Page 27 - HUB-4 Issue 98

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The facility outputs five distinct washed products: fine sand,
coarse sand, and aggregates sized at 10mm, 20mm, and
40mm. This diverse product line caters to various construction
needs and enhances AR Aggregates' marketability. To ensure
the purity and quality of the aggregates, the wash plant is
fitted with a heavy-duty electromagnet that effectively
removes ferrous metals from the feed material before
washing, consequently enhancing the quality of the final
products.
Notably, the wash plant features spray bars that raise easily
on the pre-screen, simplifying access to the screen deck for
maintenance and ensuring optimal performance of the spray
nozzles. The main pump tank, which collects sand, silt, and
fine trash, is fitted with a self-cleaning system designed to
remove polystyrene and fine trash particles before the sand
plant, ensuring cleaner fine and coarse sand products.
Advanced Water Treatment System
Integral to the wash plant's operation is its expertly designed
water treatment system, engineered to handle high silt
content in the feed material. This system begins with dirty
water being processed through a high-frequency dewatering
screen to eliminate small trash materials before it reaches the
thickener.
Several innovations contribute to the efficiency of this water
treatment system. The dynamic thickener is a standout feature
of the system, capable of raising and lowering the rake to
produce a high-density, consistent sludge that is optimal for
filter press operations. It is equipped with an analyser to
measure the settlement rate of silt particles, automatically
adjusting the use of flocculent to maintain performance.
Additionally, it continuously monitors the overflow water to
ensure cleanliness, enhancing the overall efficiency of the
water treatment process.
In addition, the thickener employs a surface scraper that
efficiently removes any remaining fine trash material, thus
maintaining the cleanliness of the water treatment plant. The
clarified water then flows into a large steel holding tank fitted
with an agitation system that prevents sedimentation buildup.
This mechanism ensures that the clarified water can be reused
effectively in the wash plant, further aligning with AR
Aggregates' sustainability goals.
Automated Filter Press Operations
The thickened sludge is transferred to a large steel buffer tank
fitted with two stirrers to ensure uniformity in consistency.
From here, the sludge is pumped at high pressure to a cutting-
edge filter press equipped with 100 2m x 2m filter plates. This
system is designed for fully automated operation, featuring a
robotic mechanism that can quickly open filter plates in
batches of ten, shake them to release the filter cake whilst
also washing each plate for optimal filtration and extended
wear life of the filter cloths.
The automation of the filter press not only enhances
throughput but also significantly reduces operational
downtime, as there are fewer moving components prone to
wear. This advanced setup allows AR Aggregates to maintain a
high standard of performance in producing dry filter cakes,
which can then be repurposed effectively.
Environmental Benefits of Recycled Aggregates
Using washed recycled aggregates offers a multitude of
environmental benefits that directly align with AR Aggregates'
objectives. First and foremost, the transition to recycled
materials leads to reduced vehicle movements, which in turn
diminishes CO2 emissions associated with transportation.
Additionally, by reusing aggregates rather than excavating
virgin materials, natural resources are preserved along with
natural habitats and ecosystems.
Conclusion
AR Aggregates’ investment in the Tyrone International
wash plant and the accompanying water treatment
system exemplifies a commitment to innovation,
efficiency, and sustainability within the recycled
aggregates industry. By integrating advanced technologies
throughout their processes, AR Aggregates not only
enhances product quality but also pioneers
environmentally responsible methods in construction
material production. As the demand for recycled materials
continues to grow, such advancements position AR
Aggregates as a leader in the field, driving the future of
sustainable construction.
www.hub-4.com May/June - Issue 98
| p27 |