Let's stop focusing on hitting a meaningless 100% C&D waste recycling target

Insanity is…

Doing the same thing over and over again and expecting a different result. Every year yet another report is produced highlighting the crisis that is facing the UK construction materials industry as a result of dwindling reserves.

The latest report from BDS Marketing Research now says this situation “is now having a serious impact on the industry.” The report goes on to say that over 100 existing pits could close over the next five years unless extensions to extraction licences are granted. The report’s author, Julian Clapp goes on to say “aggregate companies need to get their planning applications submitted soon to ensure continuous aggregate supply.”

Despite this annual warning of impending doom the opportunity that it represents for the C&D waste recycling sector is not being fully exploited. Given the obvious supply gap that exists with virgin sand and gravel and crushed rock for construction applications why hasn’t there been more investment in advanced processing systems that offer specifiers a real alternative?

It’s an issue of positioning – and for too long recycled sand and aggregates have been positioned as a low value, lower quality option. “If there really is no other option then I suppose we could use recycled material.”

So how do we change this? First of all we need an acceptance within the C&D waste recycling sector that if we persist with the most basic processing of this material we will never be able to achieve the full potential offered by recycled sand and aggregates.

The advanced processing systems that will help to move recycled sand and aggregates up the value chain are out there – and many within the industry are already using them. These companies are enjoying the benefits of their foresight and are seeing recycled materials used in high value construction applications as a viable alternative to virgin materials.

While the success of these companies is to be applauded they are the exception rather than the rule. Let’s stop patting ourselves on the back about how good we’ve got at C&Dwaste recycling. Let’s face it – the definition of recycling is so broad that it’s not hard to hit. If we’re being honest with ourselves a lot of what is happening is simply dumping under another name.

The only way we’ll succeed in moving recycled sand and aggregates up the value chain is to stop focusing on hitting a meaningless “100% recycling” target for C&D waste and instead start focusing on increasing the volumes of this material that are used in high value construction applications.

By doing this we’ll not only be ensuring that we are extracting maximum value from this valuable resource but we’ll be in a great position to take advantage of the opportunity presented by the lethargy of the construction materials industry and the inadequate planning system that combine to create the opportunity in the first place.

Co-Creation as a means of delivering efficient plant design

In recent years the issues of productivity and efficiency have risen to the top of the agenda in the global materials processing industry. There has been a shift in emphasis from one founded on the principal of ‘more capacity’ to one which seeks to ensure that every individual operation is extracting maximum value from the material being processed.

This presents a new challenge for most equipment manufacturers who will now have to go beyond their previously self-imposed boundaries and get closer to the end user to ensure that the equipment they provide will meet the productivity and efficiency requirements that are now driving investment decisions.

Every application has its own unique challenges and in order for equipment manufacturers to provide fit for purpose processing systems they need to ensure they are at the very centre of the discussion. This is especially true in the wet processing and classification market where understanding the specifics of the feed material is a critical factor in the delivery of a successful project.

The change in emphasis from ‘capacity’ to ‘productivity’ has sharpened the focus on every processing phase within the complete system as operators seek to identify where the inefficiencies lie and put a plan in place to address these. This increased focus can reveal an array of process issues that previously went unnoticed – unnecessary material spillage, inefficient separation systems which result in poor quality final products and good quality material being lost to the water treatment or waste management phase.

Any processing plant including several different processing phases must be much more than a number of individual equipment items in sequence. In order to deliver on the productivity and efficiency requirements of the industry a robust plant design process is required which requires a considerable level of consultation between manufacturer and end-user. It is only by adopting this approach that a full understanding will exist of the requirements of the project.

This process should take account of a number of issues and ensure that the plant is configured to ensure delivery of the most efficient processing system. These include material testing and analysis, space restrictions, civils design, proximity to waste storage areas, transfer point technology, water management and maintenance access.

Our experience over the last two decades in the design and delivery of successful materials washing projects has been built on the theory of co-creation – a partnership between us and you, the end-user to understand your objectives, address the issues you are facing and ensure that the processing system is designed with the in-built flexibility to ensure that any future changes in your requirements can be accommodated with the least amount of disruption.

A successful materials washing plant is built on a detailed understanding of your project as something unique and the design and specification of the appropriate technologies to ensure your objectives are met. To try and achieve this with a limited range of standardised, mass produced equipment is not possible – and the success we have enjoyed in the materials washing arena over the last 20 years is testament to this.

By conducting extensive material testing and analysis in our own laboratory a full understanding of the nature of the feed material is gained. While testing will indicate whether the final product specifications desired by the end-user are able to be achieved it is the further detailed analysis of these results that will potentially reveal opportunities to maximise product yield from the feed material. It may be possible to look at production of additional sand specifications which will not only reduce waste volumes but provide an additional revenue stream. This will often require the introduction of more complex processing systems if a specialist sand can be produced - sports sands, filter sands, foundry sands for example. While this will require additional investment the return on investment argument is a compelling one given the potential to produce a product for one of these high value applications.

By conducting a process audit on existing sites we can focus in on the areas where specific actions are required in order to improve efficiencies. This will help us to identify what the important issues are to you in that specific situation and ensure that any new processing system is built to tackle these and deliver on your requirements for increased process efficiency, productivity and plant availability.

A key element of the co-creation process is the design workshops that we undertake. These workshops typically involve a number of representatives from the customer – operations personnel as well as senior management – as well as an extensive project team from CDE. This will include a senior Technical Engineer who will be involved to discuss plant specification in detail with you and ensure that there is clarity around the site infrastructure (civils design, water requirements, power requirements).

As well as dealing with these pre-sales elements our design workshops will also introduce you to the delivery processes we have in place to ensure project delivery goes to plan. This is an area which is often overlooked and the costs of poor delivery underestimated. Our washing centric ProMan system has been proven to deliver hundreds of materials washing projects successfully and the design workshop will involve meeting with the individual Project Manager who will take ultimate responsibility for the delivery of your project and act as a single point of contact until project completion. You will also be introduced to all of the other elements of our project delivery process and meet the team of people involved in your project – logistics, design, install & commissioning, post commissioning support, training.

In summary, mass produced and standardised equipment is designed around the principle of making a production facility efficient rather than delivering successful materials washing projects. The success we have enjoyed in the global washing sector is evidence that successful plant design and delivery involves a huge level of direct contact between us as equipment manufacturers and you as end users of the equipment. Each and every plant we build is co-created with our customers and this applies whether we’re delivering a single item of equipment or a full turnkey processing system integrating many different processing phases. Our M2500 is the perfect example – almost 100 machines sold in the last 3 years and no two machines are the same.

It is this ability and our agility in regard to the plant design process that ensures we are in a position to help you deliver on your requirements for the most efficient, most productive processing system available.

Mining in remote locations - how equipment manufacturers can continue to deliver fit for purpose systems

Our experience in the delivery of mining projects across the world in recent years has revealed a number of challenges for us and other equipment manufacturers if we are to continue to provide processing systems that are fit for purpose. 

A major challenge for equipment manufacturers in the years ahead will be to provide materials processing systems that are able to be efficiently deployed in increasingly remote locations. There will also be a requirement to process increasingly difficult materials that have been overlooked until now. As our demand for steel, aluminium, copper and silica sands and other industrial minerals continues to increase mining companies are constantly looking for new and improved processing technologies that will allow them to process lower grade ores and industrial sands and produce final products suitable for use in downstream processes.

Another development we have witnessed is an increased focus on staged investment as a means of delivery for new mining projects – designing your plant in such a way as to allow for production to begin in the shortest possible timeframe while planning for further plant and process development. To use the age old adage ‘the customer is always right’, if mining companies are looking for equipment that can be more efficiently deployed, that can process increasingly difficult materials and that are is suitable for staged investment then it is the responsibility of equipment manufacturers to meet these requirements.

In looking at how we can do this I will look at a number of issues which can be categorised under these headings:

1. Built with the application in mind
2. Modularity
3. Intelligent Process Integration
4. A phased approach to design & delivery
5. System adaptability
6. Mobility – without compromise
7. A turnkey approach

1 - Built with the application in mind

Every project presents its own unique challenges. When we look at the raw material there are a several factors which will influence the selection of the appropriate processing system. The quality of the ore is the first issue to consider. In addition to this we need to analyse the level of contamination within the material that needs to be removed. This could be sticky plastic clay that requires a logwasher to provide the necessary attrition. In the case of iron ore processing we will also have to consider the levels of silica and alumina contamination which if they are not removed will lead to inefficiencies in downstream steel production processes. The presence of all of these materials necessitates that every project is considered as a stand-alone system and designed, specified and constructed individually with a full understanding of the requirements of the project.

If we take this to its logical conclusion the response from equipment manufacturers to this scenario should be to produce tailored processing systems for every individual project in order to maximise process efficiency. This represents a major shift from the typical business model for equipment manufacturers – which is to produce a limited range of standard machines that can be applied across a wide range of applications. Using standard machines presents a problem, and requires end users of the equipment to accept that they will have to compromise on performance , if they do not intend to run the equipment within the designed operating parameters. .

While the vast majority of equipment manufacturers will tell you that tailoring each individual project is not possible – the reality is that it is entirely possible. Our experience in the mining sector has shown that there are a number of individual considerations that need to be made in order to maximise the efficiency of the final processing system.

The selection of the appropriate screening media is very important – polyurethane is almost always the best match for mining projects but not all polyurethane is equal. Due consideration must be given to the abrasiveness & specific gravity of the material to ensure that the most suitable product is specified.

The choice of lining for any hydrocyclones also requires individual consideration – rubber lining may well be suitable on some materials but others will demand ceramic linings when dealing with highly abrasive mineral ores.

Consideration should also be given to the requirement for additional wear liners at specific points in the system. Easily replaceable wear liners at the feed point will have a positive impact on plant availability by minimising the time required for maintenance.

The appropriate conveyor belt specification will also require individual treatment based on the nature of the material to be processed. Enhanced top cover thickness will enhance wear resistance, maximise plant productivity and reduce costs of operation through a reduction in the spare parts requirement. Staying with conveyors, the inclusion of belt cleaning systems such as tungsten tipped scraper blades will also offer enhanced wear resistance.

The specification of appropriate pumps is also critical in an effort to ensure they will stand up to the rigours of the material to be processed.

2 – Modularity

A rise in the popularity of modular processing systems on mining projects has been evident over the last number of years. One of the major motivations for a move in this direction from our own perspective was a focus on Transfer Point Technology – ensuring the efficient transition of material from one stage of processing to another. The direct result of this approach is to maximise material retention within the circuit and avoid bottlenecks within the system where the discharge point from one processing phase is not optimised for seamless delivery to the next stage.

There are numerous advantages to this approach – greater process efficiency and reduced installation and commissioning time being the most obvious. All of this works together to ensure you are able to start extracting value from your material as quickly as possible.

In most, if not all mining projects there will be a requirement to integrate third party equipment within the processing system so it is also important that designers are aware of the likely connections that will need to be made and consider this very early on in the design process. This will streamline the project design process and ensure that once the system is up and running it operates at maximum efficiency.

The third party equipment that CDE has most experience with when designing processing systems for mining projects are attrition cells, spiral classifiers, decanter centrifuges and filter presses. Through the development of partnerships with suppliers of these systems we can ensure that our focus on Transfer Point Technology does not stop at our own products but extends to this 3rd party equipment as well. As a result of our focus on tailoring each system we are also able to manage the introduction of new equipment to our systems as and when required.

3 – Intelligent Process Integration

Intelligent Process Integration involves the introduction of several different processing phases onto a single chassis. Aligned with the previous point on modularity this allows for transfer point efficiency to be maximised. Additional advantages are a reduced plant footprint which results in a reduced civils requirement. These factors combine to reduce both the time required and the final cost of the project.

When feed systems, screening plant, fines processing, scrubbing systems are all provided as individual stand-alone units there will be a large amount of design time spent on designing civils and support structures to accommodate all of this equipment. Once the equipment reaches site the time taken to mechanically install the plant will be longer than necessary as a result of having to put all of the individual components together.

The reduction in mechanical install time is delivered because all equipment undergoes a complete pre-build to its working position in a factory environment. This is a final quality control step that allows for any fabrication issues to be addressed before equipment is dispatched. Our focus on the delivery of wet processing systems means that this approach extends to ensuring all pipework connections are already established prior to dispatch – eliminating the requirement for cutting or preparation work on site, reducing install time and eliminating the requirement to source this pipework locally either because it has been damaged in transit or is missing from the items delivered to site.

Another significant advantage of integrating several processes onto a single chassis is that all equipment can be pre-wired and tested in a factory environment. Adding to the reduction in time taken for mechanical install, the electrical installation time is also reduced. It also has the advantage of making the electrical connections a design feature of the plant – cable runs and housings are part of the design process which not only improves the aesthetics of the plant but also enhances health and safety on site.

This approach also reduces the requirement to try and find local suppliers of cables and other electrical items – particularly relevant in any discussion concerning how to approach mining projects in remote locations.

4 – A phased approach to project delivery

Through a phased approach to project delivery it is possible to show a return on your investment much more quickly. The start of this process will be detailed discussions with your mining engineers to understand the specifics of the reserve – capacity requirements, likely requirements for future upgrades. This will also involve a detailed analysis of your material in an attempt to understand whether it is possible to kick start a project with a simple processing system which can then be added to as and when required.

For example, a detailed material analysis throughout the reserve will reveal whether there is a seam of relatively clean, uncontaminated material that requires minimal processing. Following this it can be determined at what stage additional equipment may be required – for example a logwasher may need to be introduced to tackle claybound material or to help in the removal of other contaminants. Following this a third phase may be the introduction of primary stage water treatment and tailings management systems.

From an operational perspective the main advantage of adopting a phased approach is that rather than waiting for months on the delivery of a complex processing system, most of which will be under-utilised for a period of time you are able to take delivery of your first phase equipment in as little as 12 weeks. This allows you to begin to show a return on the investment very quickly which helps fund the future expansion of the plant when conditions dictate that it is necessary.

5 – System Adaptability

We have touched on the variability that is inevitable within mining projects and what is required at the outset may change over time. Future developments with your business may require a capacity upgrade to meet a rise in demand for the material you are producing. We may come across an area of your reserve with particularly challenging material that will require the introduction of a new process. Space restrictions on site or future environmental legislation may require the introduction of a tailings management system.

Given this potential for circumstances to change, it is essential that your processing system has the in-built flexibility to respond to these changes. We can’t predict the future but through a comprehensive analysis of your material we can identify whether for example there is likely to be a requirement for an additional process to be introduced and when this is likely to happen given your extraction plan for the reserve.

If we have established that your business plan indicates a likely requirement for additional capacity as extraction progresses we will design the civils on site to take this into account – minimising disruption to your operation. We will also bear this in mind when considering the location of the processing plant in the first instance to ensure that once any upgrade is required the original location is still suitable. Another step that we will take is to ensure that the original conveyor specification is fit to cope with the forecasted additional capacity both in terms of belt specification and stockpile capacity.

Similarly, if additional processing equipment is likely to be required this can be considered during the design of the original plant civils. We will also conduct a detailed analysis of the likely future water and power requirement once the additional equipment has been added to make sure that this infrastructure is in place.

6 – Mobility without compromise

Mobile makes sense. As your extraction progresses it makes sense that your processing plant should be able to be moved within the deposit to ensure maximum operational efficiencies are delivered. With a static processing plant this is not possible. As your extraction progresses your operational efficiency is reduced – increased transport movements on site as vehicles have to haul material greater distances to the processing plant, unnecessary double handling of your material as it is stockpiled at the extraction point before being delivered to the processing plant. By opting for modular equipment which integrates several processes on a single, easily transportable chassis you ensure that your processing plant can be moved quickly and easily within the deposit – or to another processing location – in order to maximise operational efficiencies.

This should be done without compromising on the specification of the screens, fines washing plants or logwashers that are included. The creation of a modular product range fit for purpose in mining projects should involve the same specification of equipment as would be included on a static plant.

One of the major areas of compromise on mobile plant is with the walkways – ladders leading to very narrow walkways are the norm on most mobile machines. This makes plant maintenance very awkward, – increasing the time and therefore the cost of carrying out plant maintenance.   Site health and safety rules may also be compromised.

This is why we believe that even on mobile or portable plant the walkways for access and maintenance should be of the same specification as would be found on a static plant. This ensures that you continue to enjoy all the benefits of a static plant in relation to maintenance access – ease of visual inspection, access to change screen media ,media, replace spray bars, and  carryand carry out hydrocyclone maintenance.

The issue of maintenance access is often overlooked when a processing plant is being specified but it is a very important consideration as it is a factor which will have considerable influence on plant availability and delivering the highest standards of health and safety on site.

7 – A turnkey approach
It is evident from the analysis of all the aspects that make up a successful mining project in the 21st century that a much greater level of interaction between equipment manufacturer and the  end user is required in order to deliver successful projects. With the many considerations that need to be made there is potential for a huge number of vendors to be involved on each and every project and this requires that a robust Project Management system is in place.

Our own process is split into three distinct phases:

1. Technical Pre-Sales
2. ProMan
3. CustomCare

Each of these phases include large amount of work. In Technical Pre-Sales the elements include process design, equipment selection, mechanical design, civil design and 3rd party equipment integration. As we move into the delivery phase of the project ProMan takes over and includes factory testing, power distribution, risk management, scheduling, budget management, construction management and quality control. Once your plant has been successfully installed and commissioned our range of After-Sales services are activated including our MasterClass training programmes, service visits, recommended spare parts lists and on-going maintenance contracts.

The effect of being able to offer this complete range of services in addition to the equipment that we provide is to significantly reduce the number of vendors involved in the project, the result of which is a more streamlined project timeline which costs less to deliver. Effective communication is crucial to the delivery of successful materials processing projects and our process provides you with a dedicated single point of contact throughout the project lifecycle to ensure you remain fully informed at every stage of the project. Another advantage of this approach is that it helps to develop both our knowledge of your business and your knowledge of our capability which will allow both parties to explore the potential for further co-operation in the future.

In Conclusion

It is clear to all involved in the delivery of mining projects in the 21st century that there are many complex issues to overcome. The demands of the industry are constantly evolving and it is essential that the products offered by equipment manufacturers continue to evolve. It is equally important that equipment manufacturers develop their processes and approach to project delivery in order to continue to meet the demands of the industry.

In summary, I believe there are 3 main considerations in this analysis of how equipment manufacturers can continue to supply mineral processing systems that are fit for purpose.

1. The individual components that make up a complete processing plant cannot be looked at in isolation and should instead be made up of modular systems with the in-built flexibility to cope with shifts and changes in individual project circumstances.

2. Off the shelf processing systems from a collection of different manufacturers will not deliver the efficiency required of 21st century mining projects. A tailored approach is required with each individual project being built according to the specific requirements of the project – capacity, feed material and potential for future development.

3. Equipment manufacturers must get closer to the project and the end-user and understand the background, the specific objectives and the plans for future development. For most equipment manufacturers this requires a huge shift in the way their business models are constructed. Our business has always been constructed on the principle that direct contact with the end-user is critical to success. We have been delivering projects in this manner for over 20 years and our project portfolio across all the sectors in which we operate is evidence of its success.

This article was developed to accompany a presentation by CDE Mining at the Bulk 2014 conference in England organised by the Materials Handling Engineers Association (MHEA) on 21st May 2014. Further information on the Bulk 2014 conference and the work of the MHEA can be found at www.mhea.co.uk

ENDS

Information for Editors:

• CDE Mining offer a range of equipment which can be applied in the processing of a wide variety of materials including iron ore, bauxite, chromite, copper and gold. CDE Mining is a Division of CDE Global Ltd who operates in the Construction & Recycling sector – providing sand and aggregate processing systems across the world, and the Specialist Industrial Sands sector – with expertise in silica sands, frac sands and other industrial minerals.

• The company operates in 7 regions – Ireland & UK, Europe & Russia, Middle East & Africa, Latin America, North America, Australasia and Asia – and currently have offices in Northern Ireland, Brazil, India & the US with dedicated Technical Sales teams working throughout Europe & Russia, Australia and Middle East & Africa.

• You can find out more about the company by visiting www.cdemining,com and www.cdeglobal.com