Page 44 - HUB-4 Magazine Issue 99

Quarrying News
Building a Landmark Wash Plant
for Thorncliffe Building Supplies
Established in 1987, Thorncliffe Building
Supplies is one of the largest independent
builders' merchants in North Wales and the
North West of England. Alongside supplying
building materials, plant hire and waste
management services, the company operates its
own recycling facilities, continually investing in
modern processing technology to improve
efficiency, sustainability and the quality of its
recycled aggregate products.
For Thorncliffe Building Supplies, the investment in a new
aggregate washing facility marked a significant step forward
in expanding its processing capabilities. The aim was to create
a modern, high-capacity operation capable of producing
consistent, high-quality aggregates and sands, whilst
exercising highly efficient wastewater management.
To deliver the project, Thorncliffe Building Supplies partnered
with CRJ Services and their partners, Bruce Engineering and
Tecnoidea to design, supply, install and commission a complete
turnkey aggregate washing solution. Now fully operational,
the site combines high-performance aggregate washing with
advanced wastewater management technology, creating an
integrated processing system built for reliability and long-term
performance.
Designed Around Efficient Aggregate
Processing
At the heart of the installation is a Bruce Engineering wash
plant, configured to maximise production while maintaining
excellent material quality across a range of aggregate
products.
Material first passes through the Bruce Electric Scalper, where
oversized material is removed before the fines enter the
washing circuit. The Bruce BWR wash plant and BWS sand
plant then work together to wash, classify and recover
valuable aggregates, producing cleaner, more consistent end
products ready for stockpiling. The plant is capable of
processing up to 80 tonnes of material per hour, producing up
to 70 tonnes per hour of saleable products.
Supporting the washing circuit is an extensive network of
conveyors, including a 38-metre lattice conveyor, radial
stockpile conveyors and purpose-built transfer conveyors that
efficiently move material throughout the process. The conveyor
system has been designed to optimise material flow while
reducing unnecessary handling, helping improve productivity
and operational efficiency.
The installation also incorporates purpose-designed walkways,
access platforms and a dedicated control cabin, providing safe
access for maintenance alongside centralised control of the
washing process.
Integrated Water Treatment for Sustainable
Operation
A key feature of the project is the integration of a Tecnoidea
water clarification system, ensuring wastewater management
forms a core part of the overall washing process.
Aggregate washing relies heavily on water, making efficient
recovery and reuse essential for operational efficiency. The
Thorncliffe installation incorporates a complete Tecnoidea
clarification plant, including a high-capacity clarifier, lime silo,
vertical stocking tank, water drip tray and automated filter
press.
As process water leaves the washing plant, suspended solids
are removed through clarification before sludge is transferred
to the filter press. Here, material is compressed into a
dewatered filter cake, making handling and transportation
easier. Meanwhile, recovered water is returned to the washing
circuit for reuse.
Around 90% of process water is recovered and recycled,
reducing the site's requirement for fresh water by
approximately 90% and helping to minimise overall
consumption.
The result is a closed-loop water management system that
supports continuous production while improving resource
efficiency.
The completed installation represents one of the largest wash
plant projects undertaken by CRJ Services in recent years,
bringing together multiple processing stages, extensive
conveyor infrastructure and a sophisticated wastewater
treatment system.
| p44 |
www.hub-4.com July/August - Issue 99