CDE has commissioned a 100tph C&D waste recycling plant for The Ashcourt Group’s Pocklington site in East Yorkshire.
The Ashcourt Group is a construction materials supplier, which operates a number of wet batch concrete batching facilities. The company produces a range of aggregate products derived from a network of quarries, wash plants and overseas imports.
The firm wished to expand its operations with the integration of a new wash plant which will be used to support its existing concrete and aggregates businesses.
Emily Summerson, group operations director, explained, “As a market-leader and innovator, The Ashcourt Group is forward-looking and recognises the need to move towards providing more sustainable construction materials. There is a market shift in what customers are looking for, many customers now care about the green credentials of their materials and materials suppliers.
“Additionally, it made sense for us as we are generating these materials which, without the wash plant, would have to be processed as a waste material. Instead we are able to wash and recover a range of sand and aggregates in a well-placed location to serve the markets from Hull to York whilst diverting more waste from landfill.”
The plant comprises a CDE R4500 primary scalping screen, AggMax 252R scrubbing and classification system, EvoWash sand wash plant, AquaCycle A600 thickener, and Filter Press sludge dewatering system.
CDE said the R4500 electric scalper with apron feeder delivers ‘unrivalled’ protection of the downstream process by maximising product yield from feed material. The construction of the VibroCentric drive removes unnecessary weight while delivering acceleration up to 5G.
The AggMax scrubbing and classification system combines pre-screening, scrubbing, organics removal, sizing, stockpiling, fines recovery and filtrates removal on a compact chassis. The integrated trash screen allows for the removal of organics and other lightweight contaminants.
The EvoWash sand washing system is engineered for in-spec sands with hydrocyclone technology and gives ‘unparalleled’ control of silk cut points. CDE added it is also equipped with the VibroSync drive centre which distributes power evenly across the full screening area and ensures ‘maximum’ transfer of energy to material for ‘unrivalled’ dewatering performance.
The integration of CDE’s AquaCycle technology is allowing the site to recycle more water. An alternative to water extraction and the process of pumping water to the plant, CDE’s AquaCycle is designed to minimise water consumption by ensuring up to 90% of process water is recycled for immediate recirculation.
The filter press eliminates the need for tailings dams or settling ponds. CDE revealed the filter cake contains 85% dry solids and can be used in several applications such as pond lining or landfill capping. The plant also features AutoLime, which controls the lime mixing process.
The plant is producing six final products (two sands; 0-2mm soft sand and 0-4mm coarse sand, and three aggregates; 4-10mm, 20-40mm and 40-80mm) as well as filter cake which will be applied in lining landfill cells.
Emily Summerson added, “Since commissioning the plant in June 2023, our recycled materials have been well received in the marketplace with great feedback on the quality. We are dedicated to providing the highest rates of recycling possible and this new plant in Pocklington is helping enhance this. We are currently diverting more than 90% of material which would have otherwise been sent to landfill.”
Discussing the value of the additional plant, director Reginald Port added, “The wash plant has allowed us to keep our tipping reserve free and internalised a lot of spend which previously went to third parties, with the wash plant we are able to become increasingly more self-sufficient to supply our own construction projects and reduce costs.
“The wash plant has definitely met our expectations, in fact, it has exceeded them with the specified tonnages. We thought 100tph would be top end processing, but we are regularly doing 115–120 tph and up to 150tph depending on the feed material.”
Mike Bibby, business development manager at CDE, commented, “Plants like this are the future of the industry and a testament to Ashcourt Group’s passion for diverting waste from landfill and creating a circular economy. It’s been a pleasure to work with the team at Ashcourt to build a solution that aligns with their goals.”
CDE and The Ashcourt Group will be hosting a virtual site tour of the 100tph waste recycling plant, where experts will detail each stage of the process. To register for the virtual site tour on Tuesday 14th November visit: https://www.cdegroup.com/ashcourt
