Metso recyle presentation

1. Recycling crushing
Economical and ecological construction
22.02.2012 JiH

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. © 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. © 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. © 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. © 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. © 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. © Metso
Typical recycling materials :
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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. © 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
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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.
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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
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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
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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)
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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
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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.
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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. © 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. © 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. © Metso
Applications for crushed Slag
GGBS = ground granulated blast furnace slag

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. © 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. © Metso
• Italy
• LT106 ASC
• Feed Slag 0-300mm
• Product 0-60 mm
• Capacity 280 tph

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
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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. © 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. © 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. © 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. © Metso28
• Germany / Chemical factory development as an industrial park
LT106
• Concrete demolition 150 tph / Totally 300 000 tons

29. © Metso29
• Japan Rikuzen Takada (Tsunami area) LT96
• Feed from destroyed buildings
• 450 000 tons in 3 years

30. © Metso
• E. Schulze, German recycling
contractor LT96
• Feed: Mixed recycling material
0-600mm
• Product: 0-32mm base material /
65mtph
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31. © Metso
• Demolition site in Germany LT96
• Feed: 0-300 mm
• Product 0-50 mm
• Capacity 120 tph
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32. © Metso
• Demolition site in Germany LT96S
• Feed: Concrete 0-400 mm
• Product 0-32 mm
• Capacity 80 tph & oversize
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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. © Metso
• Lafarge Glass recycling in UK with LT1213S
• Feed: Glass bottles
• Product 0-5 mm
• Capacity 32 tph
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