Rock Products

SEP 2018

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Page 32 of 61

ROCK products • September 2018 • 31 Resolve Aggregates plant overview. The minus ¼-in. material is then sent to the sand washing element of the M4500 which is configured with a dual pass cyclone arrangement. The sand material is first delivered to two 25-in. cyclones where the first separation occurs. The material is then discharged from the cyclones to one side of an A-Se- ries VibroSync split dewatering screen before the coarse sand is stockpiled via a radial stockpile conveyor. A selected proportion of the material passes through the dewatering screen to the fine sand sump and is then sent to the Counter Flow Classification Unit (CFCU), which further facilitates den- sity separation by using an upward flow of water to carry lighter particles up while allowing the heavier particles to fall to the bottom of the CFCU tank. The material from the bottom of the tank is then delivered to the second side of the split A-series VibroSync dewater- ing screen and a 100-mesh to 18-mesh fine sand product is stockpiled via the integrated M4500 stockpile conveyor. Meanwhile, the lightweight material from the CFCU is delivered to an addi- tional EvoWash 71 sand washing plant where a 200 mesh to 100-mesh cushion sand product is stockpiled. The plant also includes an AquaCy- cle A600 thickener, which accepts all the waste water and minus-200 mesh fines. These are dosed with flocculants on entry to the tank, facilitating the settlement of the fine particles to the bottom of the thickener tank while the clean water overflows the peripheral weir and is recycled to the wash plant. The AquaCycle recycles up to 90 percent of the process water, which is ready for immediate re-use by the system. Water recycling presents substantial benefits when environmental considerations come into play, but also as the need for settling ponds, and therefore the time spent on their maintenance, is signifi- cantly reduced. "The modularity and compact foot print of the M4500 is an obvious plus and the time it has all taken to come together has been shorter than we would have thought possible," Newell said. "The quality of the equipment design and the strength of its manufactur- ing are truly remarkable as well, as is the precision with which the plant fits together," Newell continued. "Per- haps most importantly, the AquaCycle thickener greatly diminishes our fresh water requirements. Our current plant requires 6,000 gpm; the M4500 – although it uses approximately 2,600 gpm – requires only 300 gpm of new water." The Relocation The CDE methodology is based on a tailor-made service to clients, who are invited collaborate in the development of their installation. This means that each wet processing solution is cre- ated with the client's requirements at its core. In the case of Metroplex, a mod- ular approach was required to ensure that the high-efficiency, built-to-last installation would be used throughout its lifetime by relocating it from one site to another, therefore optimizing the company's return on investment. In 2017, at the end of the economic life of the Fort Worth quarry, Metrop- lex decided to replicate the successful production model at its newly acquired quarry in Ravenna, which is located 100 miles from Fort Worth. At the new site, operating as Resolve Aggregates, the plant is currently pro- ducing in excess of 100,000 tons per month of C33 concrete sand, #8 pea gravel, #57 gravel, C144 masonry sand and asphalt sand. When required, the plant also accepts crushed material directly to the feed boot from a trans- fer conveyor. STACKING

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