Page 46 - Hub-4 Magazine issue 68
P. 46

 PROMOTED CONTENT
“We’re recovering up to six new products
from heavily contaminated material.” Viv Russell - Longcliffe Quarries Managing Director
As independent, family owned Longcliffe Quarries fast approachesits milestone centenary celebrations, the company, founded in 1927, recently partnered with wet processing equipment manufacturer CDE to help realise its ambitious environmental objectives by unlocking value from its discarded quarry by-product, a significant waste stream at its Brassington Moor Quarry.
The Derbyshire-based business produces over one million tonnes of high quality calcium carbonate powders and granules every year. Quarried from pure limestone deposits, its calcium carbonate products are vital components in animal feeds and pet foods. Its powders and granules are also supplied into the glass, plastics, and pharmaceutical industries and many more.
“We are quite a wasteful industry,” remarked Longcliffe Quarries Managing Director Viv Russell, adding that the company generates “about 300,000 tonnes of waste per year.”
The materials processor, in an effort to strengthen its commitment to sustainability in the UK’s quarrying sector, sought to address the issue by investing in a state-of-the-art turnkey CDE wet processing solution. Previously discarded clay-bound material is now being processed through the wet processing plant at a rate of 220 tonnes per hour recovering up to six different products from heavily contaminated material and creating new, high-value revenue streams for Longcliffe Quarries.
High-quality single-sized aggregates and sand grades are among the key products being recovered which is maximising available reserves and supporting Longcliffe Quarries to realise its environmental targets by upgrading its low-grade quarry by-product into saleable resources which can be returned to the local construction market.
Longcliffe Quarries is committed to a sustainable future and its CDE solution is supporting the company to achieve zero-carbon quarrying operations by 2027. Already, 98% of its energy is generated by renewable sources. Its CDE wet processing solution, the single largest investment made by Longcliffe Quarries, has led to a significant 12% reduction in the quarry’s load and haul fuel usage by efficiently processing its clay-bound material. The company’s recent achievements in further enhancing its environmental footprint follows an almost 70% reduction in net emissions recorded at Brassington Moor Quarry since 2014/15. CDE operates a unique co-design approach which involved working closely with Longcliffe Quarries to design a customised wet processing solution tailored to meet its specified commercial and environmental objectives as well as integrating seamlessly with the existing equipment already on site.
Engineered to maximise product yield from heavy clay-bound feedstock, the resulting plant features an R4500 primary scalping screen; CDE’s signature AggMaxTM modular logwasher setup for scrubbing and sizing; CDE’s patented EvoWashTM classification and dewatering system; and an AquaCycleTM thickener for industry-leading water management.
Oversize product is fed into the R4500, the high-power conditioning system created to handle the most difficult and heavily contaminated material. This prescreening method removes the +90mm oversized material and classifies it for further processing. The AggMaxTM combines feeding, scrubbing, screening and sizing on one chassis. Suitable for a variety of material streams and across various industries, it maximises product yield from feed material producing a wide range of sand and aggregate products. CDE’s EvoWashTM fines material classification systems recovers and dewaters fines producing consistent graded sand products ready for market straight from the belts.
Central to the system and to addressing the availability of clean water at Brassington Moor Quarry is CDE’s AquaCycleTM thickener. It is supporting Longcliffe Quarries to maintain its environmental commitments by allowing for up to 90% of the process water to be recycled and recirculated back into the system.
Offering near-total independence from fresh water supplies, the CDE wash plant requires only a small top-up water supply resulting in a highly efficient system extending significant operational savings to Longcliffe Quarries.
In addition, the plant also features CDE CORE, a suite of smart technology tools that offers plant operators greater control over their plant and access to real-time data on how their plant is operating to maximise plant uptime and throughput.
The total solution delivered by CDE has exceeded expectations and is supporting Longcliffe Quarries to both maximise new commercial opportunities with its recovered sand and aggregate products and achieve its longer-term sustainability aims.
The materials processor is now processing high volumes of low-grade feed responsibly and efficiently, turning heavy clay-bound material into saleable products for the ready-mix and decorative markets.
Talk to CDE today about your processing needs - cdeglobal.com


















































































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