Rock Products

JUL 2019

Rock Products is the aggregates industry's leading source for market analysis and technology solutions, delivering critical content focusing on aggregates-processing equipment; operational efficiencies; management best practices; comprehensive market

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Page 22 of 79 ROCKproducts • July 2019 • 21 and maintenance. This maintenance was becoming increasingly difficult, with the settling ponds needing cleaned seven days a week – their productivity depended on how quickly this cleaning could be done and much of the site's real-estate was locked up in these ponds. Recovering lost fines would involve reprocessing the waste material, resulting in signif- icant operational costs through double handling and downtime. Collier needed an innovative solu- tion that would deliver results. CDE's technology guaranteed to maximize productivity through water recov- ery and retention of sand, therefore improving the quality and quantity of production whilst mitigating issues related to ponds. Collier added, "In making the change, it was important that we worked directly with the manufacturer. CDE's team of local experts took the time to truly understand our site and needs, working with us to deliver a smarter, integrated solution. We knew they were the team we wanted to engage and the process of working together has exceeded both our expectations and their promise, extending right through to after-sales care. "We knew CDE could deliver our outputs while championing a more sus- tainable way of achieving that – they're the wet processing and washing experts promoting a 'New World of Resource.' Sustainability is also important to us; sustainability of our resources and of our business," Collier said. "We use smart washing solutions to optimize our natural resources in a more effi- cient way. We realize that, amongst other business priorities, there's a need to go in a more environmentally friendly direction." Raw Feed Analysis Thomas Wick explained, "Prior to start- ing work on the design of the plant, CDE had an initial visit to the George- town site to establish the causes of inefficiencies, followed by an analysis of the site's raw feed at CDE's laborato- ries to ensure the mass balance would be developed for maximum plant performance." The design and engineering teams were then able to work from a com- prehensive brief to develop the most efficient solution for the George- town site. This 'engineered to order' approach is how CDE prefers to part- ner with their customers. Wick says that after a thorough pro- cess, "A cyclone-based CDE EvoWash 251 wet processing plant was identi- fied as the most efficient system to deal with the Georgetown site's clay bound limestone material." The plant has a production capacity of up to 250 tph and is calibrated to pro- duce in spec and consistent ASTM C-33 grade sand, as well as by-product "grit" sand simultaneously, to turn the excess of 4-8 mesh into a sellable product. The efficiency of the plant is opti- mized using a waste water treatment unit, a CDE AquaCycle thickener, which allows recycling of up to 90% of the water used via a system that set- tles the solids from the dirty water in a controlled environment and expels sludge into the nearby settling ponds. This is ideal for businesses that don't have readily available water supplies. The process water, after passing into the deaeration chamber and having the flocculant added, passes gently to the center of the thickener so that the flocculant can work and act on the sedimentation of the fine material. Pond Space With a capacity of 6,600 gpm, the AquaCycle allows Collier Materials to bring pond space down to a fraction of its original footprint as 10 times less volumes of waste sludge are sent to ponds in comparison with the previous installation. CDE recognized that with the correct design of the system, along with the correct amount of water in the system,

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