Filter Press, Reclaimer Round Up

Concrete plant/yard space limitations, tightening storm and process water management rules, escalating waste-concrete hauling and disposal costs, and sustainability-driven water recycling measures are prompting more producers to invest in mix reclaiming and slurry filter press equipment. Concrete Products visits key players in both categories.


Enviro-Port

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Enviro-Port’s recently added filter press models extract water from cement fine-heavy cakes, minimizing net waste volume and weight.

Company is armed with its most extensive environmental management product line to date. Starting with the entry level Aggregate Processor, all systems it manufactures are expandable in both volume and process levels.

Wash Out Aggregate Processor. Entry-level recycler opens the door to producers aiming for a wash out center and aggregate recapture; one- or two-truck discharge versions; upgradeable.

Basic Separation Series. With the integral unloading buffer, multiple truck discharges are achieved. Proper planning positions the unit for future conversion to a Complete Recovery System.

Standard and Custom Pit Agitation Kits. Well suited for customers desiring agitation for an existing or future vault and/or wedge pit. Normally deployed with gray water re-batching and/or a filter press.

Complete Recovery Series. Design implements the unloading buffer of the Basic Separation series with above ground gray water agitation tanks that have been the company signature for years. Both gray water re-batching and filter press implementation are possible.

Filter Press. Device proves to be a great tool to extract solids from an agitated tank, vault, or wedge pit. With the filter cake, a more manageable product is produced for transportation—minimizing water weight.

Services. Enviro-Port has the knowledge and capabilities to design new installations and also work with infrastructure and recycling equipment already in place. The company assists producers in achieving their recycling and process water management goals. Enviro-Port Inc., Gratiot, Wis., 800/356-8106; www.enviro-port.com


LIEBHERR USA

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LRS Concrete Recycling Plants equip producers to maintain reliable, efficient and environmentally-friendly operations. Shown here are the series’ 606 (top right), 708 (top left) and 806 models.

LRS reclaimer models 606, 708, 806, and 908 are designed to recycle residual materials by completely separating prepared concrete into solid and fine particle categories. This process allows concrete and washout from truck mixers and plant equipment to be returned to the production process.

Concrete producers benefit from material savings, Liebherr engineers note, since 100 percent of reclaimed rock and sand, plus large amounts of water and cement fines from residual concrete or washout can be reused. The advantages of recycling include avoiding the harmful effects to the environment from concrete or slurry water disposal, along with economy tied to the re-use of aggregates, cement fines, and water when new concrete is produced.

LRS series options include mobile or stationary screw systems, dosing buffers to accommodate two to six truck mixers simultaneously, and compact layouts that occupy minimal yard space. The standard circular loading hopper in each model allows filling from various angles and helps to prevent overfilling of the reclaimer screw. The four models are available with two material processing rates to accommodate most concrete operators’ recycling requirements. Liebherr USA Co., 866/879-6312; www.liebherr.com


STEPHENS MFG.

StephensWith 30-plus years in concrete reclaimer design and manufacturing, the company offers two different size classifiers and several different ways to handle cement fines, slurry and gray water. Both classifying units have special bearings that allow screw auger tail section to be lifted for service and maintenance.

The Stephens 24-in. reclaimer separates coarse aggregates on a vibrating screen before processing the fines through the washing screw. Because of their relatively small surface area per unit, coarse material is easy to wash with spray bars on a vibrating screen. Fine aggregates are conveyed to a different location for stock piling. Slurry water flows over adjustable weirs into settling ponds; clarified water is recycled for washing out mixer trucks. The 24-in. model has polyurethane replaceable shoes on the auger and uses a 4- x 8-ft. vibrating screen. The classifier is 1,000 gallons with a 24-in. auger. The collection hopper has washout stands for discharging two trucks at once. Unit includes a pump to recycle water, controls, starters and a main disconnect.

The Stephens 36-in. reclaimer is geared for extracting coarse and fine aggregate to be resold for fill material, or washed, separated, and stockpiled for recycling. Slurry water flows over adjustable weirs into settling ponds; clarified water is recycled to wash out mixer trucks. The 36-in. model has a 1,200-gal. classifier and 36-in. auger. Rock and sand are washed together and conveyed by auger. The collection hopper has stands for washing three trucks out at the same time. A vibrating screen to separate rock and sand is optional. Unit includes a pump to recycle water, controls, starters and a main disconnect. — Stephens Manufacturing Co., Tompkinsville, Ky., 877/626-0200, 270/487-6774; www.stephensmfg.com


PRISTINE ENVIRONMENTAL

Pristine iCompany focuses on slurry water solutions, offering a full line of filter presses that can handle 1 to 60 cubic feet of solids at a time and process hundreds of gallons per minute. Adaptive and evolving, the presses can be customized with advanced PLC combinations and multiple plate and frame configurations.

In addition to cleaning slurry water, Pristine Environmental’s Automated Filter Press models are built to compact and dewater collected sludge, and automatically dispose of sludge cakes. The standard filter press package allows for complete automation with no start or stop required by the user. System senses when slurry pressure builds, applies more force to the slurry water input, and compacts the sludge while monitoring the building pressures. Along with plant-level capacity systems, the company offers a line of portable Mud Hen filter presses especially suited for construction sites or small concrete operations.

All equipment is made in the U.S.A. by trained fabricators at St. Joseph, Minn., and Las Vegas locations. Pristine Environmental/Full Circle Water, 320/529-4035, www.fullcirclewater.com; www.themudhen.com


MATEC AMERICA

MatecCompany offers two ranges of concrete-grade filter presses. The Acquae has three models, 400 x 400 BWR, 500 x 500 BWR and 630 x 630 BWR; Ignis, 800 x 800 BWR. They all vary according to plant and plate size; for instance, the Acquae 630 x 630 BWR is offered in seven models ranging from 2,880- x 1,200-mm (630/10) and 11,825- x 1,200-mm (630/50), each with a 630- x 630-mm plate. Customized systems can be tailored for every level of concrete plant.

The filter presses are made of single-block steel from thick slabs, realized through plasma, laser or water-jet manufacturing processes. Typical moisture content of processed cakes is less than 25 percent. Matec quotes hourly capacity/solid recovery based on the number of mixer trucks and National Ready Mixed Concrete Association average for washout volume. The filter presses feature HPT pumps to work at more than 20 bar; Gasser Shakers for the perfect discharging of the cakes; and, Allen Bradley PLC system with remote monitoring and assistance. www.matecamerica.com


SCROMMEL

ScrommelManufacturer has designed reclaimers to deal with the harsh realities of ready mixed concrete production. Models are built tough to withstand years of use, and carry a five-year auger warranty. Simple design and automatic operation, engineers note, make the Scrommel reclaimer easy to use and maintain.

Each model features large cone shaped discharge hoppers that use gravity. The reclaimers typically recover up to 95 percent of sand and 100 percent of coarse aggregate from returned ready mixed loads and truck washout, and process material for re-use in new orders.

The reclaimers are sold factory direct, and offered in four different sizes to meet a wide range of concrete operations. Multiple station designs allow up to four mixer trucks to discharge at once. Scrommel Resource Management, Salina, Kan., 800/595-5293; www.watertreatmentonline.com


BFK TECHNOLOGIES

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Company marks its 20th year in 2017, having logged ready mixed and precast concrete installations across the world. Its flagship series is the Snubnose Concrete Reclaimer, offered in six sizes and models for extracting reusable rock and sand from returned concrete or washout. All models are built with industry standard components, allowing users to install, operate and maintain equipment without the need for a factory-trained technician.

BFK targets simplicity of design and minimal wear parts in the Snubnose series, noting “We do not use expensive replacement parts, complex assemblies or specialty tools. You don’t even need a grease gun to run a BFK Concrete Reclaimer.” — BFK Technologies Inc., Kiel, Wis., 888/235-8235; www.bfktech.com


WATER TREATMENT SOLUTIONS

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Company custom designs and installs filtration and recycling systems for the specific water handling and recycling needs oprecast and ready mixed producers, plus concrete grinding, cutting and coring operators. Its filter press designs combine simplicity and efficiency. The EnviroSystem operates without the use of chemicals to produce manageable, dry filter cakes from process water and cement slurry. Automated control packages are available to minimize labor costs, although any such system will require some manual assistance to ensure that filter cakes drop properly and prevent active cement from setting and clogging cloth pores on the press.

Water Treatment Solutions also offers a pH adjust system that utilizes an injection of carbonic acid formed by the combination of carbon dioxide and water. The acid is environmentally friendly, safe, non-corrosive and effectively converts 95 percent or more of the CO2, virtually eliminating out-gassing into the atmosphere. The injection assembly has properly designed transfer pumps, controls, regulators, plumbing and electrical materials; training for operation and maintenance completes the turnkey system.

Filter press and pH adjust systems are sized based on the precast or ready mixed concrete operation, each providing a 100-percent closed loop design complying with federal and state environmental guidelines. Water Treatment Solutions, Hampton, N.H., 866/758-1900; www.watertreatmentonline.com


BIBKO NORTH AMERICA

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The 1000, 2000 and 4000 Concrete Reclaimers are sized, respectively, for separating coarse and fine aggregate at 10, 25 and 45 yd./hour rates and serving plants with one or two, five to 20, or 15 to 80 mixer trucks. The 1000 model also anchors a series configured for precast concrete plant material recycling and “zero discharge” operating mode.

The Bibko 4000 shown here operates without ramps or maintenance-prone butterfly valves; conveys slurry water for truck washout or water weigh batchers for recycling in select orders; and, can collect yard water for use in the reclaiming loop. The basic model ships with galvanized steel body; dual wash chamber; proprietary discharge conveyor; slurry water handling package; slurry agitator system; plus, electronic controls, wiring and plumbing components. Optional equipment includes expandable, galvanized slurry tanks; 5- or 10-yd. charging buffer to limit truck wait times at reclaimer stations; and, concrete pump washout module.Bibko North America LLC, Cedar Falls, Iowa, 855/242-5687; www.concretereclaiming.com


Oquamax

Six filter press models—FP47020C, FP63020C, FP63050C, FP80040C, FP100045C and FP150045C—are engineered to operate without clarifying or thickening tanks. Oquamax uses a unique washing system that completely clears the press and lines of any residual concrete for longer filter cloth life and no build up in the piping. The filter cloths are 100-percent pure nylon. The presses feature full automation with remote monitoring; automated filter cloth and hose washing system; stainless steel guards and electrical cabinets; and, fast cake unloading system with air hammers.

ocaomaxModels range in size from the 470-x 470-mm FP47020C, which has 20 plates and an overall footprint of 2- x 2- x 17-ft., to the 1,500- x 1,500-mm FP150045C with 45 plates and a 7- x 7- x 34-ft. footprint. Plate sizes are 630-mm, 800-mm, 1,000-mm, and 1,500-mm square. Solids recovery ranges from 0.5 tph to 30 tph, depending on model. Typical moisture content of processed cakes is between 15 and 25 percent. — oquamax.com