BULK MATERIALS HANDLING • POWDER HANDLING • QUARRYING • RECYCLING & WASTE MANAGEMENT AUGUST 2022 DUST CONTROL • RECYCLING • SIEVES, SIFTERS, SEPARATORS & SCREENING 4 Flexicon expands quick programmeship 10 DustDowndraftModu-Kleen®SeriesCollector HIGHLIGHTS: 20 ProblematicSeparating Metal at 2022POWTECH FULL ARTICLE ON PAGE 16 BEDROCK PLANT HIRE LTD DIVERTS 70-80% FROM LANDFILL WITHIN ONE YEAR OF CDE PARTNERSHIP
Less degradation Move your dry granular materials gently, reliably and with significant reductions in product degradation and/or system wear. Proven capability Dynamic Air dense phase pneumatic conveying systems have been proven in over 15,000 installations worldwide. They handle a wide range of materials and bulk densities at rates from less than a hundred kilograms per hour to 400 tonnes per hour, over distances exceeding 1500 metres. Sixteen concepts Each Dynamic Air system is custom designed from one of our sixteen different conveying concepts. So you get a conveying solution that fits your process perfectly, without compromises. The Smart Way to Unload, Convey, Weigh & Mix UNLOBULKBULKBUSTERTMBAGADER HOSEMANUALSWITCHVIBRA-JET ® AERABINTOR HOPPERWEIGH BELLA®TWINSHAFTFLUIDIZEDZONEMIXER TRANSPORTER LINECONVEYING RECEIVERSWITCH BABAGBUSTER®GBREAKERBLENDCON®SILOBLENDERBLENDCON®AIRBLENDINGHEADDYNA-SLIDETMHIGHPRECISIONAIR-ACTIVATEDFEEDER GYROTM BIN FEEDERACTIVATING STORAGESILO STORAGESILO STORAGESILO FILBINMODU-KLEEN®VENTTER BULKBAG BellaTM Twin Shaft Fluidized Zone Mixer GYRO EXTM Bin Activating Feeder BulkBusterTMBulkBagUnloaderDense Phase Transporter, J-Series Cost effective Our high material-to-air ratios reduce energy and compressed air requirements. Our low conveying velocities provide significant process savings in both operation and maintenance. Initial cost is surprisingly affordable too, thanks to our modular design concept and ease of installation. Dynamic Air Ltd. Milton Keynes United Kingdom Phone: +44 (0) 1908 622344 E-mail: sales@dynamicair.co.uk www.dynamicair.com
Bulk Solids Today 3 BST TEAM www.bulksolidstoday.co.uk Sales Director: James Scrivens Production: Sarah Daviner Accounts Manager: Avery Hudson Office Manager: Katie Brehm BULK SOLIDS TODAY is published 6 times a year by Abbey Publishing Ltd ADVERTISING & EDITORIAL Please contact us at: Tel: 01933 316931 Email: advertising@bulksolidstoday.editorial@bulksolidstoday.co.uk co.ukWeb: www.bulksolidstoday.co.uk Twitter: reproducedNosubs@bulksolidstoday.co.ukpleaseToCIRCULATIONBulkSolidsTodaywww.twitter.com/receiveacopyfreeofcharge,sendyourdetailstopartofthispublicationmaybebyanymeanswithout prior permission from the publishers. The publishers do not accept any responsibility for, or necessarily agree with, any views expressed in articles, letters or supplied AllISSN:advertisements.1365/7119contents©Abbey Publishing Ltd 2017 CONTENTS Issue 156 4 NEWS 14 COVER STORY 16 DUST CONTROL 20 SIEVES, SIFTERS, SEPARATORS & SCREENING 22 RECYCLING & WASTE MANAGEMENT
FLEXICON EXPANDS QUICK SHIP PROGRAMME
COMPANY NEWS Bulk Solids Today4 Bulk Bag Dischargers are available as BFF models requiring forklift loading of bags, and BFC models with cantilevered I-beam, electric bag hoist and trolley. Both include FLOW-FLEXER™ flow promotion devices and can be paired with QUICK-SHIP models of flexible screw conveyors. Bulk Bag Conditioners are equipped with opposing hydraulic rams and contoured conditioning plates, and a programmable scissor lift with turntable, for conditioning bags on all sides at all heights.TheQUICK-SHIP programme continues to offer FLEXICON Flexible Screw Conveyors, with tubes and screws supplied in any length from 1.5 to 12 m in diameters from 67 to 114 mm OD, with a stainless steel floor hopper, 45 or 90 degree discharge adapter, IP55 or IP65 geared drive units and IP65 control panels.Allequipment is constructed of carbon steel with stainless steel product contact surfaces, with the exception of polymer conveyor tubes.The company also manufacture custom configurations of flexible screw conveyors, bulk bag dischargers, and bulk bag conditioners, as well as tubular cable conveyors, pneumatic conveying systems, bulk bag fillers, www.flexicon.co.uk374710,Flexiconautomatedwidesystems,weightippers,drum/box/containermanualdumpingstations,batchingandblendingandengineeredplant-bulkhandlingsystemswithcontrols.ForinformationcontactEuropeLtd,+44(0)1227sales@flexicon.co.uk,
Popular models of Flexicon’s BULK-OUT® Bulk Bag Dischargers and BLOCK-BUSTER® Bulk Bag Conditioners have been added to an expanded QUICK-SHIP programme that offers bulk handling equipment on a rush basis from stock throughout Europe. To subscribe to Bulk Solids Today magazine or for more information, please feel free to visit www.bulksolidstoday.co.uk
WE DON’T DO A HUNDRED THINGS. WE DO ONE THING RIGHT! THE 6X ®. OUT NOW! We have known this for over 60 years. That’s why this new radar level sensor is not available in 100 different versions, just one perfect one. The VEGAPULS 6X is highly versatile, absolutely reliable and works in any process and environment. The only thing it doesn’t do is stress. VEGA. HOME OF VALUES. www.vega.com/radar
Michelin says the course lays the foundation for training excellence internationally and is hoping to roll it out across Europe.
MICHELIN EYES EUROPEAN ROLLOUT FOR NEW MATERIALS HANDLING TYRE TRAINING COURSE
Formalised through the National Tyre Distributors Association (NTDA) Accreditation scheme and recognised by City & Guilds, the Licensed Commercial Tyre Technician Category 2 – Specialist & Multi-Wheel course, places a big emphasis on practical training, with nine assessments for each attendee to pass.MTIC Training Instructor, Dave Womble, says: “We had previously only trained technicians to work on pneumatic materials handling tyres, but we needed to include the removal and fitting of solid elastic resilient tyres as well, including divided and multi-piece wheels that require a hydraulic press. This is a new area for us in terms of training, and we have risen to the challenge.”
• Michelin training course for technicians working with materials handling equipment sets a new benchmark for the industry • Programme with practical emphasis is being run for Camso technicians and offered to others outside the Michelin Group
Michelin has built a specialist ‘press room’ within MTIC to support the new training, providing a bespoke practical learning environment for visiting technicians, including a mock forklift chassis. It has also invested in specialist tooling technology and the centre’s own tyre press.
The new course replaces a previous Camso training programme which had been validated by the British Industrial Truck Association (BITA), but which was only available to the company’s own tyre technicians.
Michelin has launched a dedicated training programme for tyre technicians responsible for keeping fleets of forklift trucks and other materials handling equipment on the move. The Michelin Training and Information Centre (MTIC) in Stoke-on-Trent is running the new materials handling tyre fitting course, which also embraces management of solid wheels.
MTIC is running the course for Camso technicians and offering separate courses for technicians from outside the Michelin Group. Wayne Mapson, EU Service Development Manager for Camso, says: “The course really serves to differentiate us from the competition and allows us to demonstrate that we’ve taken our health and safety focus to a whole new level. “On occasions in the past, the Solideal On-Site Service Division had been unable to operate at certain big blue-chip sites – but with our NTDA-recognised training, we can now prove we’re following the very highest industry standards.”
COMPANY NEWS Bulk Solids Today6
The decision to launch the programme follows the complete integration of speciality tyre and wheel business Camso into the MichelinWombleGroup.adds: “We have developed a training syllabus which is significantly improving the expertise of Camso’s Solideal On-Site Service Division – the team responsible for keeping large fleets of materials handling equipment on the move – and has much wider appeal to the industry too.”The three-day course focuses on a number of key areas: tyre construction and sidewall markings, types of materials handling tyre, wheel recognition and measurement, safe inflation procedures of pneumatic tyres, practical assessments of all tyre and wheel combinations, as well as hydraulic trailer press safety checks, and health & safety.
DON’T NEGLECT THE ESSENTIAL HAND PALLET TRUCK
COMPANY NEWS Bulk Solids Today 7
Toyota has developed a dedicated national team of Hand Pallet Truck Specialists specifically to keep these vital workhorses safe and performing to the highest standards at all times. Our dedicated team of Hand Pallet Truck Specialists operate nationally to enable preventative maintenance, safety inspections or repairs that are required to be carried out quickly and efficiently. Whether you use a single hand pallet truck or several across multiple locations or at one site, Toyota’s dedicated team will ensure that your productivity remains high by arranging and undertaking a regular servicing and maintenance plan that fits your precise needs and work patterns.Hand pallet trucks must be routinely inspected and maintained to comply with health and safety regulations. Specialists ensure that customers are operating in accordance with all the relevant regulations, including Provision and Use of Work Equipment Regulations 1998 (PUWER 98) Regular maintenance is also essential for the safety of your workforce and a robust service programme will identify any potential issues that may compromise the safety of the hand pallet truck and its operators. It will also reassure your team that the equipment they are using is in the best possible condition. A structured service schedule from Toyota provides cost transparency and, because fees are agreed up-front, budget forecasting becomes far simpler. Toyota’s ‘Pallet Truck Plus’ is a hassle-free hand pallet truck rental option with low monthly costs on a two-year agreement. While a strict servicing and regimemaintenanceisthe best way of durability,inhighestLiftermodelsinon5-yearforkguaranteeyearcomesMaterialtrucksrangeSweden,productionatefficiency.operationalinalsobuildcanaand-significantpreventingdowntimewithallthecostdisruptiontobusinessthatmean-truckqualityisamajorfactormaintainingManufacturedadedicatedfacilityintheBTLifterofhandpalletfromToyotaHandlingwitha99-functionalontheframeandaguaranteethepumpunit.Withtheirbuilt-sustainability,intheBTrangesetthestandardshandpallettruckstrength and performance. Capable of lifting and moving loads weighing up to 2.3 tonnes, in work-cycle tests BT Lifter HPTs have been shown to deliver optimum performance for up to five times as long as other trucks on the market. But, importantly, Toyota’s HPT Specialists are trained to work on any make of hand pallet truck –not just Toyota models – which is essential for those customers that operate mixed fleets. Furthermore, to keep downtime as well as costs to a minimum Toyota’s Specialists carry out maintenance work at yourTakingfacility.truck maintenance seriously means that any potential problems can be identified before they become more serious and, over time, this not only helps to extend the performance and life of your trucks, but also protects the wellbeing of your team.
Designed to make moving palletised loads easier, safer and faster, manual hand pallet trucks – sometimes referred to as HPT’s, pump trucks, pallet jacks or pallet lifters – play a key role in countless warehouses, retail outlets and manufacturing sites all over the world.But it can be all too easy to take these humble, apparently simple pieces of equipment for granted. As a result, some companies do not realise the extent to which their operation relies on their hand pallet truck until they find themselves without it due to a breakdown.Weallknow the frustration and stress arising from delays to the production process or hold-ups in the supply chain caused by the failure of materials handling equipment, but when essential tools that are in nearconstant use, such as hand pallet trucks, malfunction it is not only a company’s ability to meet deadlines that suffers. A business’s reputation can be negatively impacted too – and that usually leads to reduced profitability.
Unlike other valves that seal with friction, Posi-flate’s unique butterfly valve uses an inflatable seat to seal with air pressure. Thus it requires less torque and a smaller actuator, resulting in lower cost. Plus, the seat automatically compensates for wear, providing longer life. Some users have reported over six million cycles and the valves are still going strong. Tel: +44 (0) 1908 622366 www.posiflate.com
Other Valves Fight Friction, We Designed it Out • Less friction • Low torque • Low maintenance • Lower actuator costs • Longer valve life • More reliable
AGGREGATE INDUSTRIES LAUNCHES REDUCED CARBON ASPHALT, FOAMIX®
Leading construction materials supplier, Aggregate Industries, has launched a reduced carbon asphalt that is 100% recyclable and ideal for the construction, repair and maintenance of new or existing highways. Foamix® offers a truly sustainable solution for base and binder course layers, and is suitable for use in highways, footways and haunching works. Foamix – a cold-mix asphalt that does not require its source materials to be processed with heat – delivers significantly less CO2 compared to standard asphalt products. There is no compromise on performance, giving equivalent bearing capacity to standard asphalt, with a proven track record for increased cohesion and strength. Containing 92% recycled materials, including 85% reclaimed asphalt pavement (RAP), Foamix® promotes a circular economy approach to road construction by reducing the requirement for virgin aggregates. It can be manufactured on site where construction is taking place using Aggregate Industries’ Sitebatch Technologies® mobile mixing plants, meaning the team can reprocess locally sourced planings from the existing road asset – either on site or at a nearby location – ensuring Foamix can be placed, compacted, and put into immediate use. This significantly minimises HGV movements across the local road network, construction times, user disruption and delivers a significantly lower scheme carbon footprint. What’s more, Foamix can be laid in one single lift up to 150mm thick using conventional surfacing equipment and laying techniques and does not require any additional specialist labour. Foamix is being launched under Aggregate Industries’ newly established Surfacing Solutions team, which combines the expertise of the contracting and asphalt divisions to offer contractors and specifiers a whole-chain approach to product specification.
COMPANY NEWS Bulk Solids Today8
Foamix has already been used as part of a comprehensive suite of materials on the UK’s first carbonneutral specificationpavementHighwaysAmeycollaboratedexperts,forsaferstrategydesignedHoltA590£8mpartTheHoltjunctionbetweenconstructionhighwayschemetheM6,36andBrettarghroundabout.worksformedoftheestimatedawardwinningBrettarghscheme,whichwaswithalowcarboninmindtodeliverandsmootherjourneysroadusers.AspavementAggregateIndustrieswithAEYates,ConsultingandNationaltoengineeradesignandmaterialthatwouldunlock
Thomas Edgcumbe, Managing Director for Surfacing Solutions at Aggregate Industries, said: “We’re delighted to be able to expand on our range of low carbon products with the launch of Aggregate Industries’ reduced carbon asphalt, Foamix. “Made of 92% recycled materials and 100% recyclable, Foamix is manufactured to provide a cost-effective and highly sustainable solution that promotes a circular economy approach to road and pavement construction. As a business we’re committed to providing materials and solutions that assist in the immediate and sustained action as we transition to a more sustainable construction industry. We are changing the way we construct and the launch of Foamix is yet another step towards that goal.”
significant carbon reductions and cost benefits utilising Aggregate Industries’ bespoke ex-situ cold recycled Foamix solution. For more information on Foamix®, visit www.aggregate. com/foamix. For more information on Aggregate Industries, visit www.aggregate.com.
COMPANY NEWS Bulk Solids Today 9
COMPANY NEWS Bulk Solids Today10 The Modu-Kleen® downdraft dust collector represents the latest dust collector technology developed by Dynamic Air to contain fugitive dust. With the new Modu-Kleen downdraft dust collector, the air enters at the top of the dust collector housing and flows downward to the cartridge filters, improving the filtering process and the material-to-air ratio. Air velocities are much lower than those with a conventional dust collector, reducing the load on each filter cartridge and extending filter life. Cartridge filters are positioned horizontally, requiring less floor space and making filter removal easier. Personnel never have to enter the filter housing for general maintenance or for cartridge filter removal. This provides a much safer and quicker method of filter removal. For fast and easy inspections, a large, quick-opening door allows
MODU-KLEEN® DOWNDRAFT SERIES DUST COLLECTOR
maintenance personnel to closely inspect each cartridge when required. In addition, any single cartridge can be removed without disturbing adjacent cartridges. Also, each cartridge filter has a unique built-in quarter turn bayonet mount, so no tools of any kind are required for cartridge dustcollector681.htmlremoval.https://www.dynamicair.com/products/ Dynamic Air Ltd. Milton Keynes, United Kingdom +44 www.dynamicair.comE-mail:1908-622344sales@dynamicair.co.uk
COMPANY NEWS Bulk Solids Today 11 If you would like to subscribe to receive a regular copy of the digital edition of Bulk Solids Today magazine, you can subscribe on our website detailsTodayadvertisingwww.bulksolidstoday.co.uk-IfyouareinterestedinwithinBulkSolidsmagazineorsupplyingeditorialcontent,pleasefeelfreetogetintouchusingtheonourwebsiteorbelow.BulkSolidsTodayissenttoourdigitalreadershipofover9,000ChiefEngineers,OperationsManagersandTechnicalManagersfromwithinsectorsincludingChemicals,Food&Drink,Mining,Quarrying,Transport/Distribution,Recycling&WasteManagementandmore.www.bulksolidstoday.co.ukbst@abbeypublishing.co.uk Tuf-Lok (UK) Tel: +44 (0) 1706 822512 Email: sales@tuflok.co.uk • www.tuflok.com Tuf-Lok ring grip pipe and tube couplings are rugged, heavy duty, self-aligning and self-grounded couplings with a high end pull. They can be used for almost any application where pipe or tube ends need to be connected. The Tuf-Lok self-aligning couplings install quickly and easily with little effort. Features • Self-aligning • Self-grounding • High pressure rated • Full vacuum rated • Stainless or mild steel • Usable on thin or thick wall pipe or tube • Low cost • Reusable • Absorbs vibration • Externally leakproof
The Posi-flate Series 585/586 butterfly valves are designed for the most the most severe of applications. They are ideally suited for very abrasive materials which can reduce valve life. The inflatable seat design provides a better seal by utilizing air pressure to expand the seat against the disc, providing more sealing area and an even pressure distribution against the disc every time. The seat whencompensatesautomaticallyforwearitinflatesagainst the disc, extending valve life considerably.Becausethe Posiflate disc only makes casual contact with the seat during opening and closing, torque requirements are substantially lower. This ease of movement also allows the disc to come to a perfect 90-degree position every time. Additionally, the smooth profile of the disc helps material flow easier and reduces build-up. For unique switchmonitoring,fail-safeapressurecanbeutilizedto verify a perfect seal. The Posi-flate 585/586 butterfly valves are available in a wide variety of construction materials including stainless steel and lightweight products/585.htmlhttps://www.posiflate.com/aluminum.
COMPANY NEWS Bulk Solids Today12
Posi-flatebelow: Milton Keynes, United Kingdom + 44 1908 622366 E-mail:www.posiflate.comsales@posiflate.co.uk
Posi-flate 585/586 butterfly valves feature seats and discs for application pressures up to 10 bar. The design improves on existing 485/486 seats to provide the same incredible valve life at even higher pressures. The 585/586 valves are designed to fit PN 10 flanges, and come in sizes 80mm to 600 mm.”
For more information or to get in touch, please use the details
HEAVY DUTY BUTTERFLY VALVE
COMPANY NEWS Bulk Solids Today 13
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Tuf-Lok UK Phone: +44 (0) 1706.822512 E-mail: www.tuflok.comsales@tuflok.co.uk
Tuf-Lok ring grip couplings are low cost, heavy-duty self-aligning couplings for either high pressure, to 150 psig, or full vacuum rated applications. Utilized in all industries where pipe ends need to be connected, they are ideal for pneumatic conveying systems as well as gas and liquid applications. These couplings install quickly and easily, reducing installation costs. They are available in 2-inch (50mm) through 10-inch (250mm) pipe sizes and are made for use on plain end pipe or tube, regardless of pipe or tube wall thickness..Other features include self-grounding, vibration resistant, leak-proof, with an extremely high end pull for difficult applications. No machining or grooving is required to maintain pipe integrity. Every coupling becomes a union, providing easy, low-cost maintenance when piping components need replacement. Standard gasket materials are available to meet special design conditions, such as food grade, higher temperatures or special chemical resistant applications.
New plant is processing 1,000 tonnes per day
Bulk Solids Today14 ON THE COVER
The project was Bedrock’s first in partnership with CDE, and its first venture into wet processing. Previously, with dry processing operations, the company was crushing and screening to produce only a low-value fill, restricting its ability to market quality recycled aggregates and minimise its environmental footprint.Theteam at Bedrock reached out to CDE due to the company’s strong reputation in Scotland – particularly within the central belt – for its technical expertise, customer relations and results-driven solutions. Accompanied by CDE business development manager Garry Stewart, Bedrock representatives visited several CDE reference sites in the local market, including Brewsters and Brocklebank. Here, the Bedrock team had the opportunity to hear firsthand experiences from existing customers operating CDE technology which proved highly influential and reinforced Bedrock’s decision to partner with CDE.
Established in 2002, Bedrock Plant Hire Ltd originally specialised in plant hire for a range of customers in construction and utilities across Scotland’s central belt. Sustained business growth led to the requirement for a landfill site with screening and crushing operations. Due to capacity and a drive to enhance their sustainability, Bedrock engaged with industry experts CDE to install a construction, demolition and excavation (CD&E) waste recycling plant at its Glasgow site, which created further opportunities for the company within the recycled aggregates market. Expanding upon the services offered by the familyrun business, Bedrock wanted to build upon its strong working relationships with some of Scotland’s premier companies and offer a one-stop shop for plant hire and aggregate recycling.
The 80tph CD&E waste recycling facility delivered by CDE consists of an R1500 primary scalping screen, AggMaxTM 83SR logwasher, a dual pass EvoWashTM sand washing fine material classification plant and AquaCycleTM A400 thickener with Flocstation.Itwasdeveloped with the intention of reducing the volume of waste destined for landfill, turning it and other low-value material into
INVESTING WITH CONFIDENCE
CD&E waste is in abundance in Glasgow as the city is regenerated, with new commercial and residential developments replacing older projects, meaning the demand for recycled aggregates has increased significantly. In late 2021, the eyes of the world were on Glasgow as 15,000 people and world leaders descended to partake in the UN Climate Change Conference (COP26), tasked to accelerate action towards the goals of the Paris Agreement and the UN Framework Convention on Climate Change. It was during this global summit the installation of the CDE plant in Polmadie was nearing completion. Thirty minutes from the important discussions taking place in the SEC Centre in Glasgow, Bedrock Plant Hire was doing its part to move towards a more sustainable future, a circular driven economy and the protection of virgin materials.
CARBON REDUCTIONFOOTPRINT
BEDROCK PLANT HIRE LTD DIVERTS 70-80% FROM LANDFILL WITHIN ONE YEAR OF CDE PARTNERSHIP
For more information about CDE wet processing solutions, visit cdegroup.com.
15 ON THE COVER
The site at Polmadie is very compact and situated in a highly industrialised area in close proximity to large residential neighbourhoods. Due to its urban setting and limited site footprint, Bedrock required a closed-loop system capable of recycling the process water and eliminating the need for settlement ponds.
The company has its sights set on the future with plans to increase capacity, as Joe McHugh, director of Bedrock Plant Hire Ltd explains.
Bulk Solids Today profitable, saleable recycled aggregates. The R-Series allows for a constant, even flow of material to be delivered to the integrated screen before being sent for additional screening, washing and sizing. The pioneering AggMaxTM modular logwasher incorporates aggressive attrition of conglomerates to release sands through scrubbing and organics removal, as well as recovering fines and removing filtrates.
Proven solutions from CDE provide maximum recycling potential and full water treatment, achieving considerable reduction in waste-to-landfill volumes. Indeed, since commissioning, the plant has led to a decrease in the quantity going to landfill by 7080% as 1,000 tonnes have been processed per day, creating 700 tonnes of saleable material. The investment has also opened new revenue streams for Bedrock through the outputs generated, with eight variations of high-quality recycled aggregates being produced for sale and use in the construction industry. They include 0-2mm, 4-10mm and 40-100mm rinsed oversize. Bedrock is also delivering drainage stone (1020mm) to the construction sector, as well as pit and utility sands for concrete. The aggregates will also be used for cable bedding and pipe bedding.
With the plant processing 1000 tonnes per day, the filter press deals with approximately 20-30 tonnes per hour of sludge to produce a dry cake from the silt and clay generated from the washing process. This cake product is used as a capping material for circularitmaterialotherinvestigatestheownBedrock’slandfillwhilecompanyusesforthetobringbackintotheeconomy.
“WE WISH WE HAD BEEN ABLE TO DO THIS 10 YEARS AGO”
PROCESSING 1,000 TONNES PER DAY
“We are proud to be part of Bedrock’s journey towards a more sustainable business model and look forward to working with its team to strengthen its position within the market in Glasgow.”
“Our experience with CDE has been extremely positive. We visited other reference sites and hearing the endorsements first-hand from existing and satisfied CDE customers was reassuring that we were indeed making the right decision on such a significant investment.“Theteam were always managing our expectations while sharing our vision. We found them easy to work with and the bespoke, compact structure of the plant is first class and unique to our requirements. We have hopes for the future that this will only be the first plant we collaborate with CDE on, especially with the relationship we are building together.”GarryStewart adds: “It has been a pleasure to work with Bedrock, a family business focused on building a sustainable future through strategic investments. It felt particularly poignant as the final stages of our project came at such a significant time for the city of Glasgow, as it played host to global climate summit COP26.
“We wish we had been able to do this ten years ago. The technology has changed remarkably in that time and CDE is at the top of its game when it comes to wet processing and waste recycling. We really see these areas as a defining part of Bedrock’s future.
CDE’s dual pass EvoWashTM employs tried and tested modular hydrocyclone technology, offering unparalleled control of silt cut points with two washes. It enables Bedrock to produce a much cleaner, in-spec product and guarantees a fast return on investment within Glasgow’s construction industry. Meanwhile, the AquaCycleTM high-rate thickener recycles up to 90% of the process water for immediate re-use. Garry Stewart says: “Reducing Bedrock’s environmental footprint was a driving force in the decision to invest in a CDE waste recycling plant. The Bedrock team were conscious of the tricky materials to be processed and had full confidence in the capabilities of our technology due to our commitment to engineering excellence and our comprehensive analysis of their raw feed, the results of which informed the development of the plant.”
CDE’s water management expertise, realised through the combination of a A400 AquaCycle coupled with a P15 filter press ensured Bedrock’s vision was feasible.
Whether to prevent product loss or avoid health risks for operatives working in your production facility, managing and controlling air-born dust particulate is vital whenever bulk solids are handled. It is essential to control respirable dust to prevent health hazards for your operatives and should be regarded as a priority. Correctly designed dust control or LEV (Local Exhaust Ventilation) will protect your employees and ensure your production and processing facilities comply with legislation.
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Apart from preventing the issues of workers being exposed to hazardous dusts and product loss, uncontrolled airborne contaminants can:
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• Produce cross contamination issues to a production process Increase worker absenteeism Reduce equipment reliability leading to an increased level of breakdowns Increase the combustion risk within a production facility Increase the plant cleaning requirement Create additional slip hazards Increase the risk of costly litigation both in the short and long term These issues can all be addressed with correctly designed LEV, helping to provide a safer environment in which to work, protecting both businesses and employees.
•
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• Understanding how much dust is created. This includes determining the plant operation (e.g. is production 8hr per weekday or 24 hr production 7 days per week, etc.) The type of dust generation is also an important factor to consider (e.g. intermittent sack tipping through to a continuous production process, etc.) Estimating the type and level of dust generated affects the type of filter unit, the filter unit size and the dust collection/discharge arrangement.
WHY YOU NEED DUST CONTROL IN BULK SOLID HANDLING
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DUST CONTROL & EXPLOSION PROTECTION Bulk Solids Today16
When applying dust control within the United Kingdom, legislation such as CoSHH (Control of Substances Hazardous to Health) and EH40 (which details the numerous dust levels acceptable within a production facility) must be considered. LEV systems should be designed following HSG258 guidelines giving advice on the effective design, commissioning and testing of LEV systems.
WHY DUST CONTROL IS CRUCIAL
WHAT ARE YOUR SPECIFIC DUST CONTROL NEEDS?
• The type of dust that your industrial process generates. This includes the products themselves and the particulate size (e.g. is the product in the form of lumps, granules, pellets, powder, etc.)
Every production facility has its own unique LEV requirement. When enquiring about the purchase of a dust filter unit/LEV system, it is helpful to know;
• Determining the air volume that is required to provide effective dust control. This affects both the filter and fan sizes.
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• Establishing whether or not your dust is potentially explosive. If your dust is potentially explosive, your dust extraction filter unit must comply with DSEAR (Dangerous Substances and Explosive Atmosphere Regulations) and the ATEX Directive.
The Kst value (the rate at which a given dust will explode, measured in Bar.m/s) must be determined to size the explosion protection system correctly.
Knowing these elements will help ensure that your LEV system will be designed to meet your unique requirements and help you make a more informed decision in choosing the right dust collector for your needs. integratedAIR Filtration can help you choose the most efficient filter from their BlueClean® range. They have years of experience in the industry, so rest assured that you are in good hands. Whether you are looking for a customised dust extraction filter unit or a full turnkey system, integratedAIR Filtration can help to provide your LEV solution.
Dynamic Air Ltd. Milton Keynes, United Kingdom +44 www.dynamicair.comE-mail:1908-622344sales@dynamicair.co.uk
DUST CONTROL & EXPLOSION PROTECTION Bulk Solids Today 17
The Modu-Kleen® downdraft dust collector represents the latest dust collector technology developed by Dynamic Air to contain fugitive dust. With the new Modu-Kleen downdraft dust collector, the air enters at the top of the dust collector housing and flows downward to the cartridge filters, improving the filtering process and the material-to-air ratio. Air velocities are much lower than those with a conventional dust collector, reducing the load on each filter cartridge and extending filter life. Cartridge filters are positioned horizontally, requiring less floor space and making filter removal easier. Personnel never have to enter the filter housing for general maintenance or for cartridge filter removal. This provides a much safer and quicker method of filter removal. For fast and easy inspections, a large, quick-opening door allows
MODU-KLEEN® DOWNDRAFT SERIES DUST COLLECTOR
maintenance personnel to closely inspect each cartridge when required. In addition, any single cartridge can be removed without disturbing adjacent cartridges. Also, each cartridge filter has a unique built-in quarter turn bayonet mount, so no tools of any kind are required for cartridge dustcollector681.htmlremoval.https://www.dynamicair.com/products/
DUST CONTROL & EXPLOSION PROTECTION Bulk Solids Today18
Scanning raw materials as ingredients come into the factory is prudent for many reasons. Although in most instances these ingredients would be inspected by the supplier, a reinspection will help to doubly ensure that suppliers are complying and hold them accountable for ingredient quality, reaffirms Jodie “Of course, the most notable benefit is preventing metal from entering the production process in the first instance. Rejecting at the end of the line is typically the most expensive phase.”
For hazardous locations, such as flour factories or chemical plants where the application presents a combustible explosion risk, Fortress supplies clear ratings to meet the defined danger standards. Always mindful of real factory conditions, the robust Gravity Metal Detector is built to be sturdy and stable enough to withstand vibrations and temperature changes without compromising performance.Availablein a selection of food-grade anti-static aperture in-feed pipe sizes, including 75mm, 150mm and 200mm, Fortress Gravity Metal Detectors apply powerful Digital Signal Processing technology to identify the smallest of metal fragments. Operatives are instantly alerted to any detection by an audible and visual alarm. A reject confirmation alert verifies that the reject device has operated correctly during every reject.
AN EASIER CLEAN To remove metal contaminants from good product flow, most Fortress customers now specify the The popularity of Fortress Technology’s Gravity Stealth metal detectors continues unabated. A critical part of most food production processes, inspecting and removing metal contaminants in upstream free-falling dry applications, Fortress draws attention to several recent enhancements designed to advance productivity, enhance safety and maintain HACCP compliance in the busiest of food factories.
“There is always value to be gained from adding upstream detection systems to most processes,” explains Fortress Commercial Manager Jodie Curry. “Machines upstream often makes it easier to detect contaminants, trace to their source and potentially alert staff to equipment failures before they become catastrophic and potentially trigger huge recalls.”
detection of magnetic and non-magnetic metals, Fortress Gravity Metal Detectors are increasingly an everyday sight on flour, rice, cereal, sugar, powder and grain production lines.
With productivity being such a critical measurement of output per hour, machine uptime on any fast moving gravity inspection line is critical. Custom manufactured to accommodate different food factory layouts, including mezzanine floors, ceiling mounts, between product chutes and hoppers, and even integrated alongside a checkweigher, the Fortress Stealth Gravity metal detector is packed full of useful labour and time saving features. Including digital automatic testing to eliminate production downtime, plus accurate, high speed capabilities.rejectOfferingbest-in-class
FOOD PROCESSORS GRAVITATE TOWARDS GRAVITY
The Bella dryer/cooler offers thermal efficiencies to 80 percent or better because air flows around material while it is suspended in the weightless zone. The result is a more consistent material.
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Dynamic Air Ltd. • +44 (0)1908 622344 www.dynamicair.com company’s new retractable easy clean diverter valve longstandinganothersanitise.andcanproductareasidentifyMakingandopendesignFortressortubularrated,system.rejectIP69K-ratherthansupportsstruts,thenewGravityfeaturessupportsfewerwelds.iteasiertopotentialwherematerialaccumulate,muchfastertoOvercoming
SAFETY AT HEIGHTS
challenge with Gravity systems - gaining access to the enclosed flap-style reject mechanism and removing from service for deep cleans and maintenance – Fortress has engineered a retractable reject unit. By placing on a carriage, processing operatives can quickly disconnect, gain access to working parts, clean and slot back into place, with minimal business disruption. Average clean times now take operatives a matter of minutes. Jodie confirms: “With open areas and smoother surfaces, operatives can now access and clean their Gravity Metal Detectors much faster. Not only does this reduce machine downtime, it also speeds up the changeover process from one application to another.”
DUST CONTROL & EXPLOSION PROTECTION Bulk Solids Today 19
To successfully comply with application-specific production standards, food processors also need an appropriate and effective testing system. Defined by the audit process of industrial metal detectors and the criteria set out by each retailer Code of Practice (COP), tests are typically scheduled throughout the day at hourly intervals to confirm the inspection system is repeatedly identifying all potential metal contaminants.Manuallyperforming these regular tests on Gravity Metal Detectors can be especially time consuming. The degree of accuracy could also be considered questionable. Mainly due to challenges of accessing machinery positioned at height. “It is virtually impossible to time and again replicate a metal contaminant passing through the exact centre of the product flow within the aperture in free flowing applications,” notes Jodie. “One of the biggest pitfalls of manual testing in Gravity applications is dropping the test sample from a height, through the centre of the product flow where the signal is the least sensitive,” she highlights. With many Gravity metal detectors located near product silos above production lines, climbing up to perform this task manually is usually a two person job and brings with it some significant safety risks. To solve this dilemma, Fortress created Halo Automatic Testing. An alternative to manual performance testing, without interrupting production, Halo mimics the signal disturbance in the centre of the aperture, without having to physically pass a metal contaminant through the metal detector or flush out a sample. In addition to reducing operational costs, Halo testing is proven to reduce waste and product rework. Through the incorporation of all these innovative features, Fortress asserts that its popular processcentric inline Gravity applications are now internationally regarded among the safest to operate andwww.fortresstechnology.co.ukmaintain.
Bulk Solids Today20 SIEVES, SIFTERS, SEPARATORS & SCREENING
SEPARATING PROBLEMATIC METAL AT POWTECH 2022
The introduction of metal contamination into a process potentially occurs at several locations such as introduction with the feed material, from plant wear and tear, and from process equipment failure. Optimally located metal detectors and magnetic separators find and remove the tramp metal before damaging delicate process plant such as screens and crushers. At POWTECH 2022 (27-29 September, Nuremberg, Germany), Bunting’s focus is on the separation of problematic metal from dry materials. On stand 3A-613, visitors will see the latest magnetic separators and metal detectors that effectively remove tramp metal and very fine iron from a wide range of granules and powders.
POWTECH is the leading European trade fair for powder and bulk solids processing and analytics. After pandemic related delays, POWTECH will run in parallel with FACHPACK, the European Trade Fair for Packaging, Technology and Processing. Environmental pressures are driving an increase in dry processing methods rather than wet to reduce the use of water and handling of wastewater. Companies in the chemical, ceramics, minerals, and food industries are changing processing techniques, which then require specific magnetic separators and metal detectors to handle fine dry materials. Effectively separating fine iron from dry powders is often challenging. Even the strongest magnetic separator may struggle to successfully remove the fine magnetic particles. In order to find a successful solution, it is important to understand the behaviour of fine materials and the process. Only then is it possible to determine the optimum method to cleanse a powder of problematic fine iron.
Bunting is one of the world’s leading designers and manufacturers of magnetic separators, eddy current separators, metal detectors and electrostatic separators. The Bunting European manufacturing facilities are in Redditch, just outside Birmingham, and Berkhamsted, both in the United Kingdom.
Bulk Solids Today 21
SIEVES, SIFTERS, SEPARATORS & SCREENING
If you are interested in submitting editorial to Bulk Solids Today magazine, please send your submission through to magazineToeditorial@bulksolidstoday.co.uksubscribetoBulkSolidsTodayorformoreinformation,pleasefeelfreetovisitwww.bulksolidstoday.co.uk
The wide range of high-strength rare earth magnetic separators displayed on Bunting’s stand 3A-613 at POWTECH includes a Plate Magnet Housing (PHMS), Drawer Magnet (HFS), Grate Magnet, Plate Magnet and Bullet Magnet. Each magnetic separator effectively removes fine tramp iron at different locations within a plant.
Metal Detectors identify and automatically eject larger tramp metal from gravity and pneumatically fed dry process lines. These are followed by different designs of magnetic separator, which attract and either hold or remove magnetic metal contamination.Areduction in the particle size range also increases the difficulty of separating fine iron. Understanding the properties of any given powder, such as the flow characteristics, is important when selecting the most effective magnetic separator.
At POWTECH, Bunting’s exhibition stand team includes the European mainland-located Dirk Mylich, Chris Gabriel, and Marcel Graef of Germany-based sales representative 3SMI. As the demand for finer and purer powders increases, so does the need to remove even the finest iron. Understanding the properties and behaviour of the powder is vitally important when considering the optimum method of fine iron separation. Often the ultimate solution is a series of Magnetic Separators and Metal Detectors located at strategic points within the process. Bunting’s engineers provide free onsite advice to determine the optimum solution for any process. For further information, please contact us on press@buntingmagnetics.com or visit our website: Bunting-Redditch – www.bunting-redditch.com
VERSATILITY AND PRODUCTIVITY Nacho Llácer, Managing Director of IMEE, said: “We are growing between 20-30% every year, so we needed a new excavator to work in our facilities and Doosan proved to be the best for the size of excavator to meet our needs, with a lower fuel consumption and a quality design. We need to load, unload, excavate and transport stockpiles to the crusher to recycle, collect the waste that arrives at our facilities (with an average of 140 trucks per day and about 2000 tonne of material per day) and carry out various jobs on the plant.
“Our operators are very happy with the new excavator - they appreciate the ease of operation and the additional comfort that comes from a new machine. The visibility, the cab and the safety are outstanding elements, as well as the robustness.”
The facilities at IMEE include a recycling plant, a treatment plant, a transfer centre and an inert waste dump. The material from construction works first comes into the delivery area, from where it goes to the separation warehouse where large recyclables such as plastics, cardboard, iron, and wood are removed. The remaining inert waste is then passed through to the triage cabin, from where soil and aggregates are passed on to a conveyor belt, which directs it to a mill where it is converted into recycled materials for use in the construction of buildings and roads.
NEW DX380LC-7 EXCAVATOR HAS BROUGHT
NEW DOOSAN DX380LC-7 EXCAVATOR AT SPANISH RECYCLING PLANT
The 40.2 tonne DX380LC-7 model offers greater productivity, high performance and lower fuel consumption thanks to D-ECOPOWER technology. All this in an efficient and very comfortable work environment, with comfortable intuitive controls, a 360° camera system, large side mirrors, powerful work lights, and non-slip steps, platforms and safety rails on the upper structure.
Bulk Solids Today22 RECYCLING & WASTE MANAGEMENT
The Mediterranean Institute of Ecological Studies (IMEE), a company based in Quart de Poblet in Valencia in Spain, has expanded its machinery fleet with a new Doosan DX380LC-7 crawler excavator. Authorized by the local community organisation, Generalitat Valenciana, IMEE provides a construction waste treatment service in the local region, covering a market area of 200,000 m2, and collaborates with public, local and regional administrations in the district.
Bulk Solids Today 23 RECYCLING & WASTE MANAGEMENT
DOOSAN DX170W-5 WHEELED EXCAVATOR IDEAL FOR SORTING MATERIALS
IMEE also a Doosan DX170W-5 wheeled excavator, which replaced a machine from another brand several years ago. This model features the well regarded DL06P engine, one of the most reliable 6-cylinder engines designed by Doosan, with EGR and SCR emission treatment technologies without DPF, a spacious cab and a fully automatic climate control system.Nacho Llácer continued: “The DX170W-5 is ideal for its size and power. We equip it with a clamp to sort and separate various materials into groups. In addition to handling work in the waste area, the Doosan DX170W-5 excavator literally rips the plastic out of the big bags, separating the content from the container, which allows us to quickly and conveniently divide and select materials and soil or rubble. It also transports and stacks the containers we use.“The different types of components used in construction generate waste that must be classified for later recovery, identifying what can be recovered for reuse. Thanks to the sorting process, we manage to recover 95% of the waste products for subsequent recycling. The lack of adequate centres like ours for construction waste creates a serious problem for our environment and is currently a huge setback.” Nacho Llácer added: “The qualities of machines today are intrinsic, such as new technologies, rear view cameras and ergonomic seats, however, I personally highly value the role of a good salesperson who not only sells a machine, but also advises you and helps you with decision-making when selecting the best products for your projects, including post sales, which is also extremely important. There are sellers who are simple order takers, who leave a catalogue on the table, but are not even experts in their product. Selling is not offering; selling is talking, listening to the needs and offering solutions to the client. A person who only distributes flyers will hardly know how to solve a problem when you have it. Therefore, it is vital for me that the manufacturers train their teams properly and prioritise the training centres.
“Undoubtedly, the staff at Ximo Magallo & CIA., the official Doosan distributor in our area, with the support of Centrocar, meet these requirements. Their team is really efficient in this sense, and they also offer a very good technical service and are fast. They solve all my problems, which strengthens my confidence in them.”Ximo Magallo & CIA. has more than 45 years of experience in public works, with highly qualified and professional personnel who are well established in Valencia.Formore on Doosan construction equipment, please visit the website: www.eu.doosanequipment.
HML
Effective metal separation is one of many important processes in HML Recycling’s specialist metal recycling operation in Accrington, UK. HML has installed Bunting Permanent Overband Magnets in their cable recycling process, and a Metal Separation Module on a new line for recycling perfume bottle tops. Bunting is one of the world’s leading designers and manufacturers of magnetic separators, eddy current separators, metal detectors and electrostatic separators. The Bunting European manufacturing facilities are in Redditch, just outside Birmingham, and Berkhamsted, both in the United Kingdom. HML Recycling has over 50 years of experience in metal recycling and works with local people and multinational organisations to implement effective metal recycling solutions. The company sponsors many local charities, sporting clubs and community projects and pledges a percentage of operating profits to worthy causes each year. HML recycle a wide range of metals including an established cable recycling plant and a new line for handling shredded perfume bottle tops. On the cable recycling plant, HML use two Permanent Overband Magnets to remove ferrous metals including steel after primary shredding. One Overband Magnet is positioned across a vibratory feeder, where the vibration liberates entrapped material to enable to cleaner separation of magnetic metals. The second Overband Magnet removes steel and other magnetic metals from a 98%-rich shredded copper cable mix to protect a granulator. Mounted above the granulator feed conveyor handling up, the Overband Magnet lifts and removes potentially damaging steel. HML have recently installed a new line for the recycling of shredded perfume bottle tops. The mix includes both ferrous and non-ferrous metals, which are removed using a Bunting Metal Separation Module. In operation, the shredded material is fed via a conveyor onto a Vibratory Feeder. The Feeder evenly spreads the material before feeding at a steady rate onto a high-strength Permanent Drum Magnet, which separates any magnetic material. A Drum Magnet has a fixed magnet element mounted inside a rotating non-magnetic shell. Any ferrous metal or magnetic particle is attracted and held to the surface of the rotating Drum Magnet shell before being transported and deposited underneath in a collection area.
RECYCLING OPERATE BUNTING MAGNETIC SEPARATORS
Bulk Solids Today24 RECYCLING & WASTE MANAGEMENT
Bulk Solids Today 25 RECYCLING & WASTE MANAGEMENT
The remaining non-magnetic mix drops onto the moving belt of a High-Intensity Eccentric (HIE) Eddy Current Separator. An Eddy Current Separator is a dual pulley conveyor system, where the non-metallic rotor cover houses an independently rotating high-speed magnetic rotor. Separation occurs when a non-ferrous metal particle (e.g. aluminium) is conveyed into the magnetic zone. The nonferrous metal particle is exposed to rapidly changing magnetic polarity. This induces ‘eddy currents’ into the particle generating an electrical current (Fleming’s left-hand rule) that subsequently creates its own magnetic field. The two magnetic fields oppose each other (i.e. North vs North pole repulsion), causing the repulsion of the non-ferrous metal particle and change in trajectory. The measured positioning of a splitter enables the separation of non-ferrous metals from non-metallic material due to the altered and unaltered material trajectories. Prior to ordering the magnetic separators, Bunting conducted control tests at their Customer Experience Centre in Redditch, UK to confirm capacities and separation capabilities. In operation, the 750mm wide Drum Magnet and Eddy Current Separator will handle up to 2 tph of 0-15mm shredded perfume bottle tops. Both the recovered aluminium and plastic will have purities exceeding 98%. “The HML Recycling installation is another exciting project for Bunting,” said Tom Higginbottom, Bunting’s Sales Engineer. “Conducting the tests at our Customer Experience Centre enabled us to understand the material and ensure that we could meet the separation expectations.”Forfurtherinformation, please contact us on press@buntingmagnetics.com or visit our website: Bunting-Redditch – www.bunting-redditch.com
BUYERS GUIDE Bulk Solids Today26 Suppliers of the Original Entecon® Aero Mechanical Conveyors Sales office for UK & ROI: SGH Equipment - Entecon® Agent Tel / Fax: 01270 651611 E: sales@sghequipment.co.uk • www.sghequipment.co.uk • Sack Openers Tip or Automatic • FIBC Fill / Discharge • Pneumatic Conveyors “Often copied NEVER matched” Other Products: Aero Mechanical Conveyors manufacturersDesignerswww.perryengineering.comandUKof: •Bucket elevators •Chain & flight conveyors • Screw conveyors & bin dischargers • Belt conveyors Bulk handling with complete confidence Tel: 01404 891400 F ax: 01404 891402 Conveyors & Elevators Dynamic Air Ltd. Milton +44EnglandKeynes(0)1908622344 www.dynamicair.com Mixers & Blenders Bulk Storage & Handling Cleaning Tuf-Lok (UK) +44 (0) 1706 822512 www.tuflok.com Powder Handling Systems Remote Silo Monitoring SYSTEMSANDOFMANUFACTURERSSILOS,TANKSCONVEYINGRedbrook,BarnsleyS751HRTel:01226730037Fax:01226730066Email:info@eb-equipment.comWeb:www.eb-equipment.com If you would like your company to be featured here, please get in touch using the details below : 01933 bst@abbeypublishing.co.uk316931www.bulksolidstoday.co.uk
BUYERS GUIDE InterBulk GROU Pwww InterBulkGroup.com Intermodal dry bulk logistics for polymers, chemicals & minerals Cost effective Environmental savings Reduced C02 emissions Manufacturers of semi/fully automatic weighing and filling machines into valve/open mouth sacks T: +44 (0)1487 711114 E: enquiries@atsackfillers.co.uk www.atsackfillers.co.uk ATEXmanufactured in the UK Sack Filling Sieves & Sifters Cont’d Vibrator y & centrifugal Solids/solids or liquid/solids separations Standard and custom designs Industrial, food, pharm. designs Tel: +44 (0)1782 597540 Fax: +44 (0)1782 597549 sales@k asoneurope .co .uk W -0729awww.kasoneurope.co.uk ISO 9001: 2000 W-0729a CLASSIFIED.qxd 5/15/08 1:33 PM Page 1 Screeners Vacuum Cleaning Posi-flate Milton +44EnglandKeynes(0)1908622366 www.posiflate.com Valves INDEX ADVERTISERSTO AJAX Screw Feeders, Mixers & IBC Systems Ajax Equipment Ltd Tel: 01204 386723 Fax: 01204 363706 www.ajax.co.uk email: solids@ajax.co.uk Untitled-2 1 22/10/2013 14:56:57 Screw Feeders, Mixers & IBC Systems Bella 19 Dynamic Air 2 Intergrated AIR 9 Posi-flate 7 Russell Finex 26 Trantec 11 Tuf-lok 11 Vega 5
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