Aggregate & Recycling Section

Pages 63-86 Aggregate Production and Recycling Section

For more information on crushing, screening and recycling equipment, visit CEG's Web site at www.constructionequipmentguide.com. Phoenix AltaFlo Thickener Reduces By-Product Waste

A family-owned business with strong local roots, J. Melone & Sons is a ready-mix operation serving a 50-mi. radius of its Stow, Mass., location.

Founded in 1959 by Joseph Melone and currently operated by his grandsons Peter, Billy, John and Greg Melone, the company prides itself on having a strong family focus not only among themselves, but also among its employees, some of whom have been with the Melones for a long as 50 years.

The company has aggregate product hauled into its site in Stow, where it is processed to produce sand as the primary ingredient in the production of its ready-mix. Over the past several decades, Melone has made major nothing toxic or inherently dangerous about the ponds themselves, but they can become quite large — in the case of Melone’s about the size of two football fields. In these slurry ponds, over a considerable amount of time, the solids separate from the water and settle to the bottom of the pond. The sediment at the bottom of the pond must be excavated out and stockpiled to make room for more sediment on a continual basis.

Increasingly, environmental concerns have developed about the impact on streams and water systems if the fines from a slurry pond were to enter them. Due to the

see MELONE page 66

(L-R) are Joe Drake of Phoenix Process Equipment; Chris Salafia of EESSCO; Peter Melone of J. Melone & Sons; and Dick Vining of EESSCO.

investments in keeping its aggregate production equipment facility up to date and has worked closely with EESSCO, based in Hanson, Mass., to achieve its goals.

In 2003, EESSCO’s Chris Salafia and Dick Vining replaced Melone’s old cone crusher, which had become outdated, with a new H3000 Hydrocone Crusher 3-ft. cone. In 2006, EESSCO replaced Melone’s original jaw plant, which was dated from 1963, with a new Jaw crusher. In 2008, again working closely with EESSCO, Melone invested in a New 4’ x 10’ double deck screen.

These investments were very successful for Melone — its overall aggregate production more than doubled, its labor costs dramatically eased and down time was reduced.

According to Peter and John Melone, over the years they have developed a great working relationship with Salafia, Vining and all of the staff at EESSCO, and have relied heavily on their expertise as they have expanded and grown their operation.

In 2018, J. Melone & Sons faced a new challenge that potentially significantly changed the way that it did business: the disposal of the sludge by-product from the manufacturing of the sand for its ready-mix operation needed to change dramatically.

When sand is manufactured, there is a very fine end-product that has no useful purpose. To dispose of it, it is mixed with water and traditionally stored in slurry ponds. There is

Page 64 • September 14, 2022 • www.constructionequipmentguide.com • Recycling Section • Construction Equipment Guide Terex MP Acquires ZenRobotics: ‘Green’ Investment in Emerging Circular Economy

Terex Materials Processing (MP), a global leader in aggregate, environmental, concrete, lifting and handling machinery, has acquired the assets of ZenRobotics Ltd., a company that designs and creates robots that pick, sort and recycle waste material.

ZenRobotics is a global leader in smart robotic recycling. Its robots, powered by proprietary AI software, make recycling more efficient, accurate and profitable. The company’s ambition is to make the circular economy a reality by turning global waste into clean raw materials.

ZenRobotics, based in Helsinki, Finland, will retain its name and become a Terex brand, with the unit reporting to Tony Devlin, who leads the Terex MP environmental businesses.

ZenRobotics was started in 2007 by creating a completely new market for robotic waste sorting. Today, it continues to automate the waste industry.

With ZenRobotics technology, operators can upgrade their recycling infrastructure to meet modern requirements and lead the way towards a more efficient, circular future.

In 2009, ZenRobotics pioneered the use of AI-based robots to the waste-sorting process. This led the team to open opportunities by introducing the first ZenRobotics Recycler in Helsinki. Since that time, it has become a global operation, marketing multiple recyclers around the world including expansion into China and the U.S. market in 2016.

In 2015, ZenRobotics launched the Heavy Picker, the world’s strongest waste sorting robot for bulky Construction and Demolition (C&D) type waste.

ZenRobotics’ goal is to help its customers extract higher value out of waste, get more actionable data and reach ambitious circular economy targets. Terex is already active within global waste markets through Terex Ecotec, Terex CBI, Terex Fuchs and Terex Recycling.

Zen Robotics will add to the Terex portfolio in global waste, where it will continue to be operated as a stand-alone business while also benefiting from MP’s broader market presence and from efficiencies enabled by MP’s global scale. This acquisition of a highly “green-focused” company further supports MP’s commitment to its environmental business and Environment, Social and Governance (ESG) goals.

Over 15 years of industry-defining product development have enabled ZenRobotics to create industry-pioneering technology. The Heavy Picker is a multipurpose waste sorting robot for bulky material. Equipped with sturdy arms, various sensors and artificial intelligence, it provides a simple, unstaffed sorting process and makes waste sorting more accurate, safe, and profitable.

The Fast Picker is a high-speed waste sorting robot for maximizing material recovery. It is compactly designed for

Zen Robotics will add to the Terex portfolio in global waste, where it will continue to be operated as a stand-alone business while also benefiting from MP’s broader market presence and from efficiencies enabled by MP’s global scale. easy integration to existing processes and conveyors in material recovery facilities (MRFs), and it increases profits by enabling fully automated sorting and higher output purity. And finally, the company launched the ZenBrain, which is artificial intelligence for sorting robots with advanced recognition ability and autonomous decision-making. This technology provides actionable data and a steep learning curve in optimizing waste sorting efficiency. “ZenRobotics is an exciting, modern company that lends itself perfectly to our pre-existing environmental expertise, and their ethos of making a circular economy more possible aligns perfectly with our goals and targets for the future of Terex MP," Devlin said. "We’re excited to see the many ways that we can apply this technology and what potential this acquisition can bring Terex MP with the application of this technology. The journey that we’re about to begin with ZenRobotics and Terex MP is one that we look forward to starting, and we extend a warm welcome our new colleagues into the Terex MP team.” Jarmo Ruohonen, CEO of ZenRobotics, said, “We at ZenRobotics are delighted to be welcomed into the Terex MP team and we look forward to sharing our knowledge. As a company, we have worked hard for the past 15 years creating technology that helps companies efficiently deal with different types of waste materials, helping to chase down targets that propel us towards a more circular economy. Terex MP is the perfect partner to help us achieve that, and being part of the Terex MP team will give ZenRobotics more global opportunities to grow.” For more information, visit Terex.com. 

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On the left is thickened sludge that has settled to the bottom of the tank and will be pumped out for disposal. On the right is completely clarified water, which will be re-used in Melone’s aggregate plant’s washing process. The vast majority of water that enters the system is clarified and re-used, leaving behind only a thick sludge for disposal. Working with the staff of EESSCO, the engineers and support teams at Phoenix Process Equipment, the infrastructure was built, and the Phoenix AltaFlo put in place.

MELONE from page 63 sizes of Melone’s slurry pond and its proximity to a stream, the decision was made that no more slurry could be added to its existing pond. The impact of that decision was financially very significant to the company’s bottom line — essentially, Melone could no longer process its own stone on site and was forced to purchase finished processed aggregate from its competitors to make its readymix, creating a very strong impact on its bottom line.

Shortly after this decision was made, a conversation started with EESSCO to see what alternatives could be explored.

There are some inherent problems with traditional slurry ponds, one being their size, quite often more than several acres; and two, their consistency. Traditional methods for creating the slurry mix creates a very watery product. In the case of Melone, 1,000 gal. of water would contain about 2 percent solid waste. So, in other words, within 1,000 gal. of water only 2 percent of that mass of water would actually be disposing of the product you are trying to get rid of. This fundamentally creates the problem with the size of the slurry pond.

Working with one of the manufacturers that EESSCO represents, a solution to this challenge was identified — the Phoenix AltaFlo thickener.

The Phoenix AltaFlo thickener is a rakeless thickener that provides ultra-high-rate mixing, flocculation and internal dilution, followed by clarification and positive sludge collection and removal in a single tank. The thickener’s unique internal geometry, a deep sidewall and steep conical bottom provides underflow concentration comparable to or better than a traditional raked thickener, according to the manufacturer.

Internal dilution helps optimize flocculation and a deep free settling zone and conical feed well achieves maximize flocculation. In addition, the AltaFlo thickener uses sedimentation technology to maximize the recovery rate of clean, clarified overflow water that can be recycled and reused in the process.

Essentially what this very complicated scientific explanation of the Phoenix AltaFlo thickener means is that this new advanced process dramatically changes the consistency of the sludge by-product that J. Melone & Sons would make. What was 1,000 gal. of water with a 2 percent solid waste content being produced every minute could be changed to 60 gal. of water with a 40 percent solid waste content being produced per minute.

Instead of needing multiple acres of a very fluid pond that gradually allows the solid content to settle to the bottom, users are now

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A Caterpillar 992K loads a 773 with aggregate from the plant.

By Colin Kund

SPECIAL TO CEG from page 1

In February 2022, H&K Group Inc. (H&K) took delivery of two new locomotives for its Birdsboro Quarry rail loadout operation.

Located in Berks County, Pa., Birdsboro Quarry has a rich mining history dating back to the 1920s. H&K acquired the quarry and commenced operations in 2000.

When H&K initially began Birdsboro Quarry operations, the two locomotives sourced for the job were SD38s from the Reading & Northern (RBMN) #’s 2002 and 2005. One of the units, HKGX #2002, featured a smiley face and also had Autism Awareness ribbons applied to it. This was done in recognition of Matthew Haines, the son of H&K’s Vice President and Chief Operating Officer James T. “Jim” Haines and Pam Haines, and grandson of company co-founder John B. Haines IV.

Both SD38s had quite a rich history. They were built in July 1969 for the Detroit, Toledo & Ironton Railroad. After the DT&I was dissolved, they were acquired by the Grand Trunk Western Railroad before being purchased by the Reading & Northern (RBMN). As part of the purchase agreement of the new locomotives, both SD38s were traded in to Motive Power Resource (MPR). The SD38s had all of their reusable parts recycled with the rest being scrapped. Fortunately, the salvaged pieces will keep other units in service for some time.

The two new EMD (Electro Motive Division, formerly a division of General Motors) SD40-2s were purchased from Motive Power Resource (MPR/MPVX) and arrived on H&K property in early February of this year. SD40-2s are among the most reliable locomotives in service today and it’s no wonder as to why they are so popular; some have been in service for almost half a century. The two units, with 3,000 hp each, are ex-Norfolk Southern (Norfolk Southern Corporation/NS), with #3549 being of Burlington Northern heritage and #6164 being of Southern Railway. Once on the property, the locomotives went right to work. Shortly before the summer of 2022, H&K’s Austin Graphics division applied the new branding to the locomotives.

Birdsboro Quarry’s loadout operation was needed to serve H&K’s stone yard and affiliated asphalt plant locations in southern Delaware. Currently, H&K loads three trains a week for shipment to H&K’s Dagsboro Stone Depot location, located in Dagsboro, Del. Many different types of aggregate are shipped to this location via rail service.

Two to three days a week, a crew of four assists with loading the train, plus the offroad truck and hauling operators. The current loadout operation has two hoppers (for ease of loading specific aggregate) and each hopper is filled by a large rigid frame haul truck. The trucks retrieve the material from the stockpiles within the quarry plant. From here, the operator of the loadout plant simply selects which hopper will be emptied and the aggregate is loaded into the railcars via a

A 773 haul truck loads one of two hoppers with aggregate for loadout.

see LOCOMOTIVES page 82

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2021 MCCLOSKEY J40: Hours: 389, Serial Number: 90232, Belt Protection Deflector Plate, Overband Magnet on Main, Working lights, Safety Beacon Lights, Telematics, Volvo D8 T4F 252HP Engine >>>>Call 2022 MCCLOSKEY ST100T: Hours: 53, Serial Number: 92129, Stacker with Impact Idlers Under Hopper, Upgraded Belt Cleaner/Scraper, Telematics, Upgraded Hydraulics, CAT C2.8 Tier 4F/ Stage V 74HP Engine >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>Call

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NEW MWS CSP200 COMPACT SAND PLANT, Serial Number: 20349, cost and energy efficient, exceptional performance, 14 x 6 dewatering screen, can produce 1 grade of sand, self regulating sump tank >>>>>>>Call 2021 MCCLOSKEY ST80: Hours: 6, Serial Number: 92183, CAT 2.2 Tier 4F 49 HP, Hydraulic Axle Jacks, Hydraulic Axle Extensions, Hydraulic Landing Gear, Hopper Wear Plates, Impact Idlers under Hopper Call 2021 MWS S190: Hours: 165, Serial Number: 91989, Screening Plant with Fitted Rinser Kit with Spray Bars on Screenbox, Aux Drive Circuit, Plain Belt on Main Conveyor >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>Call 2021 MCCLOSKEY C2: Hours: 324, Serial Number: 92089, Metal Detector on Feeder, Discharge Chute on Main Conveyor, Upgraded Belt Cleaner/Scraper on Main, Telematics, CAT C9.3B Stage V/Tier 4F 375 HP Engine >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>Call