has led to other commissions at the same sites as well asconveying a sense of solid professionalism to our customers. It is worthmentioning that we use the MB Crusher Bucket for an average of 10 hoursa day, 6 days a week. On top of all this, no special maintenance isrequired, keeping costs low compared to mobile or fixed crushers”.MB Managing Director, Guido Azzolin concluded: “In periods of globaleconomic downturn such as the one we are currently facing, the use of ourmachine for large events shows that companies who invest in research andtechnology and offer cutting-edge products will always find a place on themarket and gain prominent positions in prestigious sectors such as that oflarge-scale construction”. www.mbcrusher.com

Brazil 2014 - Behind every greatwork there is an MB Crusher Bucket


Hub issue-23 - Oct 2012 16/10/12 14:33


http://www.mbcrusher.com


The minerals and recycling arm ofRaymond Brown Group has takendelivery of three Bell wheeled loadersfollowing a successful demo.Raymond Brown already runs a fleet of fourBell B30D ADTs at its quarries in Dorset andHampshire, but this is the first time it haspurchased loaders from the South Africanmanufacturer.

Traditionally a user of Cat and Volvo loaders,the company has bought three Bell L2106Eloaders, which will be used in a variety ofapplications.

The purchase follows those of a growingnumber of big names in the recycling andaggregates industries who have switched toBell loaders in recent years.

Nick Moth, group plant manager for RaymondBrown, said: “Talking to people in theindustry, I was hearing very positive thingsabout Bell loaders, and I thought we shouldhave a look at them.

“And, since the demos, we've had verypositive feedback from operators and sitemanagers”

Moth said that the John Deere-built Bellwheeled loaders indicated some “favourable”fuel consumption figures during the initial trials- and that Bell's approach to after-sales wasalso a major factor in his purchasing decision.

“Fuel consumption is key,” he said. “And theservice and support we've had from Bell overthe years has been good. There's a lot of trustbuilt up between our two companies - wehave a very strong working relationship.”

He added: “Knowing that the loaders aremanufactured for Bell by John Deere alsogives us a lot of comfort.”

Recycling

Raymond Brown takes first Bell loaders


Prior to purchase, a Bell L2106E was put through its paces during aweek-long demonstration at Raymond Brown's Marchwood Wharf sitein Southampton.

The machine worked with sea-dredged aggregates, which are loadedinto wash and screening plant before being stockpiled ready for sale.Also on an adjacent site, the loader stockpiled woodchip, for loadinginto ships to be used as power station fuel in Sweden.

Carl Woollaston, sales support manager for Bell UK, said thedemonstration site at Marchwood was ideal for two main reasons:

The first was to show how well the Bell loader coped in terms ofmachine balance, power and operator comfort and when workingaround a busy washed aggregate plant. The second was to prove theeffectiveness of Bell's QuadCool cooling system within an environmentinvolving airborne debris such as the woodchip operation and otherrecycling applications.

QuadCool includes a unique boxed configuration of radiators, totallyisolated from the engine heat. The radiator cores are wider than themesh of the air intake screens, allowing any debris to pass through -thus avoiding clogging of the engine.

Woollaston said: “Our loaders have many benefits, not least the factthat they offer the highest as-standard specification on the market. Butthe QuadCool system genuinely means they stand head and shouldersabove the competition, particularly in applications where there's a lot ofdust or debris.

“In short, it stops the engine over-heating, it reduces downtimesignificantly, and all of our customers have been surprised at howinfrequently they need to clean it out.”

Neville Paynter, managing director of Bell UK, said: “Once again, withRaymond Brown, we've seen a major player in the industry switch toBell on the back of a successful demonstration. We're delighted thatword is now getting out that our loaders are a force to be reckonedwith.

“I'm especially proud that our reputation for dedicated service andsupport - something that forms a central part to our Bell Assureguarantees - is still as strong as ever.”


Hub issue-23 - Oct 2012 16/10/12 14:33



Hub issue-23 - Oct 2012 16/10/12 14:33

Recycling

WheeldonBrothers get theMAX X Tracttreatment


IntroductionIndustrial, commercial and domestic recyclers,Wheeldon Brothers, are reducing wastedisposal costs whilst maximising materialrecovery thanks to the Max X Tract densityseparator supplied by Worsley Plant.

BackgroundWheeldon Brothers run four waste andrecycling transfer stations in GreaterManchester which together process 120,000tonnes of construction and demolition (C&D)waste and commercial and industrial (C&I)waste every year. The processing of thismaterial leaves behind around 120 tonnes oftrommel fines each day which were sent tolandfill.Wheeldon Brothers recognised that risinglandfill tax and disposal of trommel fines couldbecome an issue for the business after a trialin Yorkshire by the Her Majesty's Revenue andCustoms (HMRC) found that some wastetransfer sites were failing to process materialto a level suitable for the lower rate of landfilltax. (Landfill tax on trommel fines below 8mmqualifies for a lower rate of landfill taxcurrently at £2.50 per tonne.)It meant that this material would have to bedisposed of at the standard rate of landfill tax(£64 per tonne), thus becoming extremelyexpensive.Wheeldon Brothers came to Worsley Plant asthe sole supplier of the Max X Tract densityseparator because it is unrivalled in its abilityto extract material with a market value. It cantherefore significantly reduce costs for thebusiness whilst generating revenue through thetrading of recovered materials. It also allowsWheeldon's to demonstrate its commitment tosustainability and shows customers that theirwaste is being dealt with responsibly.

Working with Worsley PlantWorsley Plant recommended the installation ofboth the Flex X Tract and Max X Tract densityseparators in order to safeguard against risinglandfill tax. Together the machines canseparate out material of value to generaterevenue for the company whilst reducing thevolume disposed of in landfill.The Flex X Tract separates out fines less than8mm. This material is used as cover materialat landfill sites which makes it suitable for thelower rate of landfill tax. Typically, around30% of C&D waste can be treated this way.The Max X Tract separates out heavies of 8-40mm, lights and scrap metal, much of whichcan then be traded as commodities.

Heavies• Typically amounts to 60% of material recovered• Includes bricks, stones, glass, porcelain and scrap metal• Known as 'clean hardcore', this material can be sold for around £5

per tonne

Lights• Typically amounts to 6% of recovered material• Includes paper and plastic• Landfilled at standard rate but low weight so low cost

Scrap• Typically amounts to 4% of recovered material• Sold for around £150 per tonneThe efficient use of resources can create jobs, save valuable and finiteraw materials and dramatically reduce emissions. For example, usingrecycled aluminium over primary ores in aluminium production cutscarbon emissions by 95% as well as saving energy.

Hub issue-23 - Oct 2012 16/10/12 14:33


Recycling



ResultsWheeldon's has reduced its disposal costs by over 90%.This has been achieved through:• reduced waste to landfill which means less financial outlay in terms

of landfill tax• extra revenue generated through sale of recovered materials,

including 'clean hardcore' and scrap metal.

Due to these savings, the cost of the Max X Tract densityseparator has been covered within three months of installation.How it works: Max X Tract• The Max X Tract is designed to separate materials less than 100mm

giving the customer higher value materials and reducing the amountof material going to costly landfill

• It uses industry leading, patented separation technology, is compactand can be easily integrated into existing systems

• It extracts materials in different ways to achieve better results thanother density separators. For example, metals are magnetically pulledout of the material stream

• It can process 100 tonnes per hour to recover compost, metals,wood, plastics and organics

• It results in clean high quality products which can be returned to thecomposting process, used as biomass fuel, or to be sold on assecondary commodity materials.

James Wheeldon, Wheeldon Brothers:“The Max X Tract is significantly reducing our waste disposal costs. Wedeal with a lot of C&D and C&I waste so it is perfect for our needs as itallows us to adjust the different separating actions depending on thematerial going in. We continue to work with Worsley Plant to ensure themachine is working to its optimum level.“The HMRC guidance relating to landfill tax on 'inert' trommel fineswhich was published in May 2012 really brought the issue home forus. There were people across the industry panicking about this materialpotentially being charged at the full landfill tax rate and so they wereholding on to material. Having the Max X Tract means we areextracting a significant proportion of material, much of which we cansell rather than paying to get rid of, so it is keeping our costs downwhen waste disposal costs are rising.”

Example:

Type of material Percentage of Cost vs valuematerial recovered

Fines <8mm Soil 30% Landfilled at lower rate (£2.50/tonne)

Heavies Bricks, stones, porcelain, glass, scrap metal 60% Sold for £5/tonne

Lights Paper 6% Landfilled at standard rate (£64/tonne)

Scrap Metal 4% Sold for £150/tonne

*Prices correct at August 2012.

Hub issue-23 - Oct 2012 16/10/12 14:33



Hub issue-23 - Oct 2012 16/10/12 14:33

Recycling


GurteenRecycling wasteno time with thePODFatherGurteen Recycling use the PODFatherLogistics platform to automate wastetransfer notes and managementreporting across the UK.Gurteen Recycling are a national recyclingand transport company based in the NorthEast of England. With a range of vehicletypes operating across the UK to cater forall customer requirements, they offer areliable service to a growing list of bluechip companies.One area of the business focuses on scrapmetal collection and recycling servicesfrom car garage and service centresacross the UK. Dealing principally withnational chains, huge demands areplaced on the business to ensure allcontract requirements are met and thecustomer is provided with the highest levelof service.At the start of 2012, Gurteen Recyclingimplemented the PODFather Logisticssystem to manage their drivers' weeklycollection rounds, which sync to the

mobile PDA system allowing collection details to be captured at both thecustomer and tip sites.Custom electronic job sheets have been created for Gurteen Recycling toreplicate their waste transfer forms, documenting the type and quantity ofwaste collected from each site, and then reporting on the weight of metalcollected on each round for billing purposes.The combination of data captured on the PDA ensures an accurate audittrail of activity is recorded, and also makes sure each customer site is visitedaccording to the agreed schedule. By implementing this in a real-time PDAsystem, the burden of paperwork is eliminated to the benefit of both businesscashflow and improved customer service.The PODFather Customer Portal has been made available to Gurteen'scustomers via their own website. This displays details of the next visit dateand time for each of their sites, as well as a permanent archive of allcompleted job sheets.Paul Gurteen, Managing Director of Gurteen Recycling, explains, “ThePODFather PDA system automatically records the date and time of eachvisit. The collected materials are also photographed by the PDA and GPScoordinates of each visit are stored, so even if the customer is not availableto sign the PDA, we have clear proof the visit was carried out.“The drivers have the added flexibility of being able to make unscheduledcollections and can create ad-hoc jobs on the PDA without having to rely onthe transport department booking and scheduling the job to the handheld.”The PODFather GPS tracking module is included in the Gurteen Recyclingsystem. This provides both real-time and historical tracking of drivermovements, integrated with daily routes and completed jobs.Paul concludes, “The return on investment in the PODFather system wasrealised after just a few months. It has virtually eliminated the paperworkgenerated by the recycling business, given us integrated tracking, andonline facilities for our customers.”


Hub issue-23 - Oct 2012 16/10/12 14:33



The culture of using landfill sites as aprimary method in the disposal ofwaste is long gone. Tax on landfill is setto increase again in April 2013 to £72per tonne, so now more than ever it isimperative to look for more innovativemethods of separating and recyclingmaterial.

Scottish waste handling company, HamiltonWaste & Recycling Ltd endeavour to recyclethe optimum amount of materials arriving ontheir weighbridge.

This family run business on the outskirts ofEdinburgh is leading the way with thepurchase of an EDGE Slayer. The Slayer asits name suggests reduces the size of thebulky materials that arrive into their transferstation as well as opening rubbish bags andslicing up waste that is stuck together.

Before acquiring the shredder, HamiltonWaste had to sort material on the groundbefore sending on for processing. Byintroducing the Slayer to their system theyhave reduced the input size of the material toa 350-450mm piece size enabling thematerial to then pass over a screen and onto a 4 bay picking station.

Using the EDGE Slayer has completelynegated the need for pre-sorting material onthe ground ensuring there is no personnelwalking/ working unnecessarily on site. Thisis extremely important when companies areusing large machinery such as wheel loadersand excavators.

Recycling


Innovative separating from Edge


The Slayer sizes waste material into a uniform piece size which means itcan be processed and handled easier on the screening unit and then onthe picking station. The company benefits from a maximum return onitems processed/recycled and also ensures that the company benefits inrelation to weight payload from their Lorries when the processed materialis sent on for further recycling. The innovative design of the shafts on theEDGE Slayer are extremely versatile shredding all types of waste includingC&D, C&I, Household and green waste.

Hamilton Waste had looked at numerous shredders but chose the EDGEmachine due to the Slayers robust design: versatility and low running costsin comparison to its competitors. On initial testing the EDGE Slayer wasaveraging under 20lts per hour of fuel, less than half of its competitors.Due to its design it has one of the smallest footprints on the market but ithas the largest discharge height. This was a big advantage for Hamilton'sallowing them to feed directly from the shredder to an existing screeningplant which is over 5 metres high. Without this large conveyor theiroptions were to either double handle the material or buy an additionalconveyor, both options would have added additional running costs andleft the process more expensive and unworkable.

Given the uncertainty within the Waste Recycling industry currently,recyclers need flexibility in terms of Product design and specification.EDGE Innovate employs a team of experienced design engineers in its“Design Academy”. The objective of the Academy is to devise andexplore new methods and processes to further minimise the amount ofmaterial being sent to landfill.

This year alone EDGE have brought to the market, the SLAYER XL a fullrange of Wheeled and Tracked Trommels and a range of ModularPicking Stations. 2013 will see further product launch and development.Catch us at www.edgeinnovate.com

Hub issue-23 - Oct 2012 16/10/12 14:33


http://www.edgeinnovate.com


Hub issue-23 - Oct 2012 16/10/12 14:33

Recycling

Recovered fibreloses upto 90%liquidFibre recovery has presented aninherent processing problem ofunwanted liquid retention, foxing plantmanufacturers for years. HEGER GmbHhas announced the development of acost effective solution, working with aSwedish recycler, employing theCrocodile 250T Dewatering System.

By adapting the function programme alongwith other component modifications, includingthe channel and auger design as much as90% of the liquid can now be removed.

Fercell Engineering, sole UK & Irelanddistributors of Heger foam compaction anddewatering solutions including the HEGERCrocodile dewatering product, can now offerthis solution to the materials bulk handlingsector solving a costly fibre recycling industryproblem effecting fibre dewatering.

This particular problem, sludge containing alow percentage of solids, has been solvedusing the power of the Crocodile 250T andHEGER technology which can now dewater(or reduced) to as low as 90% of the liquids -a technology breakthrough announcement.

Meeting with other fibre recyclers at the recentRWM2012, this news was met withconsiderable interest and in fact one companyin particular is eager to conduct trials with theview to specifying the HEGER Crocodile aspreferred solution for a UK five plant roll outprogramme in 2013/14.

For further information or indeed to arrangeyour own machine trial using your ownmaterials do call our friendly customer supportteam, visit our website or view a crocodileinstallation at work on our Youtube channel.

Tel: 0870 428 2688eMail: [email protected]: www.excell-es.com

www.hub-4.com/directory/9239www.hub-4.com/directory/15128

Glen Creston -‘The star of the show’!Glen Creston- 'leaders in size reduction' took the stage at theRecycling Waste management exhibition which was held at theNEC in Birmingham, United Kingdom from the 11th - 13thSeptember 2012. The Glen Creston stage set was the talk of the show; it had a greatpresence and very eye-catching, with the rich blues and dancingmen.The cast were excellent especially the Roller crusher, who was thestar of the show and carried out a great production.Demonstrating how it works and how it can benefit variousindustries.Other characters in the show included the Glen Creston's Swinghammer mill and Endecotts Test sieves and Sieve shakers whichwere all in supporting roles and also carried out a performance toremember.

As well as the stand our 'Win two tickets to a top London show'competition was a great success, where over 250 participantstook part and was won by Matt Mitton of Recycle.co.uk. Thecompetition prize was drawn on Friday 6th September at 13:00by one of Endecotts long serving employees.The show was a great hit and It is recommended that the GlenCreston products are a must see!Glen Creston manufactures and supplies an extensive range ofquality standard machines for grinding, mixing, crushing andmicronizing applications. From the Jaw Crusher, for primary sample breakage prior tofurther processing, to the McCrone Mill, which will grind toanalytical fineness, these machines can cope with a wide range ofmaterials from rocks to edible grains. Glen Creston also manufacture/design bespoke machines tocustomer's specific requirements for grinding and crushingapplications.These machines are suitable for processing a wide range ofmaterials such as chemicals, minerals, pharmaceuticals, soil,cement, coal, aggregates, agricultural products, plus many more.For pictures of Glen Creston at the Recycling Waste Managementplease visit www.glencreston.com or for more information aboutGlen Creston products please contact:

[email protected] +44 (0) 208 545 9140www.glencreston.com


Hub issue-23 - Oct 2012 16/10/12 16:46


http://www.excell-es.com

http://www.glencreston.com


http://www.glencreston.com




A brand new Volvo EC480D Ultra HighReach machine has been delivered toWooldridge Demolition of Bagshot,Surrey along with an EC360Cequipped for secondary demolitionwhich celebrate a ten year associationowning and operating VolvoConstruction Equipment products.

The EC480D has been supplied toWooldridge Demolition with a bespokethree piece demolition rig designed andmanufactured by Messrs Kocurek ofIspwich and replaces an older EC460Bmodel. With a maximum pin height of 26metres and forward reach of 14 metresthe EC480D is capable of handling a toolweight of 2500kgs. At the heart of themachine a Stage IIIB V-Act 13 litre enginedevelops 348 nett hp and is ideallymatched to its automatic sensing modehydraulic system. The equipment featuresa hydraulic modular joint which enablesthe machine to be fitted with either ultra hireach demolition equipment, a straightboom arrangement or as a standardbackacter for digging duties. Furtherstandard features to the Ultra High reachspecification include a hydraulically tiltingoperator's compartment; heavy duty bellyplates; the Volvo SIPS (side impactprotection system); five tonne additionalcounterweight, double thickness to sidepanel doors and X3 grab rotationhydraulics in addition to the standardhammer shear hydraulic circuit.

Recycling

First Volvo Dseries Ultra HighReach goes toWooldridgeDemolition


“Specification and the robust build of the Volvo product have been thedrivers in Wooldridge Demolition's decision to continue with thebrand,” commented Director Nick Anderson who took delivery of thefirst Volvo machine back in 2002. “This is especially so in recentyears where we have had to elongate the effective service life of ourequipment from three to five years. We have been very pleased withour fleet of Volvo machines as they have proved quite capable ofhandling a good five years in front line demolition work,” hecontinued. “Equally important is the consistent level of after salessupport we receive from Volvo's local customer support centre nowbased at Horsham. We can rely on Volvo to sort any issues outquickly and efficiently and to act on their promises.”

Commenting further on the new EC480D ultra high reach NickAnderson sees the latest bepoke modifications undertaken by MessrsKocurek Ltd as a significant step forward in the development of thehigh reach concept - particularly in the area of the cab. “This is oursixth machine with the Kocurek high reach design and this latestversion ticks all the boxes especially when it comes to upward andforward visibility for the operator.”

Wooldridge Demolition, based at Bagshot in Surrey undertakes allmanner of demolition contracts throughout England offering acomplete service including high rise and industrial demolition,crushing and asbestos removal and haulage / disposal of material ifneeded. Most recently, projects have been undertaken on majordemolition contracts as far afield as Grimsby and Leeds.


Hub issue-23 - Oct 2012 16/10/12 16:46



Crusher Manganese Steels Limited

Vulcan Way, Hermitage Industrial Estate, Coalville, Leicestershire, LE67 3AP, United Kingdom.T. +44 (0) 1530 817 000F. +44 (0) 1530 817 111E. [email protected]

www.cmscepcor.com

Europe’s leading aftermarket manufacturer and supplier of precision crusher spare parts andpremium manganese wear parts for the Quarrying, Demolition and Recycling Industries.

The Genuine Alternative

Hub issue-23 - Oct 2012 16/10/12 14:33


http://www.cmscepcor.com

Recycling


It's all in a day'swork for newJCB wastemasterbackhoe loaderAt RWM 2012, JCB adds the brand new4CX Wastemaster backhoe loader to itswell-established range for the waste andrecycling industry - deliveringunprecedented levels of efficiency,versatility and cost savings.

Developed in line with extensive customerevaluation and fitted with a package ofpurpose-built features, the flexible andproductive backhoe loader is transformedinto a tailor-made model for arduous wasteenvironments. With its ability to power anextensive range of specialist attachments,the JCB 4CXWM model - JCB's firstdedicated backhoe loader for the industry -will excel in the non-stop workingenvironment typically found at HouseholdWaste Recycling Centres, also known asCivic Amenity Sites.

Globally, the backhoe loader is already oneof JCB's biggest selling machines into waste,recycling and demolition applications, withlarge volume sales in Asia and SouthAmerica and a strong presence in specificEuropean markets. The JCB 4CXWM offersunrivalled versatility at a price which is lessthan the wheeled excavator typically seenon site. Its ability to perform a variety ofroles also eliminates the need for othermachines such as forklift or pallet trucks -further increasing cost savings.


The specialist new 4CXWM model incorporates additional length rearstabilisers and a front frame incorporating hydraulic legs. Thiscombination raises the entire machine well clear of the ground,offering exceptional views into a bin when compacting material witheither a grapple or compaction wheel attachment.

However, additional attachments ensure that the JCB 4CXWM ishighly effective for more than just compaction. These include grabs forhandling waste material and a sweeper collector for keeping the siteclean and tidy. Furthermore, a unique hook lift for manoeuvring binsand skips gives clear advantages over other machines in terms of siteproductivity.

The range of purpose-designed bucket options opens up a wide arrayof typical waste re-handling tasks. At the loader end, users can choosebetween high-capacity general-purpose, 6-in-1, or top grab bucketsdepending on the application and nature of the load. At the excavatorend, a hydraulic jaw bucket or a mechanical grapple both deliverhighly effective materials handling capabilities.

Safety on site is enhanced by superb all round visibility from the cab,high visibility stabiliser chevrons, convex mirrors, rotating beacon anda reversing alarm. Machine protection is assured with the inclusion ofadditional boom protection, rear screen impact protection, light guardsand puncture protected tyres.

The high specification new machine is founded on JCB's world leading4CX backhoe loader. It features the powerful 75kW (100hp) JCBDieselmax engine and incorporates innovations such as AdvancedEasyControl and 4-speed Powershift transmission with TorqueLock.

As a result, the road performance and exceptional fuel economy of theJCB backhoe loader means that travel between sites is fast, easy andcost effective compared to other equipment used in comparableapplications and controllability is excellent once it arrives.

In addition, the machine uses the most robust loader arms and axlesavailable - taken from the recently introduced JCB 5CX model. It has a4.72m extending dipper at the excavator end and excavator type seatmounted controls for easy operation. It boasts air-conditioning, animmobiliser, JCB LiveLink telematics and the latest JCB Powerslidesystem - which offers assured excavator movement from side to sideacross the whole of the machine's rear frame - all as standard.

Hub issue-23 - Oct 2012 16/10/12 15:04



Precia-Molenprovides anI400 basedformulationsystem forATEX one 2area


Precia-Molen was recentlyapproached by a major internationalmanufacturer of conformancecoatings to provide a solution thatwould satisfy four key criteria withinthe production process.Based in the USA the client suppliescoatings for various applications within theAerospace and Defence, Automotive,Appliance Controls, Industrial Controls andChemical Industries. These involve workingin harsh environments which include hightemperatures, salt spray, humidity,condensation, water immersion,noxious/corrosive gases, solvent splash,spill and immersion.

The task:With a desire to meet increasing salesprojections the client required a completelynew state-of-the-art production facility(classified as hazardous according to theATEX directive) with eight mixing stationsable to operate simultaneously. Withproduct quality and traceability critical inorder to ensure the reliability of electroniccomponents in highly demandingenvironments the system reports must satisfyUS military auditors.

A successful solution: After consultation a decision was made tosupply a 1400 D-MS Ex 2-21 with an SDUfor the proposed simple dosing system.However, after further discussion it wasclear that the client required much morefunctionality which prompted Precia-Molento include a central formulation systemutilising the GeneSYS™ MRM(Manufacturing Recipe Model) and to retainthe I400 D-S EX 2-21 as a weighingterminal with HMI functions. As dosing wasto be manually controlled the system wouldprompt the operator to make an additionand then monitor and record the actualweight added. Precia-Molen was alsogiven a further task of providing a solutionthat would also prompt operators to addthe necessary ingredients and to record theresults including raw material lot numbersfor archiving.

Key benefits:The new system has provided numerous keybenefits, including:• High accuracy dispensing of bulk

ingredients. Supervisor alarm given forover dispense.

• Operator errors minimised due to structured user dialogue and clearprompts

• Recipes maintained under change-control in line with good automatedmanufacturing practice

• Full audit trail • Record with each ingredient addition logged by weight• Raw material batch numbers (lot number) recorded• Operator identified for each batch

A successful solution: The installation included three system key components:• Stainless steel compact LoadMount with integral jacking• I400 D-MS EX 2-21 at each station to operate as HMI• Central formulation system with GeneSYS™ Manufacturing Recipe

ModuleSince installation and commissioning the new system has proved to be atotal success and is operating fully to specification. All the operators andsupervisors are very happy with the ease of use and management isreceiving the required production data it needs for quality control. Overallthe control system has been acknowledged as delivering excellentperformance at a far lower cost than a similar plant in the USA.

Bulk Materials Handling


Hub issue-23 - Oct 2012 16/10/12 15:07



Hub issue-23 - Oct 2012 16/10/12 15:04



The Yeoman Bontrup bulk transport shiphas been re-launched to perform atransport and delivery service for graniteaggregates supplied from GlensandaQuarry in Scotland. The 100,000-tonneself-discharging vessel is back in serviceafter a £35 million rebuild which includedkey material handling equipment such astransfer chutes being removed, rebuilt andre-installed. In order to enhance theperformance of this equipment, wearprotection specialists Kingfisher werecalled in to incorporate their technology toenhance the performance and servicelongevity of the chutes due to detrimentaleffects of handling hard granite stone.

The 21 month planning, engineering andrebuild process was triggered by fire damagecaused while in berth at the Glensanda superquarry in Morvern, north-west Scotland duringJuly 2010. The damage to the structure of thevessel along with its materials handlingequipment required Kingfisher to carry outlining work using its specialist wear andabrasion resistant K-ALOX lining system whilein dry-dock in Poland. The installation wascarried out by Kingfisher's experiencedinternational team of fitters who travel aroundthe globe providing repairs and wearprotection for ships, ports, power stations,mining and aggregate processing sites.

Now, following the rebuild, the YeomanBontrup has resumed its dedicated shuttleduties transporting high-quality crushedgranite aggregates from Glensanda tomarkets across northern Europe. The re-launchcomes at a time when major investment istaking place at Yeoman Glensanda on theMorvern Peninsula including the relocation ofthe primary crusher and mobile plantworkshop removing the primary crusher andconveyor from the skyline.

100k tonne bulkcarrier back inservice withKingfisher wearprotection

Hub issue-23 - Oct 2012 16/10/12 14:34





Darren Loftas, Yeoman Glensanda worksmanager, was reported as saying of theproject: 'It's great news for both YeomanGlensanda and the local community thatwe are able to make this investment in ourbusiness. In times of continued globaleconomic uncertainty, this significantinvestment demonstrates the company'songoing commitment to both the quarry andthe community.'

Commenting Kingfisher MD John Connollysaid. “We have served the marine, bulkcargo ports and quarrying industries formany years and with the knowledge gainedalong with utilisation of our range ofceramic, metallic and polymer protectionsystems we have a good understanding ofwhat works where and what doesn't.

The reasoning behind the use of our 92P K-ALOX ceramic liners on this applicationtakes in to account both its previous trackrecord of success and its excellent rating forresistance to all forms of abrasion; it is oneof the few protection systems that can caterfor the constant abrasion that occurs whenhandling hard granite aggregates.

The primary material used for themanufacture of Kingfisher's K-ALOXcomponents is calcined alumina at over90% purity. In order to achieve its finemolecular structure it is milled and dried tocreate a near submicron powder. It canthen either be pressed or slip cast intoalmost any form and kiln hardened in acontrolled process of heat treatmentreaching temperatures of 1600°C whichresults in a material with characteristics ofextreme abrasion, impact and heatresistance.

The primary use of the K-ALOX material is for the protection of plant againstabrasion and erosion when bulk solids or by-products are being conveyedor processed by mechanical, pneumatic or hydraulic means. With ahardness rating of 9 on the MOHS harness scale, K-ALOX is ideally suitedto counter both impact and sliding abrasion and erosion within the bulksolids handling or processing applications, making it ideal for bulk import orexport terminals along with protecting the transfer systems on self unloadingvessels carrying hard aggregate such as crushed granite.

As operational uptime is becoming more critical in determining the successor failure of manufacturing, processing and logistics operations, the need forhigh plant availability, extended service life and trouble free operation iskey. Plant owners and operators alike are seeking to offset the risk of supplychain failure and this is resulting in increasing demand for design,engineering, fabrication and installation work, in addition to providing wearprotection solutions. By having our dedicated expert teams on hand, we canalso take responsibility for delivering turnkey projects on time and ensurequality, cost, delivery schedules and employee safety requirements are allachieved.”

AGGREGATE PROCESSING & RECYCLING LTD - HEDGING LANE, WILNECOTE, TAMWORTH . B77 5EXTEL +44 (0)1827 280139 FAX +44 (0)1827 287770 Email: [email protected] www.agg-pro.com

GipoCOMBI RC130FDR J50 Jaw Crusher

Hub issue-23 - Oct 2012 16/10/12 14:34




http://www.agg-pro.com

While steel was originally designed tobuild structures and provide strengthand rigidity to all types of equipment ithas, over the years been incorrectlyutilised in the Bulk Material Handlingindustry in areas of high wear,assuming its strength is a solution topreventing wear in high impact areas.

This is understandable, as for numerous yearssteel and alloys were the only availablechoice.

Recent new products however, have beendeveloped to replace the dependence onsteel, demonstrating longer life, better wearresistance and demonstrably lower noiselevels in areas of the plant where wear is aproblem. Kinder & Co's polyurethane K-Rediliners are suitable for use in high impactand/or highly abrasive areas, and in manylocations are currently outlasting all traditionalwear resistant products.

Case studies collected by Kinder & Co. aredemonstrating that users are observing thedifference between traditional steel wearresistant liners and improved Polyurethane K-Redi Liners.

At the Boral Recycling Plant in Wetherill ParkNSW, Kinder's K-Redi Liner is being used inan application handling 220 tonnes per hourat 25 to 200mm of crushed bricks, asphaltand concrete from a drop height of 3 meters.Previously using 16mm thick Bisalloy steelwear liner plates...lasting 5 months onaverage, the K-Redi Liner is continuing toprovide excellent wear capabilities andshows minimal signs of wear after beinginstalled in October 2011.

Amassing more than 27 years in solvingunique problems of this nature in manymaterials handling applications, CEO NeilKinder notes; “Often the solution is quitestraightforward, but when it comes tomaterials handling issues, the industry issubject to incumbent trains of thought andalternatives often evade common perception.These types of success stories, normally opensthe eyes of experienced site workers as tohow lineal in thinking the industry can be.”


Replacing WearLiners; there arenew alternativesolutions



Hub issue-23 - Oct 2012 16/10/12 15:09



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Hub issue-23 - Oct 2012 16/10/12 14:34

Quarrying


The NEW Terex® Finlay J-1170 is a highperformance primary mobile jaw crusherbuilt around the renowned and aggressiveTerex® 1100mm x 700mm (44” x 28”) jawcrusher, with a proven track record inrecycling, aggregate production andmining applications. The Terex 1100mm x 700mm (44” x 28”) jawchamber provides excellent material reductionand product sizing in the processing of blastedquarry rock and ore material. The jaw chamberis also available with optional hydraulic release,an excellent feature when crushing constructionand demolition debris. The hydraulic releaseoption has an automatic overload protectionsystem to prevent damage by uncrushable itemsin the feed material. The machine is powered by either a Tier 3 /Stage 3A Caterpillar C9 261kW (350hp) or aTier 4i Scania DC9 70A 257kW (350hp). Hydrostatic transmission of the jaw chamberoffers operators reversible operation in the eventof a blockage. The hydrostatic system alsoprovides variable chamber speed to suit givenapplications. The crusher features hydraulic assistChamber CSS (Closed Side Setting) adjustment,and can be changed in a matter of minutes.The machine has a heavy duty variable speedvibrating grizzly feeder (VGF) with integratedpre-screen, providing an aggressive action toseparate fines material efficiently. The variablespeed VGF ensures continuous choke feeding ofthe crushing chamber for optimal productivity.

Material from the pre-screen can be diverted to a stock pile via the onboard by-pass conveyor, or join the crushed product on the main belt. The large 9.6m3 (12.55yd3) hopper has hydraulically folding sides andan innovative hydraulic self-locking mechanism to provide efficient andfaster machine set up and tear down times . “The J-1170's 45 tonne transport weight and compact dimensions meanlower transport costs between and within crushing sites. The robust andintelligent chassis design, with good clearance on both ends, alsoenables safe and easy loading onto all transport trailers. When youcombine these factors with the excellent crushing capabilities themachine easily meets the demands of owner operators and crushingcontractors” said Nigel Irvine, Sales and Marketing Director.

Key Features:• Robust proven Terex 1100mm x 700mm jaw crusher for high

capacity and large reduction ratios in quarrying, mining,demolition and recycling applications.

• Optional hydraulic release for demolition and recyclingapplications.

• Compact dimensions and quick set-up make the J-1170 theoptimum solution for contract crushing as well as demanding in-pitapplications.

• 45ton / 99600lbs transport weight ensures easy transport ofmachine between work sites.

• Full CANBUS control system. • Hydraulically assisted closed side setting adjustment minimizes

downtime and offers quick adjustment.• Excellent fuel economy • Safe, quick and easy service points for regular maintenance

Introducing the NEW Terex® Finlay J-1170primary mobile jaw crusher


Hub issue-23 - Oct 2012 16/10/12 14:34



Quarrying

First Liebherr forUK's LeadingHirer of LongReach


reversible auxiliary circuits to suit Land & Water's customers increasingrequests to use their long reach machines more and more as tool carriers.

Weighing in at 57 tonnes, the 954 fills the last gap in land and Land &Water 's fleet between its 40 tonne and 80 tonne machines - see tablebelow

Richard Maclean, from Land & Water explains. “This machine is likely towork throughout the UK - so it was sourced with a servicing and warrantypackage from Liebherr which allows us to support this product better thanwe could with just our own engineers”.

The machine comes with a sealed bucket linkage design from Liebherr thatshould save bucket pin and bush wear - particularly when workingunderwater. It is also supplied with a very impressive auto greaser fromLiebherr and Land & Water have subscribed to Liebherr's LiDAT remotetelemetry which they also find very useful. Finally, as all Land & Watersfleet, this machine was specified with biodegradable hydraulic oil that wasfactory filled.

Land & Water Plant Ltd have just takendelivery of their first Liebherr longreach excavator which has gonestraight to work quarrying sand andgravel in a quarry North Yorkshire.The machine, a Liebherr 954 isequipped with factory supplied longreach equipment giving an outreach ofeither 20 or 22m and a bucket capacityof 1.5 to 2.0m3. The bucket linkage isas a 35 tonne standard machine andproductivity is meeting Land & Watersexpectations.

The machine has been sourced primariliy tooperate in dredging and quarryingoperations, so it has been prepared to aquarry specification which includes,chevrons painted to the counterweight, areversing camera, handrails around the rearof the machine and a second, greenflashing beacon to indicate the operator hashis seat belt fastened. In addition to thequarry specification, the machine will needto be able to undertake a multiple of tasksthrough its life, so other extras are on themachine including high and low flow


Hub issue-23 - Oct 2012 16/10/12 14:34



Based in Sudbury, Suffolk, AngliaLime Company has, since 1992,pioneered the use of lime in EastAnglia through training coursesand the distribution of limematerials. Over this period thecompany has seen an increase inthe awareness and the use of limein both restoring old buildings anddeveloping new builds.

These developments have led to thedevelopment of lime-based products andsystems that make the use of lime moreefficient and convenient, while retainingthe beneficial properties of lime.

Combining abundant East Anglian localsands with hydraulic lime base binders,Anglia Lime Company offers asustainable lime-based solution forplaster repairs, repointingbrickwork, installing a limefloor or even a pre-coloured,spray applied finish for themost modern ofbuildings.

A growing market and increased demand has recently seen thecompany invest in a new drying plant with the dryer and bag filterbeing supplied by BG Europa (UK) Ltd of Wickhambrook, Suffolk.Drawing upon long standing experience within the low temperaturedrying sector BG Europa have supplied their SD 0.8 Parallel FlowDryer and SFC Pulse Jet Bag House. This combination offers a lowcapacity, versatile and cost effective package for the drying of varioussands, glass and mineral products.

Quarrying

New dryingplant for AngliaLime


Exhaust ducts

Hub issue-23 - Oct 2012 16/10/12 14:34


Quarrying



Parallel Flow Dryer

Nominally rated at two tonnes continuousfeed per hour with 5% moisture removal thedryer support base frame incorporates ahinge arrangement to allow the druminclination to be adjusted between 0.5º and3.0º to suit material specifications (factoryset at 1.0º). Manufactured by BG Europafrom 6mm thick 50D boiler plate steel thedrum shell is finished with one coat of heatresistant paint and fitted with a set of bolt-inand replaceable flights manufactured from5mm thick EN8 steel.

The dryer airplate incorporates an integralfeed chute fitted with bolt in replaceableliner plates. The hinged design of theairplate, which incorporates the burnermountings, allows easy access for servicing.

Completing the specification athermocouple is fitted within the dischargechute to measure the temperature of thedried material. Additionally, a secondthermocouple is also mounted in the exhauststack base to measure the temperature ofthe dryer exhaust gases and providealternative dryer temperature control.

Pulse Jet Fabric Filter

Ideally suited to low temperature drying applications the SFC Pulse JetFilter incorporates an efficient cleaning mechanism which does not coolthe incoming dryer exhaust gases.

With all the dryer exhaust gases filtered through the SFC 20 compactpulse jet fabric filter unit, twenty factory installed Nomex type (500mg/m2) filter bags provide a total cloth area of 9.0m2.

A snap ring collar secures the bags into the plenum plate providing an airtight seal and an easy method of replacement. With an electronic pulsecontroller allowing fine adjustment of the cleaning pulse duration andfrequency to suit operating conditions, an invertor controlled direct drivefilter exhaust fan installed on the clean air side of the filter allowsadjustment of the air flow within the dryer drum to suit the drying process.

Controls and Commissioning

Mounted on the dryer base frame a compact control panel contains thefan motor starter and inverter speed controls, drum drive motor starter andinverter speed control, temperature controller, over temperature protectionsystem, under temperature alarm system, temperature displays, stop/startbuttons and emergency stop system.

Prior to delivery the dryer and filter package was fully wired within theworkshop and tested prior to despatch to Anglia Lime.

Successfully installed in the allotted time frame the new dryer and bagfilter was fully commissioned by BG Europa engineers and integrated withthe feed and controls and the bagging system by the Anglia Lime team.

Philip Poels - Director, commented, “BG's delivery of the plant on schedulewas not compromised by their impressive flexibility of design inaccommodating our specific requirements.”

Long Standing Experience

BG Europa (UK) Ltd have provided specialist drying plants for manyindustries, including dryers for aggregates, sand, slag, mineral, glass andrecovered aluminium. Dryer drums are designed specifically for eachapplication in either counter-flow or parallel design depending on theprocess requirements. SD Series Parallel Flow Dryer Drums are mated toSF Series Pulse Jet Fabric Filters to provide efficient low temperature dryingat just above dew point. These drums are used extensively within the slagand sand drying industries and therefore flight design and drumconstruction is targeted to provide long operational life given the highlyabrasive nature of these materials. A full turnkey package is availableincluding feed bins, conveyors, fabric filters, storage silos and all controls.Alternatively a dryer can be incorporated within an existing production setup to enhance production capacities and flexibility.

Drying drum ready for installation

Internal flights

Hub issue-23 - Oct 2012 16/10/12 14:34



Quarrying


Weir Minerals offers a wide range of vibrating screens. These screensmeet the needs of modern high capacity production plants in terms ofplant availability, space and energy savings.

Dewatering Screens incorporate a sloping back deck section, fitted withslotted aperture panels. Slurry is fed uniformly along the top of this backsection, which acts as a vibrating drainage panel. The main deck slopesupward at 3°- 5° and is fitted with slotted apertures.

Single and Double Deck Banana Screens represent a major innovation inscreening technology, with exceptionally high throughput per unitscreening area. Banana screens are a high capacity, high velocitymachine with low bed depth leading to greater efficiencies andthroughput by allowing quicker stratification of the material bed.

Single and Double Deck Horizontal Screens range from 0.3m (11' 7/8”)to over 4m (13' 1/8”) wide, and up to 10m (32' 7/8”) in length, andare popular in a variety of applications, including coal sizing and DMSdrain and rinse applications. Excitation is via twin out-of-balance excitersand screens may be fitted with modular rubber/polyurethane or woven/wedge wire media.

Vibrating motion for a screen is provided by means of out-of-balancemotors or geared exciters. Linatex® vibrating screens use high g-forcegeared exciters for machines 2.4m (7' 7/8”) and wider to provide thevibration motion required.

Weir Minerals™ has been a globalleader in the design, manufacture,installation and servicing of equipmentand solutions for the mining, sand andaggregates industries for almost acentury.Linatex® vibrating screens have a reputation ofbeing quality machines providing exceptionalscreen process performance for a wide rangeof applications. All Linatex® vibrating screensare supplied as linear motion units. Linearmotion allows for screens with a lowheadroom requirement and less pegging ofscreen media when compared with circular orelliptical motion screens. Using linear motionscreens results in a lower installed cost aswell as the ability to better control the travelrate across the screen, resulting in improvedscreen efficiency.

ScreeningTechnologyfrom WeirMinerals™


Nationwide delivery service availablefor all our crushers, screens fromjaws, cones, impactors, double deckand triple deck screens and trackedstockpiling systems.

Lickley Group Rental Fleet consists of:

Powerscreen XR400 Jaw CrushersPowerscreen XH320 ImpactorPowerscreen XH320SR ImpactorsPowerscreen 1000 Maxtrak ConesPowerscreen Chieftain 2100XTriple Deck ScreensPowerscreen Warrior 1400Telestack Tracked Stock Piling ConveyorsMetso 1315 Impactor Crusher

Telephone: 0845 450 9690 www.lickleygroup.co.uk

Lickley GroupNationwide RentalsUnit 6a, Clay Pit LaneBoroughbridge,North Yorkshire, YO51 9LSTel: 0845 450 [email protected]

Hub issue-23 - Oct 2012 16/10/12 14:34



http://www.lickleygroup.co.uk


Quarrying

PMW Quarries use new WarriorScreen to reduce landfill



Huddersfield based PMW Quarries,who have been trading as a familybusiness for 30 years and whosebackground is in aggregates &haulage, have recently takendelivery of a new screen fromPowerscreen Pegson Equipment.PMW have a disused quarry sitewhich they have been operating as alandfill for inert waste but havetaken steps to improve theiroperation with the addition of aWarrior 800.

PMW's facility takes waste from twosources - their own muck-away servicewhich operates 8 tipper wagons, andmuck and soil waste from other localoperators. The waste they receive isbeing crushed on-site by a crusherbucket and then screened by their new

Warrior 800 tracked heavy-duty screen which is currently operating with50mm fingers on the top deck and a 40mm mesh on the bottom deck.

The Warrior is ideally suited to this application as it has a highlyaggressive screening action for a machine of its size which produces agood standard of end product. Additionally, its compact size and itsmanoeuvrability mean that the machine does not take up too much roomon site and can be easily relocated to suit PMW's processing needs.

When asked about the benefits the Warrior 800 is delivering DannyWatson, Managing Director - PMW Quarries commented “The additionof the Warrior 800 has proved an excellent decision for two reasons.Firstly, it is helping to reduce the amount of material which we have totip which will increase the life of our landfill. And secondly, it providesus with saleable recycled soils and aggregates, therefore an additionalrevenue stream.”

Danny went on to add “We've bought Powerscreen machines in the pastand their build quality and operating performance was another reasonfor selecting the Warrior 800”.

Hub issue-23 - Oct 2012 16/10/12 14:34



Rapid International Ltd isdelighted to announce the NorthAmerican launch of their new fullyweighed mobile continuousmixing plant. TheRapidmix400CW is the newgeneration of this highlyacclaimed continuous mixing plantrange and North Americancustomers and Dealers alike wereeager to see the new modelarrive.

The Rapidmix continuous mixing plant isnow offering full weighing options for allmaterials - aggregates, cement andwater. Measurement by weight is acritical requirement of specifications andthe Rapidmix400CW offers recordkeeping that is automated, precise anddetailed.

The new Rapidmix400CW model nowincorporates a 1200mm belt conveyorbetween the aggregate hopper and thecontinuous mixing chamber. Theweighing belt is supported on load cellsand this measures the weight allowing thefeed rate of the aggregate to bedetermined. The new plant alsoincorporates a cement weigh system,using a rotary valve feeding a weighedscrew with twin outlets for discharginginto the mixer. The water is monitoredthrough using a flow meter.

Quarrying

RapidInternationallaunch new fullyweighedcontinuousmixing plant intoUSA

The first customer to take delivery of the new model wasRollcon LLC, located in Houston Texas. Rollcon is a premiercontractor that specialises in providing quality roller compactedconcrete (RCC) paving solutions for both public sector andprivate industry clients. Rollcon worked with Rapid USA Inc tofirst demonstrate the new machine, which has now been putinto action on the latest phase of the Port of Houstondevelopment, producing up to 400 tonnes of material per hour.

Rollcon LLC decided on the new Rapidmix400CW aftersuccessful use of its predecessor, the Rapidmix 400Ccontinuous mixing plant, on previous projects. Rollcon hasconfidence the Rapidmix mobile continuous mixing plant is keyto ensuring that Roller Compacted Concrete (RCC) projects arecarried out on time and within budget. It provides the mixingefficiency needed to evenly disperse the relatively small amountof water used in the mixing of RCC. Dump trucks then transportthe RCC and discharge it into a paving plant, which places thematerial in layers typically up to 10 inches (250 mm) thick and42 feet (13m) wide.

Port paving is really suited to Roller Compacted Concrete, dueto its superb strength. It is capable of standing up to massiveloads and specialised equipment. The machine can work on avariety of applications such as bentonite landfill sealing, damconstruction, contaminated soil stabilisation as well as cementtreated base for road construction.



Hub issue-23 - Oct 2012 16/10/12 14:34



Market leading Swiss manufacture ofmobile materials processing equipmenthas recently launched their newinnovative high performance GIPOREC R90 FDR GIGA Mobile Impact Crusher withclose circuit screening unit.Available through their exclusive UK andIreland distributor, Aggregate, Processing andRecycling Ltd of Tamworth the new machineoffers quality, durability, and productivity,providing throughput and the capacity for awide variety of applications. Weighing in at32 tonnes the versatile performer is of compactconstruction, low transport weight, and as withthe other GIGA plants, the plant distinguishesitself by its high flexibility with which the basicmodel can be expanded according tocustomer wishes. The new machine offers many benefits,including:• Large feed hopper with highly efficient pre-

screening• Folding feed unit allowing very good

accessibility • Straightforward operation, maintenance and

service

• Simple attachment and detachment of the screen unit• The return conveyor can be hydraulically swiveled 180° and can be

used as a stockpile conveyor. Suitable for small and medium crushing tasks the new GIPOREC R 90FDR GIGA can produce up to three screened sizes. GIPO impactcrushers have two impact walls and have infinitely variable adjustment ofthe rotor speed which simplifies the processing of the feed material. Theproven fully hydraulic actuation concept enables the machine to handlereinforced concrete, asphalt, building rubble, natural stone, coal andblast furnace slag.The extremely powerful GIPO impactor is equipped with a machinechassis with track-laying gear, power pack, feeding hopper, feederchannel with integrated pre-screen or separate pre-screening, conveyorfeed channel and crusher conveyor belt; the design of the feeder hopperincorporates fixed hopper walls allowing quick set-up.Powered by a Deutz 200Kw diesel motor providing an output of up to200 tph the GIPOREC R 90 FDR GIGA can be operated or transportedwith or without the post screening unit. Repositioning of the machine on-site presents no problems as it can be comfortably operated from awheeled loader or excavator with radio control.GIPO impactors also have a variety of additional equipment, sideconveyor belt, permanent magnet, extended radio control, belt weigherand water spray.

Gipo launch new R90 Mobile ImpactCrusher with close circuit Screen Unit


Quarrying


Hub issue-23 - Oct 2012 16/10/12 14:34



Mantovanibenne's UK importerINMALO has supplied two MBIdemolition attachments to HeavyDecom International for a majorcontract in Portsmouth Harbour, whereHDI is demolishing and removing theredundant UHAF Dolphin cranes. Thisdemanding task required demolitionworks to be undertaken both aboveand below the waterline and all theequipment was mounted onto a largebarge which is anchored andpositioned for the work to be carriedout.

HDI brought in “The Beast”, their 200 tonnesoperating weight Hitachi EX1200, which isideally suited to the job in hand. This largeexcavator had been totally rebuilt byKocurek of Ipswich to exacting specificationsprovided by Hardy Worsey of Heavy DecomInternational. This meant that the Hitachicould now carry an hydraulic attachmentweighing up to 8 tonnes if required, workingat a maximum height of 40 metres with afour-piece boom.

Two MBI attachments were provided byINMALO for the contract. A CR100hydraulic crusher for demolishing the Dolphinfoundations above and below the water andan SH900 hydraulic steel-cutting shear fordismantling and shearing the steel structuresof the old cranes into manageable sectionsfor recycling.

The CR100 is an 11 tonnes operatingweight twin-ram crusher which is making lightwork of the foundation structures. TheSH900 is a 10 tonnes operating weightshear, believed to be the most powerful in itsclass. This particular equipment was alsorecently used to dismantle a complete boatwhich had sunk off the Egyptian coast!

Heavy Decom International insists on usinghigh quality equipment backed by excellentafter sales service and INMALO prides itselfon delivering arguably the best attachmentrange on the market, combined withthoroughly professional product support.Commenting on the MBI demolition tools,HDI's Hardy Worsey said “Both attachmentshave proved their worth on this contract andthe CR100 in particular is an amazing pieceof kit with its 2 metres jaw opening andawesome crushing power”.

Quarrying

Mantovanibenneattachmentsaid docksidedemolition



Hub issue-23 - Oct 2012 16/10/12 14:34



Market Place

www.hub-4.com

Proven fuel costs and emission reductionRaising the standard in asphalt productionThe new burner range from Asphalt Burner Services Ltd

Contact [email protected] or +44 028 7930 1237 for more information.

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Rollers andDrives for allBulkHandlingapplications

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Customers world wide enjoying world class products

Screening…behind every passion there is a driving force – this is ours ..WS85

We aim to offer the most successful screens. Whilst constantly searching for new and better solutions we do not follow short-lived trends, but build on our experience.

TEMA Isenmann Ltd4 Great Central Way Woodford Halse Northamptonshire NN11 3PZTEL 01327 264227Email: [email protected]

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Leading supplierof quality crusherwear parts

T. 01352 732284www.instantcrusherspares.co.uk

162 Chiltern Drive, BerrylandsSurbiton, Surrey KT5 8LS

Tel: 0208 399 9991Fax: 0208 390 2004

email: [email protected]

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If you wouldlike toadvertise inMarket Place

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Hub issue-23 - Oct 2012 16/10/12 14:34

http://www.euroby.co.uk


http://www.temaisenmann.co.uk



http://www.hkprocess.co.uk

http://www.rulmeca.com


http://www.instantcrusherspares.co.uk


http://www.dustechengineering.com

Hub issue-23 - Oct 2012 16/10/12 14:34

hub magazine issue 23

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