Separate, Wash, Dewater: enhance your recycling process

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Solutions for wet material recycling using water-based separation technologyDoppstadt Water Separation Systems

Doppstadt Water Separation Systems

Water is a vital asset, but sometimes not using it can be counterproductive. This is particularly apparent when top-quality materials are required, such as in the re-use of concrete. Here aggregates are often reclaimed by dry separation processes – but consequently fail to meet the quality standards.

So why not apply similar techniques to those used to produce the virgin material, e.g. water based washing and separation systems?

Both Doppstadt and Siltbuster have followed this path intensely and draw on the combined strengths of Doppstadt’s experience of 50 years in materials recycling and Siltbuster’s experience of 15 years in developing innovative water treatment and wet materials recycling systems.

DWS has developed its revolutionary new range of water based separation systems called the Gritbuster.

The Gritbuster separation systems operate with a closed water treatment circuit without the requirement of large settlement lagoons for water treatment, meaning it is much more efficient than the conventional processing of sand and gravel.

The net result is a range of compact plants that can be deployed on small sites to reprocess a range of waste materials to a higher standard than that currently achieved by most conventional recycling systems.

When it comes to materials recycling and separation, choose the Gritbuster!

ContentsGritbuster ................................................................4

Hydraulic Density Separation ........................6

Water Treatment .................................................8

Case Studies ....................................................... 10

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RECEPTION HOPPER

& FEED AUGER

WET WASHING

TROMMEL

SAND AND GRIT

DEWATERING AUGER

HYDRAULIC

DENSITY SEPARATOR

AGGREGATE

DEWATERING AUGER

FINE ORGANICS

DEWATERING SCREEN

GRITBUSTER WT-100 & WT-250

The Gritbuster Washing and Wet Waste Recycling Plants offer an effective solution for the separation, washing, de-watering and recovery of a wide range of materials and wet wastes including sand, aggregates, gully waste, road sweepings and trommel fines. The Gritbuster range comprises of two models, differentiated by feed method and capacity:

Gritbuster WT-100 : Designed for applications requiring tipping directly from highways sweeper trucks. The Gritbuster WT-100 can process up to 10 t/hour.

Gritbuster WT-250 : Specifically designed for the washing of pre-dewatered or stockpiled waste materials loaded by JCB, Loading Shovel and more. The Gritbuster WT-250 offers outstanding performance while processing up to 25 t/hour.

Separating the feed material based on both size and density, the Gritbuster process provides an unrivalled standard of washing and separation for the particularly difficult treatment of wet waste streams.

HOW IT WORKS• Raw material is loaded via a loading shovel from existing

stock piles (WT-250) or is tipped directly into the Gritbuster (WT-100)

• A screw feed auger ensures both dry and wet feedstocks are handled with ease

• The wet trommel washes and separates the aggregate whilst minimising contamination from organic matter in the recovered sand

ANTICIPATED OUTPUTSFine Heavies: (10mm to circa 300 micron) Washed Sand, Grit and Fine Gravel

Fine Lights: (10mm to circa 1mm)Fine Organics (Grass, etc.)

Oversize Heavies: >10mmWashed Aggregate & Metals etc.

Oversize Lights/Floats: >10mmLarge Organics (Wood, Leaves etc.)

Dirty Wash Water: Typically <1mmSilt & fine solids laden water

MAIN ADVANTAGES

• Reduces disposal costs by separating Organic and Inert Material

• Enables reuse of recovered sand and aggregate

• Enhances recycling potential

• Minimises waste going to Landfill

TYPICAL APPLICATIONS

• Road Sweepings

• Gully Waste

• Trommel Fines

• Sand Washing

DID YOU KNOW?Typical road sweepings contain over 70% recyclable

material, including sand, gravel, metal and plastics.

Gritbuster

Aggregate Washing, Separation and Recovery

• An integrated (WT-250) hydraulic density separator is used to further separate coarse aggregate from the lighter plastic, sticks, etc.

• The recovered sand and gravel can be reused as non-structural fill or secondary aggregate

• The output of a Gritbuster unit depends on the nature of the raw feed materials, but for typical road sweeping and gully waste we find the below outputs:

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GRITBUSTER HDS

The Gritbuster HDS has been designed to separate light, low-density particles from dense particles (e.g. organic material from sand and gravel), removing unwanted contaminants and enabling granular material and aggregates to be recycled

One of the foremost qualities of the Gritbuster unit is its outstanding resilience and its capability of handling a variety of feedstocks. Depending on the nature of feedstock the Gritbuster HDS can process up to 15 to 20 t/hour.

The Gritbuster HDS can be used for standalone material processing with its own recirculating water treatment plant, or can be fully integrated with our range of Gritbuster washing systems to provide a complete washing, destoning and separation solution.

HOW IT WORKS

• Separation of the lightweight floating materials is

achieve via an axial flow pump to induce an up flow

current within the separation chamber.

• This upflowing current carries the lighter “float” material

to the waters surface and onto a drainage conveyer,

subsequently separating lighter materials.

• The water drains through the belt and is recirculated

back to the separation chamber via the axial flow pump.

• Fast settling dense particles drop to the bottom of

the chamber where an Archimedes Screw moves the

material up an inclined trough.

• By using water as the separation media, the

performance of the unit can be optimised by simply

varying the speed of the axial flow pump

Hydraulic Density Separation

Water Based Material Separation

SEPARATION

HOPPER

DEWATERING

SCREW

SEPARATED SINK

MATERIAL

MAIN ADVANTAGES

• Enhances recycling potential, waste minimisation & landfill diversion

• Reduces waste disposal & associated costs

• Readily transportable, fast and simple to deploy, easy to operate, “Plug & Play” design

• Optimisable cut point density to allow for process refinement

TYPICAL APPLICATIONS

• Aggregate Recovery and Organics Re-moval

• Glass Washing

• Trommel Fines Separation

• Additional Processing of Gritbuster Oversize Material

• Density Based Material Separation

DID YOU KNOW?Trommel fines typically comprise of 80% material that,

if separated, would qualify for the lower UK landfill

tax, saving an operator generating 10,000 t/year over

£640,000 (approx. 870.000 Euro)! The Gritbuster HDS

not only separates all kinds of material responsibly

helping you excel at your next eco-audit, but can also

save you money!

FLOAT MATERIAL

CONVEYOR

AXIAL FLOW

PUMP

FINAL

MATERIAL

WASHING JETS

MATERIAL

OUTPUT

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WHY TREAT WASH WATER?

Key to all the Doppstadt Water Separation Systems is the use of clean water to enable washing and separation of waste streams.As the processes run, some of the waste (typically silts and clays) remains in the wash water, resulting in it being re-circulated around the plant.To ensure clean products (sand, gravel et al) and optimum performance of the separation systems, the wash water must be of a reasonable quality. Therefore a water treatment plant is necessary to maximise the process, unless an unlimited supply of clean water is available - and even if so, we’re supposed to make reasonable use of this valuable resource!

Doppstadt Water Separation Systems utilise the industry leading Siltbuster water treatment equipment, ensuring best treatment standards are achieved.

A typical water treatment plant comprises of:• Flow Proportional Chemical Dosing

(ensuring minimal chemicals are used)• Lamella Clarifier

(providing compact yet effective settlement)

• Grey Water & Sludge Holding Tanks• Filter Press or Geotextile Bags

(to de-water the slurry from the clarifier)

CHEMICAL DOSING & DEWATERING

Chemical dosing systems are an integral part of a water treatments operation. Typically supplied in an ISO20 shipping container whereby exact doses of coagulants and flocculents are mixed with the water to improve the settlement characteristic of the contaminants. Without the addition of chemicals, some materials, such as clays would not settle out in the clarifier.

Settled suspended particulates form a wet slurry

of consolidated solids. Sludge management is therfore important, because all fine material added to the system requires removal.

Typically a Filter Press is used to transform the wet solids laden slurry into a “filter cake”, a solid material that can be easily handled, transported and disposed to landfill as a non-liquid waste.

The filter cake typically comprises of all the fine sands, silts, mud and fine particulate matter washed from the feedstocks.

Water Treatment

Enabling Closed Loop Water Recycling

WATER FEED INTO

TREATMENT PLANT

LAMELLA PLATES

INCREASE AREA

SLUDGE DRAW

DOWN PORTS

TREATED WATER

OUTLET

FLOW PROPORTIONAL

CHEMICAL DOSING

THICKENED SLURRY

DEWATERED

FLOCCULATION

MAIN ADVANTAGES

• Enables closed loop water recycling

• Reduces the plants fresh water requirements to a minimum

• Chemical dosing enhances natural particle settlement characteristics

WATER TREATMENT FLOW

• Chemicals flow proportionally mixed with returned water

• Suspended solids removed from the water in a Lamella Clarifier

• Sludge periodically removed from clarifier

• Settled sludge dewatered in a Filter Press

DID YOU KNOW?One Siltbuster HB40R contains over 40m2 settle-

ment area packaged into a 6.5m2 footprint. That is the

equivalent of linking over three conventional settle-

ment tanks together. The Siltbuster not only provides

wash water of impeccable quality, but also lots of

additional space!

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Case Studies

Municipal Grit Washing and SeparationFRIESEN ISLANDS MUNICIPALITY, GERMANY

This project was undertaken on a remote island of the north coast of Germany which is a tourist destination during the summer. In advance of the summer season and influx of tourists, the drainage and sewers on the island require clean-ing to remove windblown sand, other sediments and trapped sewage waste. Usually the local authority has all waste shipped off the island by truck or container for disposal on the mainland

– a rather costly and time-consuming procedure.

Enter Gritbuster: The machine can be set up in an existing sewage treatment works on the island where it processes and separates the material in accordance with the official requirements. An alternative that has it all: flexibility, ef-ficiency and savings potential!

Road Sweeping Separation - Gritbuster WT-100 GWRTAITH GWYNEDD, NORTH WALES

Gwrtaith Gwynedd serves not only Gwynedd Council but also Conwy Council, Pembrokeshire Council and Carmarthenshire County Council, treating 14,000 tonnes of grit, gully and road sweepings every year.

The ability of the Gritbuster system to transform other-wise unwanted road sweepings and gully waste into a re-usable commodity offers a real solution to the “waste issues” of Gwynedd Council.

“Before 80% of our gully waste and street sweepings used to go to landfill, now, thanks to the Gritbuster sys-tem 90% are being recycled. That’s a huge turnaround,” - Steffan Jones of Gwynedd Council. Initially Gwrtaith Gwynedd had leased the Gritbuster WT-100. After two years, however, they purchased the machine. Harri Parry, the companies owner, says: “It has worked so well over the past two years and has proven its worth.” •

Filter Sand Washing ProjectDERRICK CONTRACTORS, WWTW, ISLE OF BUTE

The Treatment of Drinking Water requires a filtration stage, which is sometimes carried out via large sand filled filter beds, through which the water passed through to be filtered. Over time, the filtered sand, having filtered out the con-taminants, becomes dirty and nurtures a layer of algae on the surface. In order to keep the filter beds functioning, the top 15mm of filter sand has to be removed periodi-cally and disposed of/replaced or where possible washed

to a very clean standard and replaced back into the filter beds. Derrick Contractors leased a Gritbuster WT-100 System to wash the sand enabling it to be replaced into the site’s slow sand filter. Sand was excavated from the filter bed and loaded by dumper into the Gritbuster unit. Organ-ics (reeds/algae et al) were separated from the sand, the sand was washed and dewatered before being discharge directly back into the filter bed for relaying and reuse. •

Road Sweeper and Gully Emptier Hire CompanyGO PLANT LIMITED, SHROPSHIRE

Go Plant Limited, the UK’s leading operated Road Sweep-er and Gully Emptier hire company, has been a Gritbuster client since 2011. After initially trailing and purchasing a Gritbuster WT-100, Go Plant followed up in 2014 by up-grading to the larger Gritbuster WT-250.Processing around 100 tonnes per day, the Gritbuster sys-tem enables Go Plant to recycle more of the sweeper and gully waste arriving back at its Telford Depot, and there-

fore reduce its waste disposal costs. In the past, such sweepings have typically gone to landfill but this proved very expensive. “Thanks to the Gritbuster system we can now treat and recover 92% of the waste collected through road sweep-ing, massively reducing our landfill costs – which is good for the business and for the environment”, says Aidan Garvey, General Manager of Shropshire Road Sweepers. •

Independent Road Sweeper Hire Company ADMEC, Durham County

ADMEC Municipal Services Ltd is the largest independent road sweeper hire company in the North East of England, with 35 operational staff and an operational fleet of 25 mechanical sweepers.Key to ADMEC’s approach is the company’s aim to re-cover and recycle as much of the material as possible, including the water, with the target of achieving a 95% recycling rate. their Gritbuster WT-100 is helping to turn this goal into a reality.

George Tweddle, managing director at ADMEC, ex-plained: “We don’t dispose of any material to landfill any more, we’re seeing significant operational savings and the generation of a new revenue stream with the sale of the recycled material.”ADMEC uses the excess water, from the water treatment plant, to fill its road tankers which are used to fill motor-way barriers and other grey water applications. •

Materials Recovery Projects Gritbuster HDS

Various applications involving the separation of coarse granular materials based on density including the separa-tion of• Timber from construction demolition waste• Saturated timber and stone form reclaimed timber for a

large Sweedish manufacture of flat pack furniture.

• Separation of metal from plastics , etc. in car fragmen-tation waste.

• Recovery of aggregate from coarse organic fraction of sweeper waste

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Doppstadt Water Separation Systems

Unipure House, Monmouth Monmouthshire, NP25 5JA, UK

Tel: +44 (0) 1600 772256 Fax: +44 (0) 01600 775312E-Mail: enquiries@doppstadt.co.uk Internet: www.doppstadt.co.uk

©2016 Doppstadt Water Separation Systems. All pricing and references to operating weights, sizes, capacities and other performance measurements in this publication are provided for guidance only and may vary dependant upon site