Stationary plants NATURAL STONE / RECYCLING OF CONSTRUCTION MATERIAL / OLD LANDFILLS / SLAG RECYCLING

Transcription

1 Stationary plants NATURAL STONE / RECYCLING OF CONSTRUCTION MATERIAL / OLD LANDFILLS / SLAG RECYCLING

2 Kleemann designs processing plants according to individual requirements. Kleemann designs, manufactures and installs turnkey processing plants for all areas of the primary mineral industry. Decades of experience guarantee optimal coordination of the plants to the > requirements of the customer and the local specifications, > material properties of the feed material, > selection of suitable plant components, as well as > satisfaction of all quality requirements of the end product. Kleemann designs processing plants according to the individual requirements of the customer while taking into account maximum economy. The optimal process is designed and calculated using modern simulation programs. We look after you right from the very start of a project with our know-how and professional project management, and after the plant is up-and-running, with our comprehensive and reliable service.

3 STATIONARY PLANTS CONTENTS The optimal process is designed and calculated using modern simulation programs. The implementation of the process layout takes place in the project department with the creation of an initial design taking into consideration the local specifications. Together with the customer final solutions are developed, discussed and realised during project meetings. Contents overview > Page 04 Natural stone, sand and gravel > Page 06 Mixture of construction waste and recycling of construction materials > Page 08 Slag recycling and old landfills > Page 10 Semi-stationary plants in the Porti series

4 Processing plants for natural stone, sand and gravel The processing of natural stone, as well as sand and gravel, has long been a tradition at Kleemann. Over the decades a wealth of experience has been collected which can be fully utilised for each new design. Indeed in the design of stationary plants no one job is like another. Nevertheless it is still a huge advantage when we have local knowledge, and this can be provided in collaboration from the customer and our local dealers. Kleemann proves time and time again that its design concepts not only meet, but mostly exceed, specifications and requirements. Natural stone In the processing of natural stone, whether it is hard, medium-hard or soft, abrasive or non-abrasive, the quality of the end product has a decisive influence on the processing machines. Therefore, plants such as feeders, coarse separators and screening units are manufactured by Kleemann. Just as important is the crushing technology: Core components such as > single toggle jaw crushers for primary crushing of hard and abrasive stone, > impact crushers for primary crushing of hard, medium-hard and soft limestone, > impact crushers for primary and secondary crushing of construction materials for recycling, as well as > hard-stone impact crushers for secondary and tertiary crushing stages Two impact crushers of type SNH 16 in use at second crushing stage. are manufactured by Kleemann, also with German know-how.

5 STATIONARY PLANTS NATURAL STONE / SAND AND GRAVEL 05 Brief description of Stevin Rock Project, United Arab Emirates Task Machines used Feed material: Limestone Feeder: ASCH 1500 x 6000 H Feed size: Feed capacity: End products: 0/1000 mm up to 1000 t/h, depending on the type and composition of the feed material and proportion of primary screening primary screening 0/20 mm 0/5 mm crushed sand 5/10 mm crushed gravel 10/20 mm crushed gravel Two-stage wobbler grizzly: RRS 16/12 Single toggle jaw crusher: SSTR 1600 x x hard-stone impact crusher: SNH 20 End product quality: i.a.w. British Standard BS x high-output screening units: VU 3FH 2380 Sand and gravel Processing sand and gravel to produce high-quality construction materials involves designing and implementing projects according to the individual needs of the customer. Important indicators are not only the investments, but also to a large extent the operating costs later on. Therefore, the experienced project managers at Kleemann constantly keep an eye on the overall plant. Silo installations with wet classifying units for an hourly charge quantity of approx. 200 t. Equipped with log washers, screen, buffing unit and hydrocyclone plants for recycling fine sand, as well as single toggle jaw split crushers for crushing oversize. As with natural stone plants, processing machines such as washers and classifying machines are also the key components here and are a deciding factor in the end product quality. They are designed and designed and manufactured at the Kleemann plant in Göppingen. Turnkey complete solutions are planned and designed in conjunction with reliable and competent partners. Wet screening station with sand dewatering.

6 Processing plants for a mixture of construction waste and recycling of construction materials Due to less and less available landfill area and the continual depletion of raw material reserves, it is becoming increasingly important, also for the future, to separate a mixture of construction waste and recycle construction materials. Kleemann is the leader in the construction of stationary recycling plants with more than two decades of experience. Plants operational in Germany, Belgium, the Netherlands, France, the United Arab Emirates and Spain are evidence of a knowledge that is appreciated and valued far beyond the borders of Germany. Mixtures of construction waste Mixtures of construction waste must, in accordance with the law, be separated according to material or thermally disposed of. This requires the collection of waste and its subsequent separation into recyclable fractions that can be used for recycling or in some incidents, disposed of thermally. Since the beginning of this development, Kleemann has been designing, manufacturing and installing plants for sorting mixtures of construction waste and has excellent experience in the economic design of sorting processes and their implementation in real plant technology. The SHB 15/100 impact crusher is best suited for recycling rubble. A double-deck screen unit, type VU 2 1/2 GF 2060, is employed for primary screening.

7 STATIONARY PLANTS MIXTURES OF CONSTRUCTION WASTE / RECYCLING CONSTRUCTION MATERIALS 07 Brief description of the Steenkorrel Project, Netherlands Task Feed material: Feed size: Feed material: Feed size: Feed capacity: Crushing capacity: End products: rubble, demolished concrete up to approx x 1300 mm, profile, max. length approx mm excavated earth, bulk density 1.6 t/m³ 0/20 mm, max. 40 % of total feed up to 700 t/h, depending on the type and composition of the feed material and proportion of primary screening primary crusher up to 600 t/h (end grain size approx. 0/200 mm), secondary crusher up to 200 t/h (end grain size approx. 0/60 mm) 0/15 mm primary screening material 0/40 mm crushed mix (of which 20/40 mm is screened) 0/60 (X) mm demolished concrete, directly from secondary crusher, not screened Machines used Slat conveyor: NPB 2000 Double-deck heavy-duty screen: VU 2B/ST 2050 Rubble impact crusher: SHB 20/160 Vibrating chute: ARUM 20-22/40 2 x Vibrating chute: ARUM 12-14/15 Triple-deck vibrating screen: VU 3G/F 2060 Vibrating chute: ARUM 8-10/15 Scanning and sorting plant: Secondary cone crushers: 7 x 5 x 2,5 m KG 300 S 2 x Vibrating chute: ARUM 60-80/15 Double-deck air screening unit 4 x electromagnets Total output of all machines and conveyors (installed): approx kw Recycling of construction materials Mineral scrap such as bricks, reinforced concrete and roadway asphalt and concrete rubble is processed to produce high-quality recyclable construction material that can be supplied for reuse - for example as road foundation or as aggregate for manufacturing hydraulically combined bases. This process is environment friendly and spares the continually depleting supply of raw materials for the manufacture of construction materials. Kleemann customises complete or partial plants to individual requirements and offers the best processing technology at optimum economy. Steenkorrel Project, Netherlands Up to 700 t / h

8 Processing plants for slag recycling and old landfills For years Kleemann has been designing, manufacturing and installing turnkey processing plants for slag recycling that are tailor-made to individual requirements and today it is a competent contact in this specialised area. Also in the area of processing old landfill materials, Kleemann is able to draw on its wealth of experience, which also benefits customers in this complex area. Both slag recycling and the processing of old landfill materials require extensive expert knowledge in the arrangement of the entire process.

9 STATIONARY PLANTS SLAG RECYCLING / OLD LANDFILL 09 Brief description of the Ecologic Project, Slovenia Task Feed material: Feed size: Feed capacity: steel slag, building rubble 0/600 mm 100 up to 150 t/h Machines used Primary screening: Double-deck screen VU 2B 1230 Primary crushing: : Jaw crusher SStR 940 x 500 Intermediate sorting: Single-deck screen VU 1F 1235 End products: primary screening material 0/25 mm material mix 0/50 mm, individual grain sizes (chippings) 0/2, 2/4, 4/8 and 8/11 mm Secondary crushing: Classifying screen: Vertical impact crusher 2 x double-deck screen VU 2F x magnetic separators Slag recycling Command of the four core competencies, crushing, separation of ferrous and non-ferrous metals, washing and screening is a prerequisite for designing an efficient treatment process. In many areas of application a wet screen is necessary. The primary separation of ferrous and non-ferrous metals from the slag takes place before the first crushing stage using special magnetic separators. After crushing the slag with jaw crushers, the newly decomposed metals are put through a second separation stage where they are again removed from the material flow. High-quality products are crushed during the second crushing stage and placed in screens where they undergo a dry or wet process depending on the properties of the slag. Old landfills The restrictive granting of new licenses to operate landfills means the useable space for stockpiling landfill material is continuing to run short. To conserve these existing storage capacities, many operators have in the meantime been forced to extract recyclable materials from the materials already stockpiled and use them for recycling. An exact and careful design is indispensable especially in areas under space constraints. The processing of these old landfill materials, which very often have little mineral content and can thus be very cohesive, requires extensive professional competence for the selection of individual components and their arrangement in the overall process. For years Kleemann has been working successfully in this area and has already designed and realised several turnkey and highly efficient plants that are customised to the individual needs of customers.

10 Stationary processing technology at its most flexible. When high-quality end products are required from the recovery of mineral raw materials, then high demands also are placed on the technology. Generally these special qualities are produced using stationary recovery processes. In exceptional cases, for example medium-term infrastructure projects, it is sometimes not worthwhile to provide a stationary plant. For this reason, semi-stationary plants are used here and also in other areas. The semi-stationary plants in the Porti series combine the advantages of the mobile processing technology with that of stationary plants. Compared to stationary plants, they are not fixed to the ground but mounted on skids. They can be easily relocated if required, hence the name portable plants. Thanks to the modular design of the individual crushing and screening units, the most diverse processes are possible. They are thus a more reasonable alternative to real stationary plants. In comparison to track-mounted plants, the units in the Porti series can naturally only be moved with great time and effort expended. They do have, however, considerable advantages from a technical point of view, which are reflected mainly in a higher performance spectrum. Thanks to a generously dimensioned material buffer between the individual process stages, a stable and even plant operation is possible. The plants in the Porti series can be combined for use in the entire plant or can operate self-sufficiently.

11 KLEEMANN SEMI-STATIONARY PLANTS IN THE PORTI SERIES 11 Brief description of the Doriss Project, Russia Task Charged material: Feed size: Feed capacity: End product output: End products: End product quality: blasted dolomite 0/700 mm approx. 300 t/h min. 250 t/h 0/40 mm 0/30 mm primary screening, 0/5, 5/10,10/20 and 20/40 mm high-quality crushed gravel i.a.w. Russian GOST standard Machines used Plant type: > semi-stationary plant PORTICAT PC 120 Z with jaw crusher SSTR 1200 x 800 > semi-stationary plant PORTIFOX PF 16 ST with impact crusher SNH 16 > semi-stationary plant PORTISCREEN PS 19 Z with screen VU 2F 2050, > semi-stationary plant PORTISCREEN PS 19 Z with screen VU 2F 2050, Elaborate and technical solutions are also possible with portable plants. Portable plants can work with large intermediate buffers and thus provide even plant operation. The semi-stationary plants in the Porti series combine the advantages of mobile processing technology with that of stationary plants.