New Raymond Brown IBA Processing facility at Barton Stacey is a complete success.

The HUB recently visited the brand new Raymond Brown IBA processing facility at their A303 Enviropark site near Barton Stacey, Hampshire.

The new plant which processes over 100,000 tonnes a year of IBA was designed, manufactured and installed under contract by DUO Manufacturing (Division of DUO plc) over a period of four months, with testing and commissioning successfully completed in March 2015.

Lee Thompson – Operations Director – RB Aggregates, commented,”The household waste that previously used to go to landfill in Hampshire, is sent for energy recovery at the three ERFs (Energy Recovery Facilities) in Hampshire. The ERFs process non-recyclable household waste and recover energy from the incinerated waste to produce steam.  This steam is used to generate up to 38MW of electricity every year, which is enough to power over 53,000 homes. The technology sees waste burned at high temperatures under controlled conditions with the process producing Incinerator bottom ash (IBA). The IBA is then delivered to the A303 Enviropark site to be processed and recycled for use as sustainable aggregate within the construction industry.”

Raymond Brown has been processing IBA from the Hampshire ERFs for over seven years at a site near Ringwood. As part of the wider business strategy, the company relocated to the A303 Enviropark and designed and installed a new state-of-the-art processing plant. The new IBA plant is now processing all the IBA material delivered from the three ERF’s in Hampshire - Portsmouth, Chineham (Basingstoke) and Marchwood (Southampton).

IBA Processing

The unprocessed IBA is delivered to the on-site excavator which handles the ash into windrows where it is left to age for 6-8 weeks.

The aged IBA is then fed by front end loading shovel into a hopper with a variable speed belt feeder. It is then passed under a high powered overband magnet to recover large ferrous metals that are sent on for recycling.

The IBA is then fed into the 23 metre long, rotating trommel screen which is angled to process the material as it passes through the drum. All the -65mm material then passes through the screens whilst the larger material is delivered by conveyors to a picking station for further recycling. Here it is sorted with any oversize metals being removed alongside typical oversized brick and concrete which is then sent for crushing on-site and used as a recycled construction aggregate.

The -65mm material from the trommel is then fed onto a second incline conveyor and under a secondary overband magnet which recovers any smaller ferrous metals, before delivering material into the screen house and onto a large Binder screen. Here the material is split into three sizes, fine (0-5mm), medium (6-16mm), and large (16-65mm). The Binder screen starts where conventional screens become inefficient and less economical. Products that are damp or partially friable can block conventional screening applications, making efficient screening impossible. The Binder screen provides a simple solution to these challenging demands: a driving mechanism producing resonance provides two vibratory movements in which the flexible polyurethane panels are expanded and compressed in turns, and the hard-to-screen IBA is separated at high acceleration. The dynamically excited screen panels thus remain clear and allow efficient screening.

All the screened material is then delivered via respective conveyors over magnetic head drums to recover any residual magnetic materials. The three grades of material are then passed over a concentric Eddy Current Separator (ECS) to recover light and heavy non-ferrous metals which are then exported for recycling.

The three remaining grades of aggregate material are then sent to a radial collection conveyor where the blended material becomes a fully processed IBA aggregate (IBAA), which is used as a high performing sub base material for road construction or well graded granular fill material for embankments.

Adam Murnieks – Strategic Development Director (Raymond Brown), commented, “This facility at Barton Stacey followed our successful installation at Ardley in Oxfordshire. Plant design is similar to Ardley with the HUB of the plant being the very dynamic Binder ‘flip-flow’ screen, however, unlike that plant, this is situated outdoors on a larger footprint which allowed us to position the windrows differently.  This is another very efficient plant in our portfolio.”