Page 30 - Hub-4 Magazine Issue 80

Concrete Review
Fig 2. Teka TPZ1500 planetary mixer
Finding solutions within the batching plant and process
Across the concrete batch plant and the five stages of the production process, there are three key areas in which efficiencies can be made in terms of both carbon and cost; reducing raw material usage and waste, reducing power usage, and reducing maintenance interventions.
There are multiple solutions depending on the problems or requirements of the plant. By its very nature, the production process is full of bottlenecks, and it is these that are often hidden producers of waste.
For example, the practice of over-cementing is a significant contributor to CO2 emissions associated with the concrete production process. However, by switching from the ‘averaging’ method of measuring moisture in materials to Hydronix, one of the leading readymix producers was able to drastically reduce the requirement to over-cement at one of their plants, with an average reduction of 26kg of cement per cubic metre of concrete - equivalent to 1,413 tonnes of cement per year. This would save £185,000 and 1,030 tonnes of CO2 from cement reduction per year.
Alternatively, power usage is also an area where small improvements can lead to impressive savings in both cost and carbon emissions. In 2010, ConSpare replaced an energy intensive rotating pan mixer with a Teka TPZ1500 planetary mixer at a leading roof tile manufacturer. This resulted in 68,000 kWh of power saved per year, equating to 23.8 tonnes of CO2 per year and £40,800 per year.
Maintenance interventions are a third critical area where efficiencies can be made, bringing about significant reductions in downtime and spare parts. A renowned manufacturer of building materials in Scotland was using cast steel blades in their pan mixer, which required replacement after three months due to the abrasive nature of the aggregates used.
By providing the most effective equipment and smart maintenance solutions we can reduce material wastage, energy usage, and minimise spare part consumption at plant level.
Long-term economic growth cannot come at the cost of the planet. It is imperative that the concrete production industry finds a sustainable way forward through evidence-based solutions that are proven to reduce environmental impact and preserve our planet for future generations.
We believe the industry will work together as a coalition of change-makers to focus on the things that matter and drive as much carbon as possible out of the concrete production process as quickly as we can, however we can.
When replaced with Hawiflex polyurethane blades, these lasted three times longer, saving 342kg of CO2 per year and reducing component purchasing costs by 52%.
Therefore, by looking at the plant through the lens of carbon, targeted investment decisions can be made to ensure that concrete plant operators achieve maximum benefit, with process improvement and smart maintenance techniques used to reduce the emissions associated with production.
An obvious choice
It is not often that an industry has the obvious choice. From a business standpoint, all too often compromises must be made to achieve a set of aims. In this instance, however, reducing carbon from the concrete production process can realistically be achieved at the same time as reducing cost.
Fig 3. Teka TPZ mixing action
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www.hub-4.com May/June - Issue 80