NOTABLE PROJECTS AROUND THE GLOBE

Transcription

1 NOTABLE PROJECTS AROUND THE GLOBE

2 NOTABLE PROJECTS AROUND THE GLOBE Astec Industries, Inc. was founded in 1972 with the vision to apply creative thinking and state-of-the-art technology to the construction equipment industry, bolstered by a corporate culture renowned for putting customer service first. Based in Chattanooga, Tennessee, Astec Industries is a unique corporation able to draw on the expertise and specialties of each individual company to design and engineer an entire project. The depth of experience and knowledge for the entire family of Astec Industries companies enables it to take on major scope projects, choosing the very best technologies and combining them to meet your needs. VISION STATEMENT To be known as the global leader in service, innovation, quality and safety. MISSION STATEMENT To grow and prosper by designing, manufacturing and selling the most innovative, productive, reliable and safe equipment for the industries we serve, coupled with unparalleled customer service. OUR CORE VALUES Continuous devotion to meeting the needs of our customers. Honesty and integrity in all aspects of business. Respect for all individuals. Preserving entrepreneurial spirit and innovation. Safety, quality and productivity as means to ensure success.

3 TABLE OF CONTENTS Asphalt Commander 02 Cabinda Gulf Oil Ltd. 04 Century Asphalt 05 P&S Paving 06 Inland Aggregates 08 Banks Construction 09 Highland Pellets 10 Theiss Services 12 Carmeuse Group 13 Akdaglar 14 Tilcon - Millington 16 Mario Huertas Corporation 17 Argonaut Gold 18 Matrimar 20 Barsanti 21 ERG Co. - Deriner Dam 22 Martin Marietta - Jones Mill 24 The Brunei Project 25 Dolese-Coleman 26 Oak Ridge Concrete Plant 27 Ozinga Brothers 28 Azerbaijan Tartar 29 ASTEC INDUSTRIES, INC. FAMILY OF COMPANIES INFRASTRUCTURE AGGREGATE & MINING ENERGY

4 Asphalt Commander Liquid Asphalt Heaters Atlantic Ocean Heatec, Inc. 2

5 Three heaters provided by Heatec, Inc. keep the cargo of this tanker at a temperature of 270 degrees F (232 degrees C) or higher. The tanker s cargo is nearly 8 million gallons (33,360 tons) of liquid asphalt. The ship, named the Asphalt Commander, is owned and operated by Sargeant Marine, Inc., of Coral Springs, Florida. The ship is pictured here approaching port at Charleston, South Carolina on its maiden voyage with liquid asphalt. The ship is carrying 185,000 barrels of liquid asphalt that it picked up in Curaçao, near Venezuela. The asphalt heaters are housed in a large vertical compartment that can be seen directly behind the pilot house and main stack. Heatec designed, built and helped to install the heaters. Heatec engineers and technicians commissioned the heaters and remained on board during the maiden voyage. The heaters operate on either diesel fuel or heavy fuel oil and provide 15 million Btu/hour each. The heaters, manufactured and installed by Heatec, circulate fluid through 22 miles (35.4 kilometers) of piping in fourteen compartments filled with liquid asphalt. 3

6 Cabinda Gulf Oil Limited Convectec TM Heaters for Crude Oil Republic of Angola Heatec, Inc. Heatec has built a number of Convectec heaters for use by Cabinda Gulf Oil Limited, a subsidiary of Chevron Corporation, at their oil wells in Angola. These are unusually large heaters that sell for upwards of million U.S. dollars each. Heatec has also produced many smaller versions of these heaters for a variety of industries. The heaters for Cabinda are used to heat crude oil as it is piped from their offshore production fields to their onshore refinery. The crude oil flows through the heater s heat-exchanger coils, which are heated exclusively by convection gases to avoid high film temperatures. Crude oil is highly sensitive to high film temperatures, which can be a problem with radiant energy produced by a burner flame. The heaters raise the temperature of the crude to approximately 120 degrees F (48.8 degrees C) thereby lowering its viscosity so it can be easily distributed within the refinery. The crude flows through each heater at a rate of approximately 3,000 gpm. The Convectec heater is used in the petrochemical, chemical, automotive, and manufacturing industries. It is used to heat water, gases, crude oil, thermal fluids and viscous liquids. The heater is also used for heating cryogenic liquids, such as LNG, liquid ammonia and nitrogen. Capacities range from 3 million to 125 mm btu/hr. 4

7 Century Asphalt Angel Brothers Liquid Asphalt Terminal Houston, Texas, USA Heatec, Inc. When Century Asphalt Materials, Baytown, TX, sought a collaborator to design and build a new asphalt terminal that would expand with their growing operation, Heatec accepted the assignment. When Heatec completed the initial project in 2012, it had 334,000 barrels of liquid asphalt storage capacity. Heatec provided all the major equipment components, including two 10mm btu/hr heaters and two steam generators. Heatec also designed the control system that runs the entire facility. Since 2012, Century Asphalt has increased their liquid asphalt storage capacity to 570,000 barrels. They have also added a third heater and a polymer blending system all provided by Heatec. 5

8 P&S Paving Asphalt Plant & RAP Screening - Orlando, FL, USA Astec, Inc. Heatec, Inc. Kolberg-Pioneer, Inc. Astec Mobile Screens, Inc.

9 Astec, Heatec, Kolberg-Pioneer, and Astec Mobile Screens worked in partnership with P&S to design this facility in Daytona Beach, Florida. A dominant player in its local market, P&S wanted a plant that offered the newest technology to produce quality asphalt mixes using the highest percentage of recycled asphalt pavement (RAP). The 300 TPH (272 tonnes per hour) Double Barrel XHR drum dryer/mixer with an external mixer was exactly what they were looking for. This system uses v-flights and a drum variable frequency drive (VFD) to help facilitate producing many different types of mixes while controlling the baghouse stack temperature. The use of v-flights with a VFD cuts the added cost and the lost time of flight changes because they produce a more uniform aggregate veil. The more uniform veil exposes more material to hot gases resulting in better aggregate drying. In addition, it creates a high-quality mix with high percentages of RAP by employing two mixing technologies: an outer chamber on the drum to mix virgin aggregates with RAP and a separate external mixer to ensure the proper mixing of the high RAP aggregate mixture with the liquid asphalt cement. The stainless steel drum and flights withstand the higher temperatures associated with running higher RAP. Given that the state of Florida is limited in producing high-quality aggregates, the Double Barrel XHR plant has addressed the needs of P&S Paving by being able to produce a quality mix using a higher percentage of RAP. P&S Paving installed this KPI/AMS RAP plant to service their asphalt plant requirements. They process in excess of 250,000 tons (226,796 tonnes) of RAP per year.

10 Inland Aggregates A division of Lehigh Hanson Materials, LTD Aggregate Processing Plant Winnipeg, Manitoba, Canada Kolberg-Pioneer, Inc. (KPI) Johnson Crushers International, Inc. (JCI) Astec, Inc. Kolberg-Pioneer and Astec, Inc. worked together to design a plant configured to maximize the production of minus 20 mm x plus 5 mm concrete aggregates from a deposit that commonly includes 75-80% minus 5mm material. Approximately two years of planning went into designing the 1,212 tph (1,100 tonnes per hour) plant for Inland Aggregates, a major supplier of all types of screened, crushed, washed and lightweight aggregate products. Equipment shipments occurred throughout the summer of 2007 and included KPI belt feeders, conveyors, feed/surge bins, classifying tanks, and log washers; a JCI Kodiak Plus cone crusher and deck screens; and an Astec electrical package. Start-up occurred in fall of

11 Banks Construction Aggregate Material Handling System Charleston, South Carolina, USA Kolberg-Pioneer, Inc. (KPI) Banks Construction needed a way to move and stockpile more aggregate and to unload unit trains quickly. To address that, Kolberg-Pioneer provided a railcar unloading hopper/feeder, incline conveyor and elevated tripper conveyor. The railcar unloading hopper/station includes a hopper sloped at 60 with vibrators to prevent aggregate hanging up on the walls. A 36-inch (91 cm) conveyor assists in the collection of the material for subsequent transport to the tripper feed conveyor. The conveyor is designed to move up to 1,000 tons (909 tonnes) of aggregate per hour. The feed conveyor is approximately 225 feet (68.5 meters) long and is partially underground. The stationary elevated tripper conveyor is 36-inches (91 cm) wide. The system was built to carry the material across five aggregate bunkers for a total distance of 550 feet (167.6 meters). A manual flop gate chute allows aggregate to be discharged to either side of the conveyor. A special chute at the far end of the tripper conveyor allows material to feed directly onto a radial stacker that is 25-feet (7.6 meters) beyond the bunker. Stockpiles are placed on a paved and sloped surface to drain water from the aggregate that feeds the asphalt plant. This practice effectively reduces the drying cost, while achieving increased production rates. 9

12 Highland Pellets Wood Pellet Plant - Pine Bluff, AR, USA Astec, Inc. Heatec, Inc. Astec Mobile Screens, Inc Kolberg-Pioneer, Inc. (KPI)

13 Highland Pellets, LLC, partnered with Astec to build a state-of-the-art, high-capacity pellet plant in Pine Bluff, Arkansas. Astec designed the Highland plant and supplied equipment, with most of the equipment being designed and manufactured by Astec, Heatec, KPI and Astec Mobile Screens. The four-line, 22 tonnes per hour (20 tons per hour) per line, plant is capable of producing 600 tonnes of pellets annually. The plant will primarily serve the needs for the United Kingdom utility industry, whose government joined the European Union utility industry goal to use bio-mass fuels for a minimum of 20% of its overall usage. The plant, which became fully operational in first quarter of 2018, achieved recognition for being able to produce saleable pellets months ahead of what any competitive plant was able to accomplish to date.

14 Ventia Soil Remediation Rhodes, New South Wales, Australia Astec, Inc. Astec Australia PTY LTD Ventia, one of Australia s leading remediation contractors with 20 years experience transforming contaminated land into usable space, was tasked with large-scale thermal desorption at Sydney s Rhodes Peninsula in Australia. To accomplish this, Astec provided the equipment necessary to complete the job. The remediation involved two adjoining land sites and part of the adjacent bay. These sites combined resulted in the largest thermal dioxin remediation project in the world. Remediation was performed with an Astec directly-heated thermal desorption plant which included a rotary dryer and emission control system (consisting of a cyclone, oxidizer, baghouse and an acid gas scrubber - all Stockholm Convention compliant and considered best available techniques) supplied by Astec. Before remediation could begin, all equipment had to pass a proof of performance test. During remediation, the plant was required to complete monthly compliance testing. The remediation of the two land sites and the bay has revitalized Sydney s Rhodes peninsula. The successful completion of the Rhodes Remediation Projects has resulted in more than 15 hectares (37 acres) of severely degraded waterfront property being transformed into a valuable asset and returned to productive community use. 12

15 Carmeuse Group Modular Processing Plant Cedarville, Michigan, USA Telsmith, Inc. Kolberg-Pioneer, Inc. (KPI) Carmeuse contracted Telsmith to design a modular production facility for an established quarry supplying stone for lime kilns and the steel industry. With this newer facility, Carmeuse was able to reduce hauling costs, screen out and leave the fines in the pit, and run more efficiently with less maintenance. The modular approach also allows the facility to be relocated in the pit. Telsmith supplied a two-stage crushing system, located in the pit, to produce up to 1,500 tph (1,363 tonnes per hour) of nominal 3 inch (7.6 cm) minus stone. The customer installed an additional 2,000 ft (609 m) of overland conveyor to transport stone to the existing surge pile and rail load-out system. Telsmith supplied modular structures, crushing and screening equipment, plant conveyors (KPI), as well as plant design, staking layout, foundation designs and supervision assistance during erection. Wiring of electrical controls and plant erection were all done by local providers. 13

16 Akdaglar Aggregate Processing Plant Istanbul, Turkey Telsmith, Inc. Kolberg-Pioneer, Inc. (KPI) 14

17 Telsmith and Kolberg-Pioneer (KPI) collaborated to design and build a plant that would increase tonnage and reduce downtime and operating costs at the Akdaglar Quarry outside of Istanbul, Turkey. The new plant was designed to crush granite at 550 tonnes per hour and produces construction aggregate in sizes 38 mm x 0, 38 mm x 23 mm, 23 mm x 13 mm, 13 mm x 5 mm, and 5 mm x 0. The new plant became operational in early Telsmith and KPI contributed Telsmith 48 inch x 20 ft (1.2 m x 6 m) VGF, Telsmith 3648 Jaw Crusher, Telsmith 6 ft x 16 ft (1.8 m x 4.8 m) Double Deck Vibro-King Scalping Screen, Telsmith 52S (H) Gyrasphere, Telsmith 52FC (H) Gyrasphere, Telsmith 8 ft x 20 ft (2.4 m x 6 m) Triple Deck Specmaker Finishing Screens, and KPI 4500 Autogenous VSI Crushers. Detail engineering, structural steel, conveyors, and electrical controls were sourced locally. 15

18 Tilcon - Millington Modular Processing Plant Millington, New Jersey, USA Telsmith, Inc. Kolberg-Pioneer, Inc. (KPI) The Tilcon-Millington plant had a five-year supply of stone reserves located below an existing plant. The design of the existing plant made relocating it impractical and a portable plant would likely have difficulty meeting the 1,000 tph (909 tonnes per hour) production requirement. Tilcon contracted with Telsmith to design, supply and erect a modular crushing system to produce five different products including drain rock, dense grade, manufactured sand, and sized aggregates. The modular plant approach was chosen for the ability to install and go into service quickly, then be economically relocated to another site after five years. 16

19 Mario Huertas Corporation Bucaramanga, Colombia Kolberg-Pioneer, Inc. (KPI) Johnson Crushers International, Inc. (JCI) Astec Mobile Screens, Inc. Astec, Inc. Bogota-based Mario Huertas Corporation (MHC) ranks as one of the top Colombian highway contractors and has landed many high-profile projects and awards, including a $400 million, five-year highway contract in Bucaramanga, Colombia. MHC is well-established as a progressive pioneer in the industry, accustomed to conquering massive civil engineering projects in challenging conditions. When MHC won the bid to construct an 87-mile, four-lane highway across the Andes Mountains between Bucaramanga and Cúcuta, the company was tasked with the challenge of designing and building the country s first four-lane road as well as all the bridges and tunnels located in a mountain range. The complexity of the project required MHC to invest in high-quality mobile equipment that could classify aggregate without the use of water which is limited in the region as well as provide a high production rate. KPI-JCI and Astec Mobile Screens, as well as Astec, provided MHC with research and the opportunity to observe the equipment working in other countries. MHC purchased three GT165DF screen plants to clean the raw material, as well as two FT4240CC impact crushers, a 2500 vertical shaft impactor, ProSizer and a PTSC 2618 high frequency screen to make asphalt aggregate. MHC also invested in a new Astec Double Barrel plant with a warm mix asphalt system. MHC placed the equipment in a limestone quarry near Bucaramanga, which reduced travel and located all the crushing and screening equipment in the same place. According to MHC, the success of the asphalt plant is directly linked to the success of the crushing and screening of the aggregate, making the selection of quality equipment before the start of the job one of the most crucial steps in the process. Another key factor in partnering with KPI-JCI and Astec Mobile Screens was the mobility of the track-mounted equipment. The equipment s portability provided versatility and efficiency to the project. 17

20 Argonaut Gold, Inc. Precious Metals Processing System - Hermosillo, Sonora, Mexico Kolberg-Pioneer, Inc. (KPI) Johnson Crushers International, Inc. (JCI)

21 The Hermosillo plant is the second of four Argonaut Gold operations to utilize equipment from Kolberg-Pioneer and Johnson Crushers International. The efficiency of the equipment and the support provided on the first site motivated Argonaut Gold to continue to invest in additional equipment for their other sites. The mine produces 5/16 leach pad material at up to 1,000 tons per hour (907 tonnes per hour). A Pioneer jaw and Mesabi screen feed six Kodiak Plus cone crushers and LP Horizontal screens. From there, SuperStacker telescoping stackers are used to efficiently stockpile material in a leach pad for precious metal extraction.

22 Matrimar Crushing and Screening Plant Cerralvo, Mexico Telsmith, Inc. Astec Mobile Screens, Inc. Kolberg-Pioneer, Inc. (KPI) The Matrimar plant in Cerralvo, Mexico needed to double production from 2,425 tph (2,200 tonnes per hour) to 4,850 tph (4,400 tonnes per hour). To accomplish that, a new plant was to be installed along side the existing plant. Both plants were to operate independently. Telsmith, Inc. was called on to design the process flow for crushing limestone at 2,425 tph (2,200 tonnes per hour). Equipment for this project included a pan feeder, vibrating grizzly scalper, primary impactor, double deck dirt screen, triple deck Vibro-King scalping screens and double deck Vibro-King finishing screens and four Astec Mobile Screens high frequency screens and Kolberg-Pioneer conveyors. 20

23 Barsanti Crushing and Screening Plant Venezuela Telsmith, Inc. Kolberg-Pioneer, Inc. (KPI) Spanish contractor Barsanti installed and operates a crushing plant for CVG - Ferrominera in Venezuela. Barsanti contracted with Telsmith to design the process flow and provide key equipment for the plant, which crushes very friable and weathered iron ore. The facility features a Kolberg-Pioneer heavy-duty apron feeder and Telsmith vibrating grizzly scalper, Iron Giant jaw crusher, secondary cone crusher, two tertiary cone crushers, two triple deck Vibro-King scalping screens, and four triple deck Vibro-King finishing screens. The completed plant operates at a production rate of 1,466 tph (1,330 tonnes per hour). 21

24 ERG Co. - Deriner Dam Crushing and Screening Plant Artvin Province, Turkey Telsmith, Inc. Kolberg-Pioneer, Inc. (KPI) 22

25 A successful cooperative effort of ERG Co., Telsmith and KPI produced a crushing plant and a concrete plant that produced a greater tonnage than anticipated at the site of the Deriner Dam project located at Artvin province on Coruh River. ERG built the structures and ran the plumbing and wiring. KPI and Telsmith designed the plant and controls, and supplied the major components. Since completion, the plant has produced an average of 1,100 tph (1,000 tonnes per hour). Components include sand tanks, sand screws, KPI vertical shaft impactors, electrical controls and an automation system. 23

26 Martin Marietta Jones Mill Aggregate Processing Plant Jones Mill, Arkansas, USA Kolberg-Pioneer, Inc. (KPI) Astec Mobile Screens, Inc. Astec Industries, Inc. designed two modular tower structures equipped with Kolberg-Pioneer conveyors and Astec Mobile Screens high frequency screens able to produce 150 tph (136 tonnes per hour) of 9/16 x 0 inch material without the use of water. The products made are asphalt chip and manufactured sand. The plant features a railcar loading system designed to load at a rate of 2,000 tph (1,818 tonnes per hour). A 75 ton (68 tonne) hopper/feeder allows feeding material from three sides. Material is fed at a rate of 2,000 tph (1,818 tonnes per hour). Material is then transferred to one of two 120 ton (108.8 tonne) Astec silos. The silos are mounted over railroad tracks. While material fills one silo the other silo discharges into a railcar. Astec provided the system controls to automate filling the silos and discharging the proper amount into each railcar. 24

27 The Brunei Project Refinery Wastes Remediation Project Sungai Bera River, Brunei Astec, Inc. The Sungai Bera Remediation Joint Venture (SBRJV) consortium worked with Astec to design and construct a thermal system for this remediation project. The specific application includes a major oilfield waste treatment project where waste lagoons at an oil production facility were successfully remediated. The project involved a site where oil and gas fuels are produced on the west bank of the Sungai Bera River in Brunei. At this site, there are three large, unlined pits which have been used for the temporary disposal of oily wastes. These basins cover an area approximately 6 hectares (or 15 acres). The consortium chose an indirect type of thermal technology to produce thermally treated/processed materials and recovered condensate. The condensate was routinely returned to the refinery distillation process for recycling. The total volumes that were thermally processed were approximately 80,000 cubic meters (2,825,173 cubic feet). In addition, other materials were transported to the facility from off-site oil field related sources. This has amounted to approximately 35,000 barrels of recovered oil product. The average daily treatment rate has been 265 tons per day (240 tonnes per day), with hourly rates averaging 12 tonnes per hour (13 tons per hour). The facility used the treated solid materials to rebuild the formally contaminated lagoons. As a final step, the site was re-vegetated at the completion of excavation, thermal treatment and backfilling. The project was completed in only 22 months. 25

28 Dolese Coleman Plant Aggregate Processing Plant Duncan, OK, USA Telsmith, Inc. Astec, Inc. This complete 800 tph (725 tonnes per hour) modular plant was completed by Telsmith as a turn-key project. This plant services the southeast Oklahoma and north Texas market. The plant footprint covers in excess of 37 acres (15 hectares) and produces up to 12 different spec products. The plant is completely automated and runs at a +90% availability. 26

29 Concrete Plant National Lab Y-12 Project Oak Ridge, TN, USA CEI Enterprises, Inc. Kolberg-Pioneer, Inc. (KPI) The TSC Concrete Plant, manufactured by CEI Enterprises, was selected to produce the concrete for the new uranium processing facility (UPF) at Y-12. The contractor was required to produce 235,000 yds of concrete under the stringent specifications of the Department of Energy at Oak Ridge, TN. This site is configured with a redundant arrangement of two complete plants, able to continuously produce concrete without downtime. Two special aggregate handling systems are incorporated to ensure a steady flow of aggregates to the plants. KPI provided an aggregate tripper conveyor for feeding the aggregate bin sections of the plants. A second, standard stockpile tripper conveyor manages incoming haul trucks to dump aggregates in an unloader and travel a single haul road to relieve congestion on the site. One month after installation was completed, the facility was required to pass both mix uniformity testing and mix verification testing for each plant. The entire battery of tests was successfully completed for each of the 44 mix design samples on the first pass, a rare feat for standard batch plants but typical of the TSC performances. The plants were also audited for certification by the American Concrete Paving Association and both plants were certified successfully without exceptions. 27

30 Ozinga Brothers Triple-Lane Concrete Batch Plant & Aggregate Storage Facility Des Plaines, IL, USA RexCon, Inc. RexCon designed, manufactured, and supervised the installation of a triple-lane Custom RexBatch 150 concrete batch plant in Des Plaines, Illinois on Jarvis Street, situated between the Chicago O Hare airport and the Illinois toll road. The plant was supplied to Ozinga Ready Mix Concrete. One of the largest concrete plants in the country, the plant is capable of sustaining up to 800 cubic yards (611 cubic meters) of hourly production and features two all-gravity dry batch lanes and one central mix lane. RexCon delivered and erected the new plant while two older concrete plants supplied concrete for both construction of the new plant as well as Ozinga s existing customer base. Working around these plants and the on-site LNG gas filling station for Ozinga s truck mixers, the entire operation required tight erection choreography and strict engineering tolerances to minimize disruptions to the existing concrete plants, which were relocated once the new plant became operational. All aggregate arrives via dump trucks to feed a RexCon-supplied aggregate storage facility consisting of five drive-over, in-ground hoppers, eight conveyors and six vertical inside-storage hoppers. The entire aggregate facility is capable of holding over 4,300 tons (3900 tonnes) of aggregate in addition to the plant s 780 tons (707 tonnes) of aggregate and 6,200 tons (5,624 tonnes) of cement storage, allowing the company to sustain enormous production rates in a climate-controlled facility regardless of seasonal weather conditions. To sustain the required production rates, the hoppers feed a series of eight different conveyors leading to the plant. This is the company s highest rated production facility. 28

31 Azerbaijan Tartar Plant Aggregate Processing Plant Baku, Azerbaijan This complete 500 tph (454 mtph) modular plant was provided by Telsmith in connection with an engineering/consultation firm. The plant featured the new Telsmith Hydra-Jaw, cones, TL screens and KPI wash equipment and Astec aggregate surge silos. Telsmith, Inc. Kolberg-Pioneer, Inc. (KPI) Astec, Inc. 29

32 ASTEC INDUSTRIES, INC. INFRASTRUCTURE GROUP Astec, Inc. Astec Australia Pty Ltd Astec Mobile Machinery GmbH Dillman Equipment Carlson Paving Products, Inc. Roadtec, Inc. AGGREGATE & MINING GROUP Telsmith, Inc. Osborn Engineered Products, SA (Pty) Ltd Astec do Brasil Telestack, LTD Kolberg-Pioneer, Inc. (KPI-JCI) Astec Mobile Screens, Inc. Johnson Crushers International, Inc. (KPI-JCI) Breaker Technology Ltd ENERGY GROUP CEI Enterprises, Inc. GEFCO, Inc. Heatec, Inc. Peterson Pacific Corp. Power Flame, Inc. RexCon, Inc Shepherd Road Chattanooga, Tennessee USA a Company