Recycling crushing
Economical and ecological construction
22.02.2012 JiH
© Metso Date Author Title2
Why recycle ?
• Recycling Preserve of Nature, Minerals, Environment
Nature:
- Gravel resources ...
© Metso Date Author Title3
The need for recycle crushing is
growing rapidly because :
• Legislations are getting tighter
•...
© Metso Date Author Title4
Recycle crushing is becoming good
business when :
• Dumping of demolition material is
expensive...
© Metso
Crushing VS Trucking
Date Author Title5
Trucking cost 0.03 - 0.06 EUR/ton/km
Excavation/Demolition 20000m3
Excavat...
© Metso Date Author Title6
Case Germany
Germany
• Dumbing costs 20 e/ton
• Selling price 0-45 mm / 5 euros/ton
• Scrap iro...
© Metso7
Recycling crushing process
Selective demolition
Recycle crushing
Sorting Re-use
• Such as:
- Fill material
- Road...
© Metso
Typical recycling materials :
8
Concrete Bricks
Asphalt Slag
• Feed materials and
typical products:
- Concrete => ...
© Metso
Recycling crushing with Lokotracks
• Feed: Asphalt
- 0-22
• LT1110S
• LT1213S
- 0-40/50
• LT96, LT1110
• LT106, LT...
© Metso
Pre-sorting of the recycling feed material to be
crushed
• Sorting is crucial for successful recycling
operation
•...
© Metso
Lokotrack Jaw in Recycling
• Jaw crusher advantages:
- Economical to crush also abrasive
materials
- Can be used f...
© Metso
Lokotrack Impactor in Recycling
• Impact crusher advantages:
- High reduction ratio’s
- Very high capacity, linear...
© Metso
Typical process constraints
• Steel from reinforced concrete
- Feed material preparation
- Magnet separation
• Met...
© Metso
Applications for crushed concrete and bricks
Crushed aggregate
• Crushed aggregate made of demolition
waste (concr...
© Metso
Applications for crushed concrete and bricks
Recycled concrete & Crushed bricks
• Recycled concrete
- Recycled con...
© Metso
Use of crushed recycled materials
Concrete
Date Author Title16
Concrete
Quality
0% 20% 50% 100%
Recycled aggregate...
© Metso
Applications for crushed Slag
• Resulting from the separation of a metal from
its ore
• Slag can be broadly catego...
© Metso
Applications for crushed Slag
SLAG is a product of the steel making process.
Before useless byproduct but now acce...
© Metso
Applications for crushed Slag
GGBS = ground granulated blast furnace slag
© Metso
• Traditionally old asphalt material was only
worthless waste
- Material consists of
- High quality aggregates and...
© Metso
Asphalt crushing with Lokotracks
• Typical end products
- 0-40 mm (LT96, LT106)
- 0-22 mm (LT1110S, LT1213S)
• Exa...
© Metso
• Italy
• LT106 ASC
• Feed Slag 0-300mm
• Product 0-60 mm
• Capacity 280 tph
© Metso
LT slag applications
Multistage crushing Japan, Tetsugen
• LT106 + LT300GPB
• Feed: Steel slag
• Actual Production...
© Metso
LT slag applications
Multistage crushing Japan, Tetsugen
• LT106 + LT1213S + LT300GPB
• Feed: Steel slag
• Actual ...
© Metso
Active Setting Control (ASC)
LT96,LT106,LT116
Setting can be returned back
automatically or manually after an
over...
© Metso26
• UK KKB Regeneration Ltd LT1110
• Tarmac asphalt 0-50 mm / 180-200 tph
• Sticky application (some concrete mixe...
© Metso
Finland / Mäkitalo LT1213S
Feed asphalt blogs 0-500 mm
End product 0-16 mm
Capacity 120 tph
In 0-12 mm production ...
© Metso28
• Germany / Chemical factory development as an industrial park
LT106
• Concrete demolition 150 tph / Totally 300...
© Metso29
• Japan Rikuzen Takada (Tsunami area) LT96
• Feed from destroyed buildings
• 450 000 tons in 3 years
© Metso
• E. Schulze, German recycling
contractor LT96
• Feed: Mixed recycling material
0-600mm
• Product: 0-32mm base mat...
© Metso
• Demolition site in Germany LT96
• Feed: 0-300 mm
• Product 0-50 mm
• Capacity 120 tph
31
© Metso
• Demolition site in Germany LT96S
• Feed: Concrete 0-400 mm
• Product 0-32 mm
• Capacity 80 tph & oversize
32
© Metso
• Germany rental unit
• Feed concrete 0-500mm
• Product 0-32 mm
• Capacity 200 tph
• Site development project
-Bui...
© Metso
• Lafarge Glass recycling in UK with LT1213S
• Feed: Glass bottles
• Product 0-5 mm
• Capacity 32 tph
34
Lt recycaplication
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Lt recycaplication

  1. 1. Recycling crushing Economical and ecological construction 22.02.2012 JiH
  2. 2. © Metso Date Author Title2 Why recycle ? • Recycling Preserve of Nature, Minerals, Environment Nature: - Gravel resources preserved Minerals: - Less consumption of raw materials Environment: - Less transportation need (less fuel) - Less emissions, noise, dust - Amount of waste decreased - Less dumping ground space needed Savings: - Less transportation - No dumping costs
  3. 3. © Metso Date Author Title3 The need for recycle crushing is growing rapidly because : • Legislations are getting tighter • Dumping costs are constantly growing • New standards will be developed for the use of recycled material
  4. 4. © Metso Date Author Title4 Recycle crushing is becoming good business when : • Dumping of demolition material is expensive • Transport distances are long • Demolition project is situated in a city center • Metal prices are high
  5. 5. © Metso Crushing VS Trucking Date Author Title5 Trucking cost 0.03 - 0.06 EUR/ton/km Excavation/Demolition 20000m3 Excavation/Demolition 30000tons Transport cost 30 km 40500EUR Number of loads, 20 tons/truck 2025trucks loads LT1213S production -40mm 150t/h Crushing hours 200hours hours/day 16hours Crushing days 12.5days
  6. 6. © Metso Date Author Title6 Case Germany Germany • Dumbing costs 20 e/ton • Selling price 0-45 mm / 5 euros/ton • Scrap iron selling price 150 euros/ton • Factory demolition contract - Contractor will charge 12 e/m3 • Demolition,preparation,crushing • Addtion to that 0-45 mm 5 e/ton • Iron 150 e/ton
  7. 7. © Metso7 Recycling crushing process Selective demolition Recycle crushing Sorting Re-use • Such as: - Fill material - Road base and pavement - Asphalt and concrete remixTo be removed: -Too big a re-bars
  8. 8. © Metso Typical recycling materials : 8 Concrete Bricks Asphalt Slag • Feed materials and typical products: - Concrete => 0-32/40/50/60 - Asphalt => 0-22 / 0/40 - Bricks => 0-32/40/50 - Slag => 0-22
  9. 9. © Metso Recycling crushing with Lokotracks • Feed: Asphalt - 0-22 • LT1110S • LT1213S - 0-40/50 • LT96, LT1110 • LT106, LT1213 - Remark: No compression crushing with asphalt above 10-15° C - Jaw - cone combinations are possible • Feed: Concrete and bricks - 0-32 • LT1110S • LT1213S - 0-40/50 • LT96 • LT106 • LT1110S • LT1213S • LT1315 - Also primary - cone combinations are possible 9
  10. 10. © Metso Pre-sorting of the recycling feed material to be crushed • Sorting is crucial for successful recycling operation • Correct size feed material will increase the capacity • Uncrushable materials must be pulled out from feed material • Rebar longer than feed opening must be removed - Max. rebar length about 500mm • Rebar thicker than the minimum setting must be removed - Max. rebar diameter about 20mm • No asphalt recycling above 10-15°C temperatures with jaw crusher. 10
  11. 11. © Metso Lokotrack Jaw in Recycling • Jaw crusher advantages: - Economical to crush also abrasive materials - Can be used for very hard and abrasive materials - Different tooth shape for different applications - Recycling (separate the steel from the end product) - Relatively thick rebar can be handled - Coarse end product with a relatively low share of fines - The crushing process can be observed, open cavity 11
  12. 12. © Metso Lokotrack Impactor in Recycling • Impact crusher advantages: - High reduction ratio’s - Very high capacity, linear with the power input - Impact crusher can take larger feed than comparable size jaw crusher - Suitable for asphalt recycling at higher temperatures than with jaw crusher - In recycling applications good separation of re-bar from concrete - Good shape of end product - Impact crusher generates more fines than jaw crusher 12
  13. 13. © Metso Typical process constraints • Steel from reinforced concrete - Feed material preparation - Magnet separation • Metals in slag - Active setting control • Behaviour of asphalt in warm temperatures - Crushing in winter time - Using support material (mix) 13
  14. 14. © Metso Applications for crushed concrete and bricks Crushed aggregate • Crushed aggregate made of demolition waste (concrete and bricks) can be used instead of fresh gravel and rock aggregates for e.g. road base and sub base and foundations of buildings. • Construction with recycled crushed aggregates is no different from construction with gravel or rock aggregates • Good results experienced by using crushed concrete in road base - Better load-bearing capabilities have been measured with thinner layer thickness 14
  15. 15. © Metso Applications for crushed concrete and bricks Recycled concrete & Crushed bricks • Recycled concrete - Recycled concrete can be produced out of assorted crushed concrete. - Most of the times crushed concrete is used for frost resistant backfills e.g. as roadbase. - Erosion control Riprap • Crushed bricks - Crushed bricks are often used as backfill material. 15
  16. 16. © Metso Use of crushed recycled materials Concrete Date Author Title16 Concrete Quality 0% 20% 50% 100% Recycled aggregate % Demanding application -freezing - erosive -... Less demanding application e.g. foundations, channelworks Typical application
  17. 17. © Metso Applications for crushed Slag • Resulting from the separation of a metal from its ore • Slag can be broadly categorized as ferrous (iron/steel) and non-ferrous (copper, lead/zinc) depending on the industry from which they come • During smelting, when the ore is exposed to high temperatures, these impurities are separated from the molten metal and can be removed • The collection of compounds that is removed is the slag SLAG is a product of the steel making process. Before useless byproduct but now accepted as a valuable material in many different applications.
  18. 18. © Metso Applications for crushed Slag SLAG is a product of the steel making process. Before useless byproduct but now accepted as a valuable material in many different applications. Main types: Iron blast furnace slag Steel slag Electric arc furnace slag Usage: Replacement 30-50% cement in concrete Road base Asphalt aggregates Concrete aggregates Slag ballast Mineral wool insulation Erosion control
  19. 19. © Metso Applications for crushed Slag GGBS = ground granulated blast furnace slag
  20. 20. © Metso • Traditionally old asphalt material was only worthless waste - Material consists of - High quality aggregates and expensive bitumen and additives • In modern road paving these valuable materials can be reused efficiently From 10% up to 100% of new asphalt surface can consist of old removed and recycled asphalt • Damaged asphalt surface can be removed with a milling cutter - Waste generated is small in particle size and can be reused as it is • Removal of asphalt surfaces are done by excavators and resulting waste is in form of asphalt blocks - Waste material needs to be crushed before reuse Applications for crushed asphalt
  21. 21. © Metso Asphalt crushing with Lokotracks • Typical end products - 0-40 mm (LT96, LT106) - 0-22 mm (LT1110S, LT1213S) • Example - LT1213S - Feed material: Asphalt blocks - Feed size: 0-600 mm - End product: 0-22 mm • Capacity: 220 tons per hour • Compressive crushing (Jaw or cone) cannot be used in temperatures above 10- 15 C • Impact crushing does not have this temperature limitation LT1213 in asphalt recycling
  22. 22. © Metso • Italy • LT106 ASC • Feed Slag 0-300mm • Product 0-60 mm • Capacity 280 tph
  23. 23. © Metso LT slag applications Multistage crushing Japan, Tetsugen • LT106 + LT300GPB • Feed: Steel slag • Actual Production capacity • 0 - 40mm • 246 t/h Date Author Title INTERNAL 23
  24. 24. © Metso LT slag applications Multistage crushing Japan, Tetsugen • LT106 + LT1213S + LT300GPB • Feed: Steel slag • Actual production Capacity - 0-25 mm - 238 t/h • Production limited by small excavator - Up to 300 t/h possible
  25. 25. © Metso Active Setting Control (ASC) LT96,LT106,LT116 Setting can be returned back automatically or manually after an overload - Setting can be opened or closed under load ASC cylinders Clamping cylinder Toggle plate Accumulator for clamping cylinder Pressure relief valve(s)
  26. 26. © Metso26 • UK KKB Regeneration Ltd LT1110 • Tarmac asphalt 0-50 mm / 180-200 tph • Sticky application (some concrete mixed with asphalt as a support material)
  27. 27. © Metso Finland / Mäkitalo LT1213S Feed asphalt blogs 0-500 mm End product 0-16 mm Capacity 120 tph In 0-12 mm production using LT1100 cone crusher ”wear costs with impactor”
  28. 28. © Metso28 • Germany / Chemical factory development as an industrial park LT106 • Concrete demolition 150 tph / Totally 300 000 tons
  29. 29. © Metso29 • Japan Rikuzen Takada (Tsunami area) LT96 • Feed from destroyed buildings • 450 000 tons in 3 years
  30. 30. © Metso • E. Schulze, German recycling contractor LT96 • Feed: Mixed recycling material 0-600mm • Product: 0-32mm base material / 65mtph 30
  31. 31. © Metso • Demolition site in Germany LT96 • Feed: 0-300 mm • Product 0-50 mm • Capacity 120 tph 31
  32. 32. © Metso • Demolition site in Germany LT96S • Feed: Concrete 0-400 mm • Product 0-32 mm • Capacity 80 tph & oversize 32
  33. 33. © Metso • Germany rental unit • Feed concrete 0-500mm • Product 0-32 mm • Capacity 200 tph • Site development project -Building demolition -Material preparation with scissors
  34. 34. © Metso • Lafarge Glass recycling in UK with LT1213S • Feed: Glass bottles • Product 0-5 mm • Capacity 32 tph 34

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