Solutions for wet material recycling using water-based separation technology

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1 Solutions for wet material recycling using water-based separation technology Doppstadt Water Separation Systems Separate, Wash, Dewater: enhance your recycling process with our Gritbuster solutions innovative versatile cost-effective Hire, Sale, and Technical Support

2 Doppstadt Water Separation Systems Water is a vital asset, but sometimes not using it can be counterproductive. This is particularly apparent when top-quality materials are required, such as in the re-use of concrete. Here aggregates are often reclaimed by dry separation processes but consequently fail to meet the quality standards. So why not apply similar techniques to those used to produce the virgin material, e.g. water based washing and separation systems? Both Doppstadt and Siltbuster have followed this path intensely and draw on the combined strengths of Doppstadt s experience of 0 years in materials recycling and Siltbuster s experience of years in developing innovative water treatment and wet materials recycling systems. DWS has developed its revolutionary new range of water based separation systems called the Gritbuster. The Gritbuster separation systems operate with a closed water treatment circuit without the requirement of large settlement lagoons for water treatment, meaning it is much more efficient than the conventional processing of sand and gravel. The net result is a range of compact plants that can be deployed on small sites to reprocess a range of waste materials to a higher standard than that currently achieved by most conventional recycling systems. When it comes to materials recycling and separation, choose the Gritbuster! Contents Gritbuster... Hydraulic Density Separation... Water Treatment...8 Case Studies... 0

3 Gritbuster Aggregate Washing, Separation and Recovery GRITBUSTER WT-00 & WT-0 The Gritbuster Washing and Wet Waste Recycling Plants offer an effective solution for the separation, washing, dewatering and recovery of a wide range of materials and wet wastes including sand, aggregates, gully waste, road sweepings and trommel fines. The Gritbuster range comprises of two models, differentiated by feed method and capacity: Gritbuster WT-00 : Designed for applications requiring tipping directly from highways sweeper trucks. The Gritbuster WT-00 can process up to 0 t/hour. Gritbuster WT-0 : Specifically designed for the washing of pre-dewatered or stockpiled waste materials loaded by JCB, Loading Shovel and more. The Gritbuster WT-0 offers outstanding performance while processing up to t/hour. Separating the feed material based on both size and density, the Gritbuster process provides an unrivalled standard of washing and separation for the particularly difficult treatment of wet waste streams. MAIN ADVANTAGES Reduces disposal costs by separating Organic and Inert Material Enables reuse of recovered sand and aggregate Enhances recycling potential Minimises waste going to Landfill TYPICAL APPLICATIONS Road Sweepings Gully Waste Trommel Fines Sand Washing DID YOU KNOW? Typical road sweepings contain over 70% recyclable material, including sand, gravel, metal and plastics. HOW IT WORKS Raw material is loaded via a loading shovel from existing stock piles (WT-0) or is tipped directly into the Gritbuster (WT-00) A screw feed auger ensures both dry and wet feedstocks are handled with ease The wet trommel washes and separates the aggregate whilst minimising contamination from organic matter in the recovered sand An integrated (WT-0) hydraulic density separator is used to further separate coarse aggregate from the lighter plastic, sticks, etc. The recovered sand and gravel can be reused as non-structural fill or secondary aggregate The output of a Gritbuster unit depends on the nature of the raw feed materials, but for typical road sweeping and gully waste we find the below outputs: RECEPTION HOPPER & FEED AUGER WET WASHING TROMMEL SAND AND GRIT DEWATERING AUGER HYDRAULIC DENSITY SEPARATOR AGGREGATE DEWATERING AUGER FINE ORGANICS DEWATERING SCREEN ANTICIPATED OUTPUTS Fine Heavies: (0mm to circa 00 micron) Washed Sand, Grit and Fine Gravel Fine Lights: (0mm to circa mm) Fine Organics (Grass, etc.) Oversize Heavies: >0mm Washed Aggregate & Metals etc. Oversize Lights/Floats: >0mm Large Organics (Wood, Leaves etc.) Dirty Wash Water: Typically <mm Silt & fine solids laden water

4 Hydraulic Density Separation Water Based Material Separation GRITBUSTER HDS The Gritbuster HDS has been designed to separate light, low-density particles from dense particles (e.g. organic material from sand and gravel), removing unwanted contaminants and enabling granular material and aggregates to be recycled One of the foremost qualities of the Gritbuster unit is its outstanding resilience and its capability of handling a variety of feedstocks. Depending on the nature of feedstock the Gritbuster HDS can process up to to 0 t/hour. The Gritbuster HDS can be used for standalone material processing with its own recirculating water treatment plant, or can be fully integrated with our range of Gritbuster washing systems to provide a complete washing, destoning and separation solution. HOW IT WORKS Separation of the lightweight floating materials is achieve via an axial flow pump to induce an up flow current within the separation chamber. This upflowing current carries the lighter float material to the waters surface and onto a drainage conveyer, subsequently separating lighter materials. The water drains through the belt and is recirculated back to the separation chamber via the axial flow pump. Fast settling dense particles drop to the bottom of the chamber where an Archimedes Screw moves the material up an inclined trough. By using water as the separation media, the performance of the unit can be optimised by simply varying the speed of the axial flow pump SEPARATION HOPPER DEWATERING SCREW SEPARATED SINK MATERIAL 7 FLOAT MATERIAL CONVEYOR AXIAL FLOW PUMP FINAL MATERIAL WASHING JETS MATERIAL OUTPUT MAIN ADVANTAGES Enhances recycling potential, waste minimisation & landfill diversion Reduces waste disposal & associated costs Readily transportable, fast and simple to deploy, easy to operate, Plug & Play design Optimisable cut point density to allow for process refinement TYPICAL APPLICATIONS Aggregate Recovery and Organics Removal Glass Washing Trommel Fines Separation Additional Processing of Gritbuster Oversize Material Density Based Material Separation DID YOU KNOW? Trommel fines typically comprise of 80% material that, if separated, would qualify for the lower UK landfill tax, saving an operator generating 0,000 t/year over 0,000 (approx Euro)! The Gritbuster HDS not only separates all kinds of material responsibly helping you excel at your next eco-audit, but can also save you money! 7 7

5 Water Treatment Enabling Closed Loop Water Recycling WHY TREAT WASH WATER? Key to all the Doppstadt Water Separation Systems is the use of clean water to enable washing and separation of waste streams. As the processes run, some of the waste (typically silts and clays) remains in the wash water, resulting in it being re-circulated around the plant. To ensure clean products (sand, gravel et al) and optimum performance of the separation systems, the wash water must be of a reasonable quality. Therefore a water treatment plant is necessary to maximise the process, unless an unlimited supply of clean water is available - and even if so, we re supposed to make reasonable use of this valuable resource! CHEMICAL DOSING & DEWATERING Chemical dosing systems are an integral part of a water treatments operation. Typically supplied in an ISO0 shipping container whereby exact doses of coagulants and flocculents are mixed with the water to improve the settlement characteristic of the contaminants. Without the addition of chemicals, some materials, such as clays would not settle out in the clarifier. Settled suspended particulates form a wet slurry Doppstadt Water Separation Systems utilise the industry leading Siltbuster water treatment equipment, ensuring best treatment standards are achieved. A typical water treatment plant comprises of: Flow Proportional Chemical Dosing (ensuring minimal chemicals are used) Lamella Clarifier (providing compact yet effective settlement) Grey Water & Sludge Holding Tanks Filter Press or Geotextile Bags (to de-water the slurry from the clarifier) of consolidated solids. Sludge management is therfore important, because all fine material added to the system requires removal. Typically a Filter Press is used to transform the wet solids laden slurry into a filter cake, a solid material that can be easily handled, transported and disposed to landfill as a non-liquid waste. The filter cake typically comprises of all the fine sands, silts, mud and fine particulate matter washed from the feedstocks. 7 WATER FEED INTO TREATMENT PLANT LAMELLA PLATES INCREASE AREA SLUDGE DRAW DOWN PORTS TREATED WATER OUTLET FLOW PROPORTIONAL CHEMICAL DOSING THICKENED SLURRY DEWATERED FLOCCULATION MAIN ADVANTAGES Enables closed loop water recycling Reduces the plants fresh water requirements to a minimum Chemical dosing enhances natural particle settlement characteristics WATER TREATMENT FLOW Chemicals flow proportionally mixed with returned water Suspended solids removed from the water in a Lamella Clarifier Sludge periodically removed from clarifier Settled sludge dewatered in a Filter Press DID YOU KNOW? One Siltbuster HB0R contains over 0m settlement area packaged into a.m footprint. That is the equivalent of linking over three conventional settlement tanks together. The Siltbuster not only provides wash water of impeccable quality, but also lots of additional space! 7 8 9

6 Case Studies Municipal Grit Washing and Separation FRIESEN ISLANDS MUNICIPALITY, GERMANY This project was undertaken on a remote island of the north coast of Germany which is a tourist destination during the summer. In advance of the summer season and influx of tourists, the drainage and sewers on the island require cleaning to remove windblown sand, other sediments and trapped sewage waste. Usually the local authority has all waste shipped off the island by truck or container for disposal on the mainland a rather costly and time-consuming procedure. Enter Gritbuster: The machine can be set up in an existing sewage treatment works on the island where it processes and separates the material in accordance with the official requirements. An alternative that has it all: flexibility, efficiency and savings potential! Road Sweeper and Gully Emptier Hire Company GO PLANT LIMITED, SHROPSHIRE Go Plant Limited, the UK s leading operated Road Sweeper and Gully Emptier hire company, has been a Gritbuster client since 0. After initially trailing and purchasing a Gritbuster WT-00, Go Plant followed up in 0 by upgrading to the larger Gritbuster WT-0. Processing around 00 tonnes per day, the Gritbuster system enables Go Plant to recycle more of the sweeper and gully waste arriving back at its Telford Depot, and therefore reduce its waste disposal costs. In the past, such sweepings have typically gone to landfill but this proved very expensive. Thanks to the Gritbuster system we can now treat and recover 9% of the waste collected through road sweeping, massively reducing our landfill costs which is good for the business and for the environment, says Aidan Garvey, General Manager of Shropshire Road Sweepers. Road Sweeping Separation - Gritbuster WT-00 GWRTAITH GWYNEDD, NORTH WALES Independent Road Sweeper Hire Company ADMEC, Durham County Gwrtaith Gwynedd serves not only Gwynedd Council but also Conwy Council, Pembrokeshire Council and Carmarthenshire County Council, treating,000 tonnes of grit, gully and road sweepings every year. The ability of the Gritbuster system to transform otherwise unwanted road sweepings and gully waste into a re-usable commodity offers a real solution to the waste issues of Gwynedd Council. Filter Sand Washing Project DERRICK CONTRACTORS, WWTW, ISLE OF BUTE Before 80% of our gully waste and street sweepings used to go to landfill, now, thanks to the Gritbuster system 90% are being recycled. That s a huge turnaround, - Steffan Jones of Gwynedd Council. Initially Gwrtaith Gwynedd had leased the Gritbuster WT- 00. After two years, however, they purchased the machine. Harri Parry, the companies owner, says: It has worked so well over the past two years and has proven its worth. ADMEC Municipal Services Ltd is the largest independent road sweeper hire company in the North East of England, with operational staff and an operational fleet of mechanical sweepers. Key to ADMEC s approach is the company s aim to recover and recycle as much of the material as possible, including the water, with the target of achieving a 9% recycling rate. their Gritbuster WT-00 is helping to turn this goal into a reality. Materials Recovery Projects Gritbuster HDS George Tweddle, managing director at ADMEC, explained: We don t dispose of any material to landfill any more, we re seeing significant operational savings and the generation of a new revenue stream with the sale of the recycled material. ADMEC uses the excess water, from the water treatment plant, to fill its road tankers which are used to fill motorway barriers and other grey water applications. The Treatment of Drinking Water requires a filtration stage, which is sometimes carried out via large sand filled filter beds, through which the water passed through to be filtered. Over time, the filtered sand, having filtered out the contaminants, becomes dirty and nurtures a layer of algae on the surface. In order to keep the filter beds functioning, the top mm of filter sand has to be removed periodically and disposed of/replaced or where possible washed to a very clean standard and replaced back into the filter beds. Derrick Contractors leased a Gritbuster WT-00 System to wash the sand enabling it to be replaced into the site s slow sand filter. Sand was excavated from the filter bed and loaded by dumper into the Gritbuster unit. Organics (reeds/algae et al) were separated from the sand, the sand was washed and dewatered before being discharge directly back into the filter bed for relaying and reuse. Various applications involving the separation of coarse granular materials based on density including the separation of Timber from construction demolition waste Saturated timber and stone form reclaimed timber for a large Sweedish manufacture of flat pack furniture. Separation of metal from plastics, etc. in car fragmentation waste. Recovery of aggregate from coarse organic fraction of sweeper waste 0

7 Doppstadt Water Separation Systems Unipure House, Monmouth Monmouthshire, NP JA, UK Tel: + (0) Fax: + (0) enquiries@doppstadt.co.uk Internet: 0 Doppstadt Water Separation Systems. All pricing and references to operating weights, sizes, capacities and other performance measurements in this publication are provided for guidance only and may vary dependant upon site