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SEPTEMBER/OCTOBER 2023 | VOL.17 ISSUE NO5 | www.AggBusiness.com

Closing in on emission-free quarrying PONSI BLY

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INTERVIEW WCA’s Ian Riley on cement’s profitability & decarbonisation journey p10

CRUSHING & SCREENING Ambitious brands looking to crush it globally p28

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Screening powered by jaw-crusher-generated excess electricity p16

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DRILL RIGS, HAMMERS & BREAKERS A well-drilled Czech mate p37

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CONTENTS MARKET REPORT

“Resilience is a notable characteristic of the UK and Ireland aggregates and quarrying machinery markets, with much of it on show in 2023” p19

SEPTEMBER/OCTOBER 2023 | VOL.17 ISSUE NO5 | www.AggBusiness.com

Vol.17 ISSUE No.5 September/October 2023

Regulars

37 DRILL RIGS, BREAKERS & HAMMERS – 2

05 COMMENT

Indeco’s growing attachment to the new marketplace; Epiroc’s a prized Czech mate

Groundbreaking fully solar-powered cementplant landmark; Volvo CE strengthens management team

08 ASSOCIATION NEWS

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44 WATER RECYCLING, FILTRATION & MANAGEMENT

Saving the Nature Restoration Law

Showcasing the fully automated soil- and water-treatment plant

50 EVENTS

48 BLASTING & ALTERNATIVES

All the key events in the quarrying & aggregates world

Impressive new ways to optimise your quarrying blasts

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Fresh strategic investment powers BKT’s growth vision

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INTERVIEW WCA’s Ian Riley on cement’s profitability & decarbonisation journey p10

CRUSHING & SCREENING Ambitious brands looking to crush it globally p28

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Screening powered by jaw-crusher-generated excess electricity p16

41 TYRE TECHNOLOGY

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Tracking aggregates reuse & waste management

Closing in on emission-free quarrying DUCE OU

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DRILL RIGS, HAMMERS & BREAKERS A well-drilled Czech mate p37

COVER STORY: A hybrid diesel-electric Metso Lokotrack crusher provides free excess electricity for Tverås Maskin

Specials 10 INTERVIEW

Features 28 CRUSHING & SCREENING

WCA CEO Ian Riley on putting the cement industry on the path to profitability & decarbonisation

New international players target impact in crushing and screening

16 QUARRY PROFILE

32 LOADING

Metso-enabled free screening electricity empowers Tverås Maskin

A lot of headline-grabbing loading-unit news makes for a vibrant sector of the quarryingequipment machine market

35 HAULING

19 MARKET REPORT

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Driverless hauling passes its exhibition close-up

The UK & Ireland aggregates sectors are again showcasing their impressive resilience to cope with varied market challenges

24 RECYCLED AGGREGATES Making C&D waste pay in the Middle East

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35 www.AggBusiness.com

10 AGGREGATES BUSINESS EUROPE September/October 2023

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COMMENT

HEAD OFFICE EDITOR: Guy Woodford ASSISTANT EDITOR: Liam McLoughlin CONTRIBUTING EDITORS: Munesu Shoko, V.l. Srinivasan,

Shem Oirere, Partha Basistha, Eugene Gerden, Shadrack Kavilu EQUIPMENT EDITOR: Mike Woof DESIGNERS: Simon Ward, Andy Taylder PRODUCTION MANAGER: Nick Bond OFFICE MANAGER: Kelly Thompson INTERNET, IT & DATA SERVICES DIRECTOR: James Howard WEB MANAGER: Sarah Biswell SOCIAL MEDIA MANAGER: Tatyana Mechkarova MANAGING DIRECTOR: Andrew Barriball PUBLISHER: Geoff Hadwick CHAIRMAN: Roger Adshead ADDRESS Route One Publishing Ltd, Second Floor, West Hill House, West Hill, Dartford, Kent, DA1 2EU, UK TEL: +44 (0) 1322 612055 FAX: +44 (0) 1322 788063 EMAIL: [initialsurname]@ropl.com (gwoodford@ropl.com) ADVERTISEMENT SALES SALES DIRECTOR:

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EDITOR Tracking aggregates reuse & waste management

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fforts to build a circular economy within Europe’s aggregates and wider building-materials industry are gathering pace, and a new report from a leading UK industry player highlights an eye-catching, technology-based approach to it. Tarmac’s Changing mindsets on aggregate reuse and recycling in the built environment report details the role of digital waste tracking in enhancing the future of CD&E (Construction, Demolition and Excavation) waste management.

As it notes, introducing a mandatory digital waste-tracking system in the UK is imminent.

Announced as a notion by the Environment Act 2012 to replace the existing paper-based system, the new tracking system will mark a new era for land and waste recovery. As a result, Tarmac’s report recognises that waste and the reuse of resources is a key topic for the CD&E industry, going into detail about the necessity for improvement on the industry’s current performance. With 138 million tonnes of CD&E waste produced each year in the UK alone, the report stresses that more must be done to see waste as a valuable resource and optimise its use.

The aim is to digitally track every part of the waste chain, from waste producer to recycling or disposal point. Tarmac says that while this will be a big change for everybody involved in waste management, it will also present new opportunities and challenges for the CD&E industry.

The key report informs companies of waste management’s environmental impact and shares advice on navigating upcoming changes and legal obligations.

Commenting at the report’s launch, Hannah Haeffner, national recovery & recycling manager at Tarmac, said: “We want this specialist report to ignite action across the construction and demolition industries. Many suppliers, contractors, developers and others working in the built environment are already taking great strides to recover and reuse waste, but we can do more. We can’t manage what we can’t measure, and our hope is that digital waste tracking will provide more accurate,

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more reliable and more up-to-date information so that we can build more informed waste strategies at a national level.”

The Chartered Institute of Wastes Management (CIWM) has welcomed Tarmac’s proactive approach to this key industry issue.

Sarah Poulter, CIWM’s chief executive, said: “I am pleased to see Tarmac taking a lead on waste management in construction and trust that it opens up further discussions that result in innovative medium and long-term solutions.”

Remaining in the UK and on the circular economy, Aggregate Industries’ recently announced acquisition of OCL Regeneration, a British provider of highway waste-recycling solutions, is another example of how Europe’s building-materials majors are embracing a more environmentally friendly approach in their operations. Aggregate Industries says that acquiring the Kent-headquartered business will further strengthen its asphalt and surfacing operations, where it is a key player on National Highways and local authority contracts.

OCL was founded in 2006 as a recycled highway construction-materials business. It focuses on recycling a selection of materials from highway maintenance and construction projects, including aggregates, asphalts, concrete and tar, which otherwise would have to be specially disposed of.

The materials are reprocessed and reused in new highway construction or maintenance projects as low-carbon products, resulting in reduced emissions and support of the circular economy. OCL has six depots in Avonmouth, Medway, Hampshire, Lincolnshire, Northumberland and Oxford.

I interviewed Stuart Gready, OCL’s founder and managing director, earlier this year.

Passionate about the circular economy and with an impressive pre-OCL CV running quarries and asphalt plants for the UK majors, Gready likened OCL to a “speedboat navigating around the oil tankers” when it comes to providing a cogent response to industry carbon-reduction targets. It will be fascinating to see not only how Aggregate Industries deploys its new speedboat but also which other buildingmaterials big hitters seek out their own. GW © AGGREGATES BUSINESS EUROPE September/October 2023

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NEWS

Groundbreaking fully solarpowered cement-plant landmark C emex and Synhelion have announced a significant milestone in their joint effort to develop fully solardriven cement production by scaling their technology to industrially viable levels.

This includes the continuous production of clinker, the most energy-intensive part of cement manufacturing, using only solar heat.

At the beginning of 2022, the companies announced the first-ever successful production of solar clinker in a small-scale batch-process pilot. Advancing from that stage to production under plant-like and continuous conditions reaffirms the tremendous potential of this technology to reach industrialscale implementation. Cemex and Synhelion will take further steps toward building a solardriven industrial-scale pilot cement plant.

“I am convinced we are getting closer to the technologies that will enable net-zero CO2 cement and concrete production,” said Fernando A. González, CEO of Cemex. “The solid progress I see here proves that solar cement is not just a

dream; it is achievable through continued collaboration and backed up by rigorous research and testing.”

Gianluca Ambrosetti, Co-CEO and Co-founder of Synhelion, added: “This is an exciting milestone for everyone involved, achieved through the excellent collaboration between the teams of Cemex and Synhelion.

Our technology can make an important contribution toward decarbonizing cement production, and we look forward to more trailblazing achievements in this field.”

Clinker is produced in a rotary kiln at temperatures nearing 1,500°C. Fossil fuels are typically used to heat the kiln and are responsible for approximately 40% of direct CO2 emissions.

Synhelion’s breakthrough technology provides sufficient heat to produce clinker without using fossil fuels. Replacing fossil fuels entirely with solar energy is a game-changer in Cemex’s efforts to achieve carbon neutrality by 2050. Additionally, the technology creates the conditions to separate, and therefore capture, the remaining CO2 from calcination in concentrated form

Cemex and Synhelion have taken their fully solar-driven cement production technology to industrially viable levels. Pic: Cemex

without additional effort.

The partnership between Cemex and Synhelion has received important recognition recently. The U.S. Department of Energy awarded US$3.2mn to Solar MEAD, a joint project between Cemex, Sandia National Laboratories, and Synhelion to study the conditions to maximise heat transfer to the raw cement mix. The collaboration also received an honourable mention in the Eco-Innovator category of the Corporate Citizenship Innovation Awards sponsored by the Boston College Center for

Corporate Citizenship.

This project is part of Cemex’s Future in Action programme, which focuses on achieving sustainable excellence through climate action, circularity, and natural resource management to become a net-zero CO2 company by 2050.

Two essential elements of this programme are Cemex Ventures and Cemex’s R&D Centre in Switzerland. Through them, the company is discovering and investing in the companies they believe will provide the proven, scalable technologies to achieve carbon neutrality.

Volvo CE strengthens management team

Joakim Arndorw is Volvo CE’s new head of sales region international Volvo Construction Equipment (Volvo CE) has announced several changes to its executive management team (EMT), with

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© AGGREGATES BUSINESS EUROPE September/October 2023

senior appointments designed to strengthen its global leadership and transformation journey.

Mats Sköldberg is appointed

head of technology at Volvo CE. Most recently, Mats was head of technology for Volvo CE in China and has held several other senior technology roles in recent years.

Scott Young is appointed head of sales region North America. Young takes up his new role after working as head of the Volvo CE Uptime Center of Expertise. He has held various other roles in strategy, technology and other functions within Volvo CE. Jay Parker is appointed to the newly created EMT role of head of digital & IT. Creating this new role at EMT level reflects the importance of digital in the company’s overall transformation journey.

All three appointments will support Volvo CE’s leading cultural, sustainable and technological transformation while demonstrating the expertise and dynamism already embedded across all

regions of Volvo CE. Melker Jernberg, head of Volvo CE, said: “Our leadership team will be greatly strengthened with the addition of Scott, Mats and Jay, as they join during a significant time of change for our industry. With their diverse experience, cross-functional understanding, and genuine passion, I have no doubt we will continue to lead our company’s sustainable transformation going forward.”

Joakim Arndorw is the new head of Volvo CE sales region international in another key appointment. Arndorw will move to his new senior position from his role as managing director for Swecon Anläggningsmaskiner, the retail operations for Volvo CE in Sweden. Joakim will be part of Carl Slotte’s head of sales region Europe management team.

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ASSOCIATION NEWS

Saving nature (Restoration Law)

W

hat a story over the summer break! The lives of members of the European Parliament and their assistants can be depressing at times when thousands of carefully negotiated proposals end up in the bin.

A centrepiece of the EU Green Deal, the Nature Restoration Law (NRL), has been subject to a political battle in the European Parliament around the following question in a post-pandemic Europe which faces an energy transition, extreme weather conditions, high inflation and war in Ukraine: Do we need more Green Deal or should we reduce our ambitions?

On 22 June 2022, the European Commission tabled a proposal for a regulation on nature restoration. The proposal sets multiple binding restoration targets and obligations across a broad range of ecosystems. These nature restoration measures should cover at least 20% of the EU’s land and sea areas by 2030 and all ecosystems in need of restoration by 2050 and intend to reverse the decline of pollinator populations by 2030.

The conservative European People’s Party (EPP) selected the Nature Restoration Law as the one piece too much for Europe’s economy to take on and decided to attempt

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© AGGREGATES BUSINESS EUROPE September/October 2023

to reject the proposal altogether and turned down the Commission proposal in the agriculture and fisheries committees.

The story continued in the lead Environment Committee, where the EPP failed to find a majority to kill the bill. The vote was tied, with 44 in favour and 44 against, which meant MEPs had the pleasure to vote on more than 2,300 amendments to the text. After three hours of voting, Committee Chair Pascal Canfin was forced to postpone a final vote until the next meeting of the Committee on 27 June.

The vote on amendments continued that day, leaving MEPs the final vote on the heavily amended report, and they rejected it by failing to have a majority with 44 in favour and 44 against. The lead ENVI Committee was bound to recommend to the plenary session on 12 July to reject the report.

However, MEPs refused by 312 to 324, offering a substantially changed proposal with flexibilities brought forward by EU member states. The Parliament returned to the arena with a text approved by 336 MEPs in favour and 300 against, leaving it to very difficult trilogue negotiations.

Aggregates Europe – UEPG and other non-energy extractive industry associations observed the breathtaking developments and identified the gaps and shortcomings of the

NRL. For instance, areas within or outside of Natura 2000 sites should be considered differently, with nature-protected areas being a priority to be restored. In addition, areas designated to be restored should not be seen as no-go-areas if a player like our industry can use the land/sea and undertake the restoration as part of our temporary economic activity.

Aggregates Europe – UEPG, the European aggregates industry association, supported the intention of nature restoration and underlined its strong expertise in this area, suggesting amendments to the proposal of the Commission. Together with Eurogypsum and BirdLife Europe, Aggregates Europe – UEPG signed several letters in support of a Nature Restoration Law which would recognise the achievements of our industry and enable us to significantly contribute to nature restoration.

The Commission and environmental NGOs are deeply frustrated with the NRL summer story in the European Parliament.

Aggregates Europe – UEPG discussed the state of play during a meeting with DG Environment on 18 September, and with BirdLife Europe, and will continue pushing for the needs of the European Aggregates Industry if we are expected to deliver on nature restoration. AB

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INTERVIEW

Putting the cement industry on the path to profitability and decarbonisation In addition to achieving decarbonisation targets, cement producers are facing major challenges around price pressures and profit levels.

Ahead of its October Annual Conference in Dubai, World Cement Association CEO Ian Riley spoke with Liam McLoughlin about how the industry can achieve profitability alongside its climate goals

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INTERVIEW

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he World Cement Association (WCA) chose Dubai as the location for its Annual Conference in 2022 and again in 2023. CEO Ian Riley says the reason for this is linked with the COP global climate summit being held in the Middle East in both years. COP 27 was held in Egypt in 2022, and COP 28 will take place in the UAE from 30 November to 12 December this year.

“That seemed a good opportunity to talk to the cement industry in the region about decarbonisation and what action the sector can take to address the climate and carbon emissions,” Riley says.

He adds that Dubai is also quite a convenient location in terms of the distribution of the WCA membership, with around 90% of its cement-manufacturing members being based in Asia and Africa. This contrasts with the WCA’s associate corporate members connected to the cement industry, with most of the ClimateTech company members located in North America and a few in Europe.

In terms of how the WCA membership has progressed since the lockdown days of 2021, Riley says: “It’s always easier to meet new people now that COVID is passed, and we can have conferences and so forth in real life. We had a very successful conference in Dubai [in 2022] and a lot of comments on the usefulness of the discussions and how we engaged the participants, and that is very much what we plan to do again this year.

“We have continued to add members through the COVID pandemic, and particularly after that.”

This year’s WCA conference theme is ‘Improving Profitability in a Time of Multiple Global Crises’, and Riley says that price pressures and profit levels are currently the major issues facing producers around the world.

Some countries, such as the UK and US, have seen substantial increases in cement prices which has boosted cement companies operating in those markets.

However, in much of the rest of the world there is substantial over-capacity, and one of the biggest changes is in the profitability of the Chinese cement industry over the last year.

“Between 2017 and 2022, China had excellent profitability due to the restrictions on supply that came from implementing the government’s environmental policies,” says Riley.

In 2016 the Chinese government introduced rules stating that when air quality was poor in certain industries – including cement – they were required to shut down.

As a result of this, cement kilns typically had to shut down for around 100 days of the year, dependent on some environmental factors, in particular around nitrogen oxide (NOx) emissions. In addition, if a cement plant was burning municipal waste, it would be more likely to be kept open. The combination of these factors meant that up to 15% of Chinese cement capacity was taken off the market.

“That brought the supply and demand into a pretty decent balance, and maybe even a shortage in the high season,” Riley adds.

“Consequently, the price of cement in China was pretty healthy for about five years.”

The Chinese market started a slowdown in the second quarter of 2022. Chinese cement companies generally struggled with profitability last year, and in the first half of this year many of them were losing money.

Riley says that a similar situation to China of over-supply exists in most countries around the world. In some of those countries

the producers have maintained a reasonably stable situation, but in many others oversupply has periodically led to price pressures.

Another major issue that the cement sector is currently facing is the rise in energy prices over the last year, with coal prices increasing around threefold. This has had a huge impact on cement producers as energy is by far the largest single cost in cement production.

Supply chain issues are also impacting the industry. “Supply chains have not functioned as smoothly as in the past and there have been shortages that weren’t anticipated, with some places struggling to get key supplies such as bags,” says Riley.

Innovations in digital technologies and opportunities to reduce clinker factor are showing particular promise in terms of helping tackle some of the climate and sustainability issues.

“One of the big attractions with digital technologies is that they are relatively inexpensive and quick to apply,” says Riley.

“If you decide that you want to use AI to optimise your combustion process, within a pretty short space of time you can be operating a system and gaining the benefits.”

Artificial intelligence (AI) technology is being deployed in a number of different ways in the cement sector, with one being in process control. “One of the approaches is in trying to duplicate your best production days, so that all of your days are like these,” says Riley. “This involves trying to understand the different factors that made the better days better and the worse days worse.”

Ian Riley (second from left) at the 2022 WCA Annual Conference in Dubai

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© AGGREGATES BUSINESS EUROPE September/October 2023

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INTERVIEW

The Chinese cement sector had high profitability from 2017 to 2022 due to government supply restrictions. Image: CUCC

He adds that companies have produced some interesting results using these kinds of approaches, including reducing fuel consumption and improving quality consistency. “If you have better quality consistency it allows you to reduce the clinker factor because, with more reliable quality clinker, you don’t need to have the same buffer to make sure you are above the required standards,” explains Riley.

Another way AI is being used in the cement industry is with prescriptive maintenance, using the different patterns that are picked up from the many sensors present in a cement plant such as for temperature, voltage, current and vibration.

“Initially when these sensors are set up you normally have a control limit with a minimum and a maximum, but by the time it gets to that point it’s usually too late,” Riley says. “What the AI systems are trying to do is pick up patterns that communicate a problem, long before you get to an out-ofcontrol situation.”

Some companies have been able to use AI systems to anticipate maintenance problems or identify something that is wrong or that they wouldn’t normally have been able to pick up. As the system becomes more experienced, then it can pick up more and also give a better indication of what the possible causes might be.

Referring to AI might make some people think of ChatGPT-type chatbots, but Riley says this is not really how the cement sector is utilising the technology. “Effectively it’s in using the capabilities of algorithms to pick up patterns and relate that to other things.

Improving maintenance and process control are gradually being rolled out and more and more companies that I talk to are using AI. I guess we will get to a stage where everybody is using it. It’s not particularly expensive to install and it’s clear that it brings some pretty worthwhile improvements,” Riley highlights.

In terms of regulations covering the cement sector, Riley says the most significant development is the latest European standards

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“I think in the carbon markets in particular we will see a lot of changes and a lot of tightening up of standards, protocols and auditing”

for low-clinker limestone calcined clay cement (LC3), that were introduced in 2022.

Looking at the broader issue of how decarbonisation will be achieved in cement, construction and other industries, he adds: “As this becomes more important, the measurement of reductions in carbon footprint and the way that carbon offsets are done will become more important.

“This whole area is still fairly immature in its development. For example, if you look at the market for carbon offsets, you see a huge variation in price for a tonne of offsets from a dollar up to around a thousand dollars-plus.”

Riley says that there is also a large variation in quality, with some offsets not being permanent and it being difficult to establish whether they are additional or something that would have happened anyway. This has led to a number of scandals around double-selling.

“I think in the carbon markets in particular we will see a lot of changes and a lot of tightening up of standards, protocols and auditing, trying to make sure that we have a real grip on what’s going on,” Riley adds.

Riley explains that there have been significant developments in the reporting of Scope 3 CO2 emissions. Scope 3 emissions relate to the extraction and production of purchased materials and fuels, transportrelated activities that are not owned by the cement producer and outsourced activities.

Despite it not being compulsory, an increasing number of large companies are reporting Scope 3 emissions and have included these in their decarbonisation commitments.

“It’s a real challenge to measure your carbon footprint when Scope 3 is included because you’re really measuring somebody else’s activities and emissions,” he adds. “If you have an extended supply chain that’s a lot of people that you don’t directly control.”

The construction industry has seen the use of EPDs – environmental product declarations – to quantify the carbon footprint of a product over its lifetime. Riley says that EPDs tend to have a lot of ‘wiggle room’ in the way they are produced, but as time progresses there will be more rigour in how they are calculated.

Cement and concrete production are highly energy-intensive, and in 2018 the UK-based policy institute Chatham House estimated that the cement industry was responsible for 8% of global CO2 emissions.

Riley says the cement industry continues to work on reducing its CO2 emissions, and the latest estimates indicate that these have been cut by 2-3% in the last couple of years.

“There is a little progress but it isn’t at the speed that it needs to be in order for us to reach the targets that have been set globally, and indeed that particular companies have set,” he adds.

He says that over 30 carbon-capture projects have been announced at manufacturers around the world, and more than 100 cement plants are looking at such initiatives. These types of projects take at least six years to design and build before they come online and are commissioned. Riley predicts that carbon-capture and storage projects will only start to make any impact at the end of the current decade.

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INTERVIEW

The use of carbon-capture utilisation and storage (CCUS) technology has been accelerating in the cement industry over the last two years.

Riley says there has been more consideration in the industry of the most effective ways of capturing the carbon: “With a cement plant you can either have an ‘end of pipe’ solution where you have got your emissions and you deal with those, or you can look at the pre-calciner stage.

The advantage of the pre-calciner stage is that you can get a much more concentrated stream of CO2, either through oxy-fuel combustion or indirect heating. About 80% of the CO2 emission comes from the pre-calciner.

“Different approaches are being taken but I think oxy-fuel is currently considered to be the most attractive.”

Riley explains that, while cost is still a restraining factor with CCUS projects, it should be possible to reduce this down to less than €100 per tonne of CO2 captured with the scaling up of such initiatives.

“There are some economies you can make if you are designing a cement plant from scratch rather than retro-fitting,” he adds.

“The interest in Europe is to install the carbon capture now because everybody expects the carbon price to continue to increase as the carbon budget is reduced.

Therefore, if you are at a level now where that more or less pays for the carbon-capture project then you’d expect over the next 10 or 20 years that you would come out well ahead by capturing and storing rather than paying for the emissions.”

Riley says that the main impact in decarbonisation efforts over the last couple of years has been more with traditional levers such as fuel switching, using more biogenic fuels (fuels which are produced from combusting organic matter), progress on fuel efficiency, and reducing the overall clinker factor. Low-carbon LC3 cement plays a role in the reduction of clinker and this is expected to become even more prominent going forward.

“Almost all of the large cement producers have now announced LC3 projects,” says Riley. “We still don’t have much production today, but within a couple of years we should see a significant increase in the use of LC3 cement.”

Nearly all of the current carbon-capture cement projects are in Europe, with some in North America.

China is conducting the majority of energy-efficiency projects, and the country’s government set new standards for energy efficiency in 2022, with companies being given until 2025 to meet these. Riley says that only a third of plants were compliant with the standards when they were announced, leaving the remaining two thirds needing to make improvements to keep operating.

China’s approach is not being followed elsewhere. “You don’t see the same efforts on energy efficiency in Europe and North America, even though there are plants in those regions which have much worse energy efficiencies than the modern plants,” Riley adds. “The amount of capital that they have to invest just doesn’t justify putting in the money.”

He says that the emphasis in Europe in particular has been on alternative fuels to reduce the carbon that is caught under the

EU’s Emissions Trading System (ETS) that sets a cap on greenhouse gas emissions by sectors including cement.

In North America the situation regarding emissions has been transformed with the 2022 Inflation Reduction Act climate legislation, which has introduced tax incentives to cut CO2 emissions. Riley says this is leading to the US catching up with Europe on the issue.

In terms of how the major global cement producers – including Cemex, Heidelberg Materials and Holcim – are progressing on their pathways to become net-zero across their operations by 2050, Riley says they would all claim to be on-track.

“There is a lot of activity in carbon capture and storage among the big players,” he says. “Heidelberg Materials in particular have really pioneered that with the Norcem CCS project in Brevik, Norway. Heidelberg has recently announced a number of other CCS projects including one in Sweden.”

Both Cemex and Holcim are also working on carbon capture and other carbonreduction technologies centred around electrification and fuel substitution.

“For the large producers with LC3, one of their first considerations was in securing the raw materials before moving into production, because you risk the whole thing becoming too expensive if you have to pay too much for the raw materials,” says Riley.

“With CCS the technology is coming from suppliers such as ThyssenKrupp. The major players in Europe are at the forefront, but not alone in terms of implementing carbon capture and storage.”

Smaller and mid-sized players are also prominent in decarbonisation efforts, and in fact the first two LC3 cement factories to become operational in the world were the Cementos Argos plant in Colombia in 2020 and the Abidjan, Ivory Coast facility operated

by Turkish-owned Cimpor.

In China President Xi Jinping has made a commitment for the country to be carbon

Over 30 carbon-capture projects have been announced at manufacturers around the world. Image: Conch

“We still don’t have much production today, but within a couple of years we should see a significant increase in the use of LC3 cement” Ian Riley, World Cement Association CEO

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INTERVIEW

neutral by 2060. In terms of how the Chinese cement sector is progressing in light of this, Riley says the industry’s focus is still on energy efficiency and it is somewhat unique in the way it is doing this.

“Carbon capture in China is really being pioneered by the energy industry, in particular by the coal-fired power stations,” he says. “The expectation is that the technology will be developed there and then it can be rolled out to other industries.”

He adds that there is strong interest in LC3 technology in China, so there may also be some movement on this.

A number of WCA members are developing ClimateTech solutions for use in the global cement sector. Some relate to the use of supplementary cementitious materials such as LC3.

“With LC3 you are calcining the clay, so there is a carbon footprint associated with the calcination of the clay,” Riley says. “If you could mechanically activate the clay rather than using calcination that would be pretty interesting.”

As an example he highlights Canadian WCA member Carbon Upcycling which has developed a process designed to improve the cementitious properties of supplementary materials including clays, fly ash, steel slag and various other materials.

“One of the challenges the industry has looking to 2050 is that the availability of fly ash and blast furnace slag is going to be reduced as we move away from coal-fired power plants and from traditional steel technology,” he says.

In addition to the use of cementitious materials, another area of technology development is in sequestering CO2 in concrete and aggregates. WCA member Blue Planet has developed technology to produce synthetic aggregates from a calcium source such as waste concrete and CO2.

“That is another approach where you effectively have CO2 stored in the aggregate.”

Another WCA member CarbonCure is sequestering CO2 into the concrete mix, enabling a reduction in cement in the concrete mix.

Riley says that the recycling of concrete is an interesting area.

“In the UK, for example, you typically have a mixture of construction waste and excavation waste which gets processed and mixed together,” he adds. “A lot of these recycled aggregates are not finding their way back into concrete but are being used as fills.

There is the potential to do things differently where you keep the concrete separate and you have the opportunity to use, not only the aggregates in there, but also the residual cement for the sequestration of CO2 through processes such as those developed by Carbon Upcycling or Blue Planet.”

It is estimated that a third of the aggregates used in the UK are recycled, but Riley says it’s very difficult to find the data on how much of this comes from concrete.

Traditional CO2-reduction levers that the cement industry has been using for many years include fuel efficiency, changing to lower carbon fuels including waste, and reducing the clinker content in cement, and these remain the most important part of reduction activity.

“All of these steps can save costs as well as reducing carbon,” Riley states. “The interesting question is probably why people have not gone further, as there is probably another third that we can reduce from where we are today by using these traditional levers.

You might have to invest a bit of CapEx [capital expenditure], but in most cases the cost is not too high.

“At least in some cases I think there is a

concern about getting contractors to move from Ordinary Portland Cement (OPC) to blended cement. As an example, in North Africa, virtually all of the cement in Algeria is blended and in Egypt almost all of it is OPC, and in many cases you are talking about the same contractors. It’s not easy to explain why it has been easier to move to blended cements in some places than others.”

A major issue currently facing European cement producers is the phasing out of the free allocation of carbon credits from 2026 under the EU Emissions Trading System (EU-ETS). The Carbon Border Adjustment Mechanism will gradually replace the free allocation system and is intended to level the playing field between EU and non-EU cement producers.

As free allocations are phased out in ETS Phase IV, Riley says that cement producers in Europe will have to buy an increasing number of carbon credits on the market. “If you look at the current pricing of close to €100 per tonne, that is going to add another €80 per tonne to the cost of clinker,” he says. “This is a huge increase in variable costs, and presumably this will be passed on in higher prices.”

Even a dramatic increase in the price of cement will not hugely impact demand for the material as it represents a fairly small proportion of the costs of a building project.

“In Europe cement has typically been around 2% of the cost of a construction project, so cement costs going up is not going to make a big difference on demand,” Riley adds. AB

“All of these steps can save costs as well as reducing carbon”

There is a lot of CCUS activity among major cement players.

Image: CUCC

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QUARRY PROFILE

FREE SCREENING ELECTRICITY EMPOWERS TVERÅS MASKIN A hybrid diesel-electric Metso Lokotrack crusher provides free excess electricity for a leading Norwegian crushing and screening contractor’s screening needs. Guy Woodford reports

B

esides cars, the Norwegian crushing and screening business is also transforming rapidly towards electric drive.

Another excellent example of this trend is a major crushing contractor Tverås Maskin & Transport AS (Tverås Maskin), which achieves significant savings with Metso’s Lokotrack hybrid diesel-electric crusher and mobile screen.

The mobile scalping screen utilises the surplus of electricity the Lokotrack jaw crusher provides. Due to this substantial benefit, the company has taken several steps

towards a complete, emission-free quarry operation.

Primary crushing and scalping in Norway are typically carried out as separate processes. Normally, the primary crusher is fed by a dump truck via a chute and short conveyor. After the scalping screen, the clean materials are piled for secondary crushing.

This is exactly how Tverås Maskin contracts a crushing and screening operation at Balhald quarry, near Trondheim, central Norway. Usually, one crushing contract is between 50,000 and 100,000 tonnes.

The main working equipment is Metso’s Lokotrack LT120E hybrid diesel-electric crusher and Lokotrack ST2.8E diesel-electric mobile screen. Within the process, the 0-700 mm-sized blasted granite is first crushed to 0-150mm in size by the C120 jaw crusher.

After that, fines are removed using the ST2.8E scalping screen.

The core of the hybrid operation is the Lokotrack jaw crusher, where the on-board diesel motor powers a 420kVA generator and electric motor instead of a normal, direct crusher drive. The jaw is not spending all the power capacity created, so the surplus is guided via cable to run the ST2.8E screen.

The diesel-electric Lokotrack ST2.8E scalping screen separates the crushed materials into 0/20mm, 20/60mm and over 60mm fractions. Pic: Metso

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“By benefitting from the free electricity, we save at least 10 litres of diesel per hour that would normally be used for dieseldriven screening,” Vidar Bjerkås, operations manager at Tverås Maskin, explains.

“As electric-driven, our screen now requires about 50% less servicing, while all diesel motor-related service points are minimised.”

According to Bjerkås, more savings are also achieved at the primary crushing stage.

“The diesel motor now runs at a steady and rather low rpm when plugged into a generator instead of directly to the crusher.

Steady running is a clear fuel-saving aspect.”

Tverås Maskin and Metso Norway have agreed on an economical and environmentfriendly way to deliver essential wear parts on-site. This is called ‘Full Container Load’.

According to this service agreement, a container of high-quality Lokotrack crusher and screen wear parts was delivered directly from the Metso foundry to Tverås Maskin’s work site. After using a part, a new one will be automatically delivered to keep the stock full.

“Together with our customer, we selected which wear parts would be most needed within the Lokotrack crushers and screens.

Based on that, a wears selection tailor-made for Tverås Maskin was collected,” says Jan Helge Borgard, area sales manager of Metso Norway.

“This point-to-point wears delivery saves costs, is good for the environment and secures 100% wear parts availability on-site at all times,” adds Borgard.

Tverås Maskin aims for constant and steady production to achieve the most cost-efficient result. At Balhald quarry, while processing hard rock, an average of 180-200 tonnes per hour is crushed and screened, depending on the dump truck travelling distance. A peak production of 500 tonnes per hour has been reached. The mobile Lokotrack fleet is moved around Norway four to five times a year. The company foresees the possibility to utilise the full electric mobile fleet connected by an external network.

“In fact, without our electric-drive option and demand for environment-friendly operations, we would automatically be out of several contract negotiations,” Bjerkås stresses.

“We have had good co-operation with Metso since the 1980s. When meeting any challenge, it’s easy to get connected to the right Metso experts. Together, all obstacles will be solved.

“Reliability, cost-effectiveness and advanced technology. Those words describe all Metso Outotec products very well,” he adds.

Today, Tverås Maskin operates 11 Lokotrack crushers and screens. The company produces more than two million tonnes of aggregate per year, with its broad customer base including several nationwide clients, such as the Norwegian Road Authority and well-known aggregates and recycling company Fransefoss. AB

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Vidar Bjerkås of Tverås Maskin (right) and Arild Valderhaug of Metso. Pic: Metso

Vidar Bjerkås keeping a close eye on production at Balhald quarry. Pic: Metso

Tverås Maskin produces more than two million tonnes of aggregate annually for its customers. Pic: Metso

The hybrid diesel-electric Lokotrack LT120E jaw crusher powers the jaw and the ST2.8E scalping screen at Balhald quarry, Norway. Pic: Metso

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MARKET REPORT

A Cat 972 XE medium wheeled loader in the pile. Pic: Caterpillar

Impressive market resilience Resilience is a notable characteristic of the UK and Ireland aggregates and quarrying machinery markets, with much of it on show in 2023. Experts tip it to continue next year as new economic and political factors emerge. Guy Woodford reports

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he Mineral Products Association (MPA) has published a new regional construction and mineral products market report, giving a detailed assessment of historical, current and future trends across every region of Great Britain.

Primarily prepared to help inform and support the local mineral planning system, the annual report compiles industry data and broader context to paint a clear picture of the main drivers of activity in heavyside construction materials and industrial minerals, an essential tool for producers and planners alike.

The report includes summaries for all regions and devolved administrations in Great Britain, illustrating the recent performance of the construction and mineral products markets, with critical insight into the sectors expected to drive growth in the UK’s around 280 million tonnes a year (Aggregates Europe – UEPG 2021 estimate) mineral product demand over the next five years (2023-27).

While London is often regarded as the key hub of new construction projects and infrastructure, representing 21% of the total value of construction output in 2022, the report highlights that the East of England and the Yorkshire and Humber area are both expected to see the fastest rate of growth (2.2%) over the next five years, led by energyrelated projects.

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Data on mineral-product sales volumes is collected through a rigorous survey among MPA producer members, representing most mineral products markets, including 90% of total GB market sales for primary aggregates and asphalt, for example, and 75% for readymixed concrete.

The report reveals that construction demand for mineral products in 2022 recorded a gradual loss in momentum as the year progressed due to a worsening macroeconomic environment and slowing activity in key construction segments.

Tonnages of primary aggregates sales fell by 8.2% annually compared to 2021, asphalt by 6.5%, and ready-mixed concrete by 3.8%.

The East Midlands was the biggest asphalt and crushed rock market in 2022, accounting for 15% and 29% of total sales in Great Britain, respectively. The region also emerged as the most resilient to the downturn last year, recording the smallest falls in demand.

Meanwhile, London was the biggest demand centre for ready-mixed concrete, accounting for 19% of total sales volumes from fixed plants. Demand in London last year remained broadly flat, in contrast to the 5.5% decline recorded at a national level.

Finally, much of the sand and gravel used in Great Britain to manufacture ready-mixed concrete is produced from the West Midlands, the East of England and the South East, accounting for 53% of total sand and gravel sales in 2022.

The front cover of the MPA’s new British regional construction and mineral products markets report. Pic: MPA Luke George, economist at MPA and author of the report, said: “This new report provides a valuable insight into the contrasting dynamics in construction and mineral products markets across the various regional and devolved administrations of Great Britain. We aim to provide a unique, easy-to-use point of reference to support MPA members, planning professionals and other industry experts in their decisionmaking processes. This report cuts through the overwhelming quantity of industry data that’s available and revised almost daily.

“Minerals and the wide range of construction products derived from them are key elements to successfully delivering many of the Government’s ambitious policy objectives, such as on housing and © AGGREGATES BUSINESS September/October 2023

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MARKET REPORT

infrastructure, including achieving the energy transition and delivering Net Zero. The UK economy's success in delivering on these objectives will depend on local mineral planning authorities and mineral producers having robust evidence around future market needs, given delivery is heavily reliant on the availability and supply of essential mineral products.”

Mick Knight, industry manager – Quarry and Aggregates, for Finning UK & Ireland, Caterpillar’s UK and Ireland dealer, says quarry operators, especially larger companies, are increasingly focused on meeting their net-zero emissions goals.

“We can do a lot now to drive best practices and make sites and operators more efficient to reduce fuel use and carbon emissions. For example, using telemetry to connect equipment, operators, and sites has produced significant gains.”

Knight explains that while machine technology is widely used in the aggregates and quarrying sector, there is huge scope to increase the use of telemetry as well as semi-autonomous technology, such as Cat Command, and other features in the use of machines to provide greater productivity, efficiencies and ensure operator safety.

“Better use of telemetry on the machines can significantly improve site productivity and play a pivotal role in ensuring machine performance and health, improving efficiencies. Technology such as VisionLink Productivity provides valuable insights into the performance of the equipment. It can also uncover potential site set-up issues and pinch points. Telemetry can highlight operator performance issues and the correct use of the ease-of-use functions. It can also reduce machine idle time, fuel consumption and exhaust-pipe carbon emissions. The Next Gen technology features built into the latest Cat machines, such as ease-of-use features, are designed to improve operator competency precision and ensure safety is paramount.”

“Our customers are still busy, and demand for machines remains high” Mick Knight, industry manager, Quarry and Aggregates, for Finning UK & Ireland.

Pic: Caterpillar

Finning has introduced a dedicated ‘eco-drive’ training programme aimed at operators to hone and develop their skills and make the most of the technology features they offer. In addition, Knight says the company has also introduced an ‘eco-training advanced’ scheme aimed at managers involved in planning operational logistics, focusing on using data insights to pinpoint opportunities for efficiency improvements across sites.

Knight added: “Sustainability continues to drive other operational decisions in the aggregates sector. This is evidenced by the increase in the volume of machine rebuilds that Finning conducts for companies in the sector, including Hanson, Aggregate Industries and Imerys. Rebuilds also offer other significant benefits for aggregate firms financially, with firms typically saving around 55 – 60 per cent when compared with the cost of a new machine.”

Asked about aggregates demand levels in the UK and Ireland, Knight says: “Although official figures show the industry is contracting, our customers are still busy, and demand for machines remains high.

“It’s important for Finning that we provide our customers with a range of options regarding fleet succession planning. We’re seeing a surge in demand for used machines, particularly those well maintained under a Finning service programme. To reassure customers, we can also provide a full machine inspection and service records for used machines.”

A Cat 966 XE placing processed material on a stockpile Pic: Caterpillar

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MARKET REPORT

Ashcroft Group’s Volvo EC550E crawler excavator at Partridge Hall Quarry in Burnby, East Yorkshire.

Pic: Volvo CE

Commenting on large UK & Ireland construction projects influencing demand for aggregates, machine purchases, and rental, Knight says: “HS2 is ongoing and continues to drive demand for aggregates and will do so for the foreseeable future. We’re also seeing several significant rail infrastructure projects driving demand – such as the works to upgrade the Lower Thames Crossing and the road improvements on the A428 in Northampton and the A303 and A30 in Southwest England. We’re also involved in several power-generation developments; an accelerated programme of renewable developments is underway, which is also driving demand for aggregates.”

Looking ahead to aggregates and quarrying machine demand over the next 18 months, Knight continues: “The latest MPA market forecast [April 2023] indicated a deterioration in market prospects for mineral products sales in 2023, underpinned by a shallow recession this year, slowing construction activity and heightened delivery risks of the existing project pipeline.

“Sales volumes for primary aggregates and ready-mixed concrete (RMC) are expected to fall at an annual rate of 3% in 2023, with reductions of 4% for asphalt and 8% for mortar. These markets are then expected to resume modest growth from 2024, assuming a rebound in private house building and roads after a short-term blip, two areas particularly exposed to the impact of weakening economic activity and the surge in cost inflation. Meanwhile, throughout this year and next, sales volumes should continue to be supported by infrastructure, driven by major projects including HS2, as well as by work in industrial warehouses and logistics projects.”

Volvo Construction Equipment (Volvo CE) also has a strong presence in the UK quarrying machine market. Speaking to Aggregates Business, Phil Battle, director of strategic accounts at SMT GB, Volvo CE’s UK distributor, emphasised the “remarkably

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resilient” nature of the British quarrying and aggregates industry. “It is an industry which is going through a great deal of change to develop and innovate its customer solutions to lower overall greenhouse gases (GHGs) in all its operations. The leading quarrying and aggregates companies are extremely focussed on detailed roadmaps to decarbonise their industries, and SMT is helping to support and advise on this strategy.”

Battle says the present economic climate is challenging for the UK quarrying and aggregates industry, but this is “nothing new” for an industry that has, in the last couple of decades, had to navigate through the impact of the financial crisis in 2008, COVID-19 and latterly the macro-economic fallout from the war in Ukraine, including supply chain issues and high inflation costs. “Looking at the situation today, it is clear that certain sectors such as housebuilding are in a slowdown as a direct impact of higher interest rates set by the Bank of England to combat inflation, which in turn filters down to housebuilding demand in the market due to the higher mortgage rates for lenders. Regarding the quarrying and aggregates companies, this has meant less demand for some of their products, such as asphalt and ready-mix, which are largely dependent on a strong and healthy housebuilding market. However, the latest data suggests that commercial building continues to expand, which may (in the short term) soften the impact of the decline in housebuilding.”

Battle says that despite media attention and some criticism of government spending levels for core infrastructure,

civil engineering projects have remained robust, albeit the pace of growth has slowed recently. “As this sector has remained strong in the first half of 2023, primary quarries with supply chain contracts in place have seen their output remain steady, and as we track machine utilisation across both major projects and downstream primary quarries, we can see that civil engineering projects remain busy, despite delays in infrastructure timescales.”

Does Battle think current demand levels are likely to change in 2024? “Listening to the two main political parties, they are both in agreement that it is paramount that there needs to be significant investment in Great Britain to drive growth and prosperity, including generating good quality and well-paid jobs. The political party that is successful in the general election next year will need to quickly spell out their plan to drive growth and explain where it will make key investments. There needs to be a structured plan for energy, with a mixture of large projects such as Sizewell C and Small Modular Reactors (SMRs), to ensure we have a reliable (secure) energy supply to meet current and future energy demand.

“However, in the short-term, we need to see a commitment to a well-funded transport policy, including backing for Road Investment Strategy (RIS) 2 and 3. This will include important projects such as Lower Thames Crossing (LTC), A303 Stonehenge tunnel and many other significant National Highways schemes aimed to connect Britain. I would also like to see the successful party commit to HS2 in full and a better focus on the overall levelling up agenda. This should include © AGGREGATES BUSINESS September/October 2023

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MARKET REPORT

projects such as the Northern Powerhouse rail link, which will be a key investment into the future economic success of northern England.”

Battle stresses that investment in core British infrastructure needs to be done in a way that will decarbonise construction activities and help to accelerate change towards diesel-free jobsites. “Quarrying and aggregates companies, supported by Volvo CE and SMT, are already working in partnership to lower the impact of CO2 by utilising net-zero construction-equipment machines, supported by solutions. Volvo CE has the largest range of commercially available electric construction equipment products in the market. SMT and Volvo CE are fully committed to introducing a full range of technologies and solutions to help our customers decarbonise, and the pace of this transformation is accelerating.

However, SMT is also supporting customers to minimise their CO2 footprint with their existing fleets of diesel internal combustion engine machines, which will continue to operate for many years. It is critical that we work with customers to lower their CO2 impact across the whole lifespan of their machines, which includes how we rebuild and recycle machines at the end of their life.”

Battle explains that the leading quarrying and aggregates companies are looking past some of the short-term economic uncertainties and see the climate-change situation as a far greater threat to their longterm security and, therefore, something that they need to act on today, rather than wait for legislation or for the perfect solution to become available. “The real pioneers are already taking a close look at our solutions and are considering how they might need to

adapt how they have worked in the past to adopt and embrace the future,” he concludes.

Retail sales of UK construction and earthmoving equipment bounced back in June 2023 after falling below yearon-year levels in May, according to the Construction Equipment Association (CEA) and Systematics International’s construction equipment statistics exchange.

Sales in June were more than 8% above those in the same month last year, including very strong sales of mini/midi excavators, the most popular product in the UK. As a result, sales in Q2 ended up at 3% above the second quarter last year.

Sales in H1 2023 reached 19,600 units, 7% ahead of the same period of last year.

While the CEA notes that current sentiment in the market is still anticipating a modest downturn in sales in the second half of the year, this will be from 'record' high levels achieved in the year's first half.

Road rollers show the strongest growth at 37% above last year's levels, following very strong sales in June.

The pattern of sales on a regional basis in the UK and Northern Ireland is mixed. This year's strongest sales are still in Scotland and the South East of England, where sales remain around 30% ahead of last year's.

Only three regions are seeing lower growth than last year, consisting of the North West of England (-16%), Northern Ireland (-5%) and London (-4%).

Equipment sales in Ireland are also reported in the statistics exchange. Sales in May and June 2023 were at similar levels to the same months of 2022, and sales in the first half of the year are 3% above last year's, due mainly to a very strong first quarter.

GlobalData, a leading global business intelligence consultancy, reports that the Irish construction market size was $26.2 billion in 2022. The same source projects the market to achieve an AAGR (annual average growth rate) of more than 4% during 2024-2027, assuming an improvement in the wider economy, and this will be supported by investment in the transport and electricity sectors. The rise is good news for the country’s building-materials producers, off-highway machine manufacturers, and machine dealers.

The leading contractors in the Irish construction market are SISK Group, P.J. Hegarty & Sons UK Ltd, Royal BAM Group NV, John Cradock Ltd, McKeon Group, Quintain Ltd, Stewart Construction, Ronan Group Real Estate, SIAC Construction Ltd, and Wills Bros Ltd. SISK Group led the market in 2022. AB

Volvo CE’s A60H articulated hauler is a popular model with quarrying customers, including many in UK and Ireland. Pic: Volvo CE

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RECYCLED AGGREGATES

Making C&D waste pay in the Middle East

The Tadweer facility in Abu Dhabi Pic: Tadweer

The Middle East has seen a resurgence in post-COVID-19 construction activity, particularly in the Gulf Cooperation Council (GCC) region, partly due to high oil prices. Given the high price of premium building materials and environmental sustainability concerns, developers have increasingly sought to use more recycled aggregates from construction and demolition (C&D) waste. V L Srinivasan reports

N

ot long ago, most C&D waste generated by infrastructure building works in the Middle East was dumped in landfills.

Not anymore. Across the region, C&D waste is now turned into quality recycled aggregates and used in many major construction projects.

The price of sand, gravel, clinker, cement and other key building materials has soared due to the sheer volume of Middle East construction activity, regional economic expansion and growing urbanisation. As such, the growing availability of recycled aggregates provides much-needed relief for bottom-line-minded project managers.

Furthermore, a greater use of recycled aggregates reduces a project’s carbon emissions and developers’ reliance on imported building materials.

Governments such as the UAE, Saudi Arabia and Qatar have enacted legislation allowing construction firms to use a minimum of 20% to 40% of the recycled aggregates in their infrastructure works, including new commercial and residential builds.

According to the study Securing Valuable Resources for a Sustainable Future by Boston Consulting Group, GCC countries are generating between 105 and 130 million tonnes of waste per annum, primarily from C&D waste, municipal solid waste (MSW),

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and agricultural waste, with Saudi Arabia and the UAE accounting for around 75% of it. While these estimates are based on official reporting, the study said that GCC countries face additional challenges from limited waste tracking and illegal waste dumping, particularly agricultural waste and C&D waste.

conserve natural resources and diverts construction waste from landfills, which can generate a substantial volume of harmful odours and gases.

He continued: “Recycled aggregates are less expensive to produce than virgin materials. Using recycled aggregates in construction projects will decrease the load on existing landfills and help companies

Increased lifespan of landfills Salman Zafar, an expert in waste management and founder of EcoMENA, a volunteer-driven initiative creating environmental awareness and fostering sustainability worldwide, particularly in the MENA (Middle East - North Africa) region, said that recycling C&D waste can expand the lifespan of landfills and help reduce the cost associated with the maintenance of existing landfills and building new ones.

Zafar said that recycling also helps

“Recycled aggregates are less expensive to produce than virgin materials. The use of recycled aggregates in construction projects will decrease the load on existing landfills and help companies meet their sustainability targets.”

Salman Zafar, founder of EcoMENA

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RECYCLED AGGREGATES

meet their sustainability targets. By diversion of construction waste from the landfills, companies will also be able to cut down on landfill tax/tipping fee.”

UAE In the UAE, C&D waste constitutes 70% of the total weight of solid waste. Dubai alone produces nearly 5,000 tonnes of C&D waste every day, with Abu Dhabi generating around 7,000 tonnes daily, accounting for 71% of total waste in the Emirate.

The UAE’s Ministry of Climate Change and Environment issued a Ministerial Resolution in 2019 on recycling C&D waste for roads and other similar infrastructure projects. Government and private contracting organisations can use recycled aggregates for 40% of their total building material needs as part of the new resolution, and the decision is implemented by various departments and local civic bodies across the Emirates.

While some developers remain apprehensive that recycled products are inferior to virgin materials, once they confirm the prescribed specifications, they can outperform or remain at least just as good as virgin materials.

The UAE government has even established the Abu Dhabi Waste Management Centre – Tadweer – which not only deals with C&D waste, but also other refuse such as used engine oil, old tyres, and plastic items.

Tadweer has set up two factories established for this purpose. The first is in

An aggregates recycling plant in Al Dhafra, UAE. Pic: Tadweer

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Abu Dhabi and managed by This Middle East Services; the second is in Al Ain and managed by Star International Waste Management LLC. These two units together handle 10,000 tonnes per day.

Tadweer also opened Ghayathi Crusher in the Al Dhafra region in 2018 but closed the plant after a year. The unit had a stockpile of 1.6 million tonnes of material ready to be crushed at the time of closure.

It was re-opened in 2021 to promote environmental sustainability and develop an integrated waste management system in Abu Dhabi.

The Ghayathi crusher can handle 2,000 tonnes of C&D waste daily and produces high-quality aggregate for the construction of vital infrastructure projects, such as roads, to contribute to the sustainable development of the Al Dhafra region.

Dr Salem Al Kaabi, director general at Tadweer, said that the decision to reopen the unit aligned with its continued efforts to fulfil Abu Dhabi’s vision of diverting 75% of its waste from landfills.

“The crushers run by Tadweer play an important role in achieving this target through recycling huge quantities of C&D waste and turning them into useful materials to use in vital projects in Al Dhafra region and across the country.”

The facility will ensure significant savings for the local economy and articulate Tadweer’s strategy of meeting the demand for recycled aggregates from the Emirate’s crushers, using them in vital projects in collaboration with other government entities and private sector partners.

“All operations at the plant comply with the highest international standards and

Pic: Tadweer

“The crushers run

by Tadweer play an important role in achieving this target through recycling huge quantities of C&D waste and turning them into useful materials to use in vital projects in Al Dhafra region and across the country.”

Dr Salem Al Kaabi, director general at Tadweer

practices, and the materials generated by the facility will play a critical role in driving construction and infrastructure development in the region,” added Al Kaabi.

Private sector’s role The private sector is playing an active role in recycling C&D waste via companies such as Ducon Green, Al Dhafra Recycling

© AGGREGATES BUSINESS September/October 2023

25

RECYCLED AGGREGATES

Industries, The Rostamani Group and Dulsco.

Al Dhafra Recycling Industries has supplied 1.2 million tonnes of recycled aggregates to the prestigious $11 billion Etihad Rail project undertaken by the UAE government to link all seven Emirates.

BEEAH Recycling is another UAE-based company that has developed a selfsustaining model for waste management and zero-waste strategies. The company has made great headway towards a zerowaste solution, achieving a more than 76% diversion rate.

Dulsco, a people and environmental company based in Dubai, has signed an agreement with the UAE Ministry of Environment and Climate Change to set up two C&D waste recycling plants in the emirates of Ajman and Um Al Quwain. These facilities recycle the entire C&D waste from the two emirates, converting them into recycled subbase and aggregates for use in construction, replacing up to 40% of the virgin materials.

Qatar Qatar, which has completed major infrastructure projects including seaports, airports, roads and developing new cities, valued at around $300 billion during the run-up to the 2022 FIFA World Cup, is not far behind compared with other countries in dealing with C&D waste.

An estimated eight million tonnes of C&D waste are generated annually. Qatar’s National Environment and Climate Change Strategy (QNE) has implemented a robust policy framework to safeguard Qatar’s environment for future generations. As part of the policy, the government has set a target of using 35% of recycled aggregates in various construction projects.

A C&D waste processing site in Al Dhafra, UAE. Pic: Tadweer

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© AGGREGATES BUSINESS September/October 2023

Recycled aggregates stockpiles in Qatar. Pic: Qatar Ministry of Municipality & Environment

Qatar’s Minister of Environment and Climate Change, Sheikh Dr Faleh bin Nasser bin Ahmed Al Thani, said: “My ministry has a fundamental role in the success of sustainable development projects, achieving the country’s goals in preserving the environment, promoting green growth, and limiting the effects of climate change.”

Al Thani’s ministry released a book titled Implementation of Recycled Aggregate in Construction in January 2022. “With the vast investment made in infrastructure projects, Qatar has set targets for the efficient use of natural resources, with a recycling target to use 20% of recycled aggregate to replace primary aggregate in government construction projects by 2022,” the ministry said in a statement at the book’s official launch.

The state-owned Qatar Primary Materials Company (QPMC) signed a MoU with Qatar’s Ministry of Municipality and Environment in 2019. It has been treating C&D waste in the Rawdat Rashid landfill and converting it into materials usable in construction projects.

Besides the Rawdat Rashid landfill, QPMC also manages three more sites at Umm Al Zubar, Jary Alsamar and Bu Salba, respectively, which are the recycling sites of Qatar’s Ashgal (Public Works Authority). The combined production of recycled aggregates is 660,000 tonnes per month, according to

the Ministry’s book.

The company is also looking at the possibility of producing washed sand in the facility that will be established for use in infrastructure projects and construction projects (including concrete and asphalt layers) to meet Qatari specifications and standards.

Saudi Arabia In Saudi Arabia, the Kingdom’s Sovereign Wealth fund – the Public Investment Fund (PIF) - has set up the Saudi Investment Recycling Company (SIRC).

The state-of-the-art facility is the first step toward meeting the national ambition of diverting 60% of C&D waste from landfills by 2035 in line with the Kingdom's effort to accelerate the transition to a circular economy.

The aim is to produce recycled aggregates that can be used for new roads and buildings while at the same time reducing the estimated 20 million tonnes of C&D waste dumped in vacant plots around the city each year. Located in Al Khair, north district of Riyadh, SIRC's new plant treats up to 600 tonnes of C&D waste per hour.

Riyadh region’s Mayor, Prince Faisal bin Abdulaziz bin Ayyaf, assured his administration’s support in the project’s implementation, saying: “The waste recycling facility in Riyadh will offer numerous economic, social, and environmental benefits to society that are above and beyond the direct return on investment.”

Besides SIRC, in 2021, Averda, a global waste management company, opened an integrated and environment-friendly waste management facility for the $20 billion Red Sea Project in Saudi Arabia. Averda said all forms of waste generated by the project were considered in the design of the waste system. Tonnes of rubble, rock and concrete generated by the construction of the foundations, buildings and infrastructure were sorted and treated by special machinery,

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RECYCLED AGGREGATES

Pic: Qatar Ministry of Municipality & Environment

“My ministry has a fundamental role in the success of sustainable development projects, achieving the country’s goals in preserving the environment, promoting green growth, and limiting the effects of climate change.”

for privately owned structures,” she suggested.

According to Al-Shalfan, the demolition of buildings causes pollution to the environment due to dust resulting from the process, disturbing the owners of neighbouring buildings, and other financial losses from not using the discarded building components.

“Deconstruction contributes to enhancing sustainability by reducing solid construction waste. It leads to promoting the concept of reuse and recycling in the Kuwaiti society, which results in positive effects on the environment and the economy, as well as preserving natural resources,” she added.

Egypt Egypt has undertaken several projects, including constructing a new capital city, the New Administrative Capital. The C&D waste from these projects is estimated to be four million tonnes per year, constituting 60%-70% of the total waste generated in the country. This waste is managed through disposal in landfills, causing huge deposits of C&D waste, thus posing an environmental problem. Currently, there are eight C&D waste management plants in the country, and 31 more are under various stages of construction. AB

Doosan Construction Equipment is now

Sheikh Dr Faleh bin Nasser bin Ahmed Al Thani, Qatar Minister of Environment & Climate Change

transforming it into smaller particles. The company said they are then being reused for other purposes, such as aggregate for building roads.

Kuwait Kuwait has also recognised the environmental and economic benefits of using recycled aggregates. According to a study titled Integrated Solid Waste Management System, 76.2% of Kuwait’s waste can be recycled. By installing seven recycling plants, 90% of Kuwait’s C&D waste and 95% of its waste tyres and organic waste can be recycled. The raw materials produced by the recycling plants could generate revenue of US$137 million per year. The estimated total profit from the system would reach $450 million in 2040, the Kuwaiti study said.

The state-run Public Authority for Industry is planning to build an industrial zone housing companies specialising in waste recycling, including C&D and industrial waste. The zone will cover a two km² area with 215 factories specialising in recycling waste, including tyres, plastics, wood, metals, and construction materials.

Sharifa Al-Shalfan, a member of Kuwait’s Municipal Council, has an answer to minimise the impact of C&D waste. She submitted a proposal to the Municipality nearly ten months ago to dismantle buildings instead of demolishing them.

“Dismantling is a good option to reduce waste by reusing and recycling the parts and pieces of buildings. This should be made mandatory for public buildings and optional

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© AGGREGATES BUSINESS September/October 2023 24.04.2023 10:12:08

27

CRUSHING AND SCREENING

The Jonsson L120-330 double crusher on display at steinexpo

New international players target impact in crushing and screening The recent steinexpo quarrying show in Germany threw the spotlight on two brands planning to expand their presence in the international crushing and screening market.

Liam McLoughlin reports

M

etso is aiming to further expand the global footprint of the Jonsson mobile crushing and screening brand that it bought in 2018.

Speaking to Aggregates Business at September’s steinexpo quarrying and construction equipment event in Germany, Timo Nakari, VP of the Jonsson business line, said that when Metso acquired the Swedish company its business was centred in the Nordics but Jonsson machines are now available around the world.

The massive 133-tonne Jonsson L120330 mobile crusher was on display at the steinexpo show in Nieder-Ofleiden. The machine can be transported and takes around two hours to set up.

"Most of our customers [for Jonsson machines] will be quarry operators," says Nakari.

All Jonsson machines are electric and Nakari says the L120-330 is unique as it has two crushers - a jaw and a cone - on the same chassis.

The large Jonsson machines include primary crushers ranging from 80 tonnes to 150 tonnes. "We also have five cone models and plenty of screeners," says Nakari.

Around 300 exhibitors and 440 brands were present at steinexpo this year, and for the first time this included Chinese crushing and screening equipment manufacturer

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© AGGREGATES BUSINESS September/October 2023

Mesda, which was making its debut at a European show.

Baojian Wang, VP international cooperation of Guangxi Mesda Group, said his aim is to bring the company to international markets, particularly Germany and other European countries.

He added: "Mesda promoted electricpower mobile machines in China from the very beginning. For a decade of growth, the sustainable, and environmentally-friendly power solutions have been a very important value of Mesda, that we would like to offer to the [international] markets."

As part of its expansion plans Mesda appointed Patrick (PJ) O’Donnell to the new position of business development director at the end of 2022.

He will be responsible for development of the global network for Mesda's crushing and screening business, and to establish a sales and service network which is close to Mesda's end customers.

Having worked for a number of global manufacturers O’Donnell has over 20 years of business development and sales experience in the crushing and screening industry.

Metso has extended its manufacturing capacity of mobile track-mounted crushing and screening equipment in the Indian city of Alwar with the opening of new manufacturing facilities. The manufacturer

says the extended facilities will help it capitalise on market opportunities for its quarrying equipment across India, south-east Asia, the Middle East and southern Africa.

Following the extension, the total size of the Alwar factory will be approximately 340,000 square metres, adding 35% more capacity to the factory.

Markku Simula, president of the aggregates business area of Metso, says the Alwar site in the state of Rajasthan has had several extensions since it initially opened in 2008, with the latest being the largest yet, increasing the size of the factory by about one third and making it the company's largest manufacturing facility.

He added that the new extension will focus entirely on producing mobile trackmounted crushing and screening machines from several Metso Group brands. In addition to the mobile Metso Lokotrack equipment, the increased capacity will be used to manufacture mobile McCloskey and Tesab equipment. At the same site, Metso also produces wear parts and pumps for the aggregates and mining industries.

Simula says that India, south-east Asia and the Middle East represent "tremendous growth markets" for Metso.

"If you look at our aggregates business globally, we are extremely strong in North America and Europe," he added. "Where we see the future growth opportunities is the

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CRUSHING AND SCREENING

eastern hemisphere. The countries that are most vibrant right now are India and Saudi Arabia. There is a lot of activity in quarrying in India. The Indian domestic [crushing and screening quarrying equipment] market is very competitive. We are by far the number one international player in India and the second largest overall after one of the domestic players."

Simula says particular opportunities in India come from the Indian government's plans to increase highway construction in the country from 39km per day to 60km per day.

Metso's NW Rapid range of portable wheel-mounted crushing machines, which can be set up very quickly, was developed to meet the needs of the Indian quarrying sector Simula adds that there are also major opportunities for Metso's business in Saudi Arabia from a number of huge projects such as The Line linear smart city that is under construction in Tabuk Province.

The 170km-long city is part of the Saudi Vision 2030 project to diversify the country away from its current dependence on oil production.

The Alwar factory now employs approximately 1,300 people in total. The official opening of the new facilities took place on September 19, 2023, and Metso says that production ramp-up to reach full capacity will continue until the end of the year.

Currently, 38% of the Alwar plant's output is for the Indian domestic market with 62% being exported to 80 different countries.

The new factory showcases the most modern manufacturing practices, hosting several sustainability-driven functions like automated warehousing, automated assembly lines, modern painting lines and 13,000 solar panels installed to enable the increased energy production. After the extension, solar energy covers 85% of Alwar’s total power generation, which is the maximum permitted as per state government guidelines.

“With the increased manufacturing capacity, Alwar becomes the major Metso site for increased domestic business in India and exports to Metso’s customers globally," Simula says. "Additionally, significant investment has been made in engineering and R&D resources, making it one of our key global engineering hubs."

Kleemann's new MOBIREX MR 100(i) NEO/ NEOe impact crusher can operate via diesel or electric power

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© AGGREGATES BUSINESS September/October 2023

An aerial view of BKT’s Bhuj facility

Chinese crushing and screening company Mesda made its European show debut at steinexpo The expanded engineering centre at Alwar now has around 100 engineers and Simula says it will play an important role in product development for the company.

Kleemann has launched the MOBIREX MR 100(i) NEO/NEOe mobile impact crusher, the first member of the new NEO line.

The Germany-based manufacturer says the machine is efficient, powerful and extremely flexible – and all-electric operation is possible with the NEOe variant.

It adds that the machine's compact dimensions and a low transport weight mean the new MOBIREX MR 100(i) NEO/ NEOe can be used flexibly, quickly and in a very wide variety of applications. Operation in tight spaces on work sites or in frequently changing places of work is easily possible.

Operation ranges from different recycling applications, such as the processing of concrete, rubble and asphalt, to the processing of soft to medium-hard natural stone.

The new impact crusher is available with two versions: Depending on the application area, it can be run all-electrically with the drive concept E-DRIVE and thus, locally, free of CO2 emissions [MR 100(i) NEOe].

Alternatively, the machine is available with the tried-and-tested diesel-direct drive D-DRIVE. Kleemann states: "Very high product quality is expected from an impact crusher, and this is precisely what the MOBIREX MR 100(i) NEO / NEOe delivers. This is guaranteed not only by the powerful crushing unit with its 4-ledged rotor with a large impact range and versatile rotor ledge options, but also by the 4 m2 large, optional, single-deck secondary screening unit. This

makes it possible to produce a classified final grain size. Through the use of an optional wind sifter, the final product quality can be additionally increased."

It adds that, thanks to a SPECTIVE operating unit specially tuned to the functions, operation of the MR 100(i) NEO / NEOe is simple and intuitive. With SPECTIVE CONNECT, operators have all relevant data on speed, consumption values and fill levels at their fingertips on a smartphone or tablet and prepared in a clearly arranged manner.

SPECTIVE CONNECT also offers detailed troubleshooting aids to assist with service and maintenance. A unique feature in this machine class is the fully automatic crusher gap adjustment and zero-point determination.

Zero-point determination compensates for wear during crusher start and a homogeneous crushing product is retained.

The new MOBIREX MR 100(i) NEO/NEOe machine will be introduced gradually starting in 2024 in Europe and North America.

Terex-owned Simplicity, an established name in the aggregates and mining Industry, has introduced the new MHS620X Modular Screen Plant, a mainstay of screening efficiency in Terex’s modular product offering.

The MHS620X features the new “extra clearance” 6’x20’ ESX Horizontal Screen launched earlier this year at ConExpo providing increased space between the screen decks resulting in easier maintenance access to the media, therefore improving overall maintenance safety. Other key features of the MHS620X include an extra heavy-duty I-beam frame, rigid diagonal truss construction and galvanized steel structure including walkways, stairs, and guard rails. The MHS620X emphasises safety, sustainability, ease of operation, and streamlined setup times.

The complete Simplicity’s modular product line consists of several pre-designed wet and dry screening “plug and play” modules. The variety of bolt-on options are interchangeable and can be fastened on-site using basic hand tools, eliminating any disruptions to ongoing operations. For use in various applications like mining, aggregates, demolition and recycling and industrial minerals applications, this product offering can be incorporated into a compact site or as part of a multi-plant system. AB

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LOADING

Komatsu has unveiled its all-new digital solutions for quarry and large construction sites. Pic: Komatsu

Headline-grabbing loading A major global manufacturer’s new cutting-edge digital solutions for quarry and large construction sites, two exciting next-generation loader series from leading sector players, and eye-catching electric-powered wheeled loading shovels from a top Chinese manufacturer start work at a major UK building-materials supplier’s key London facility. Guy Woodford & Liam McLoughlin report

K

omatsu has unveiled its all-new digital solutions for quarry and large construction sites. Using these solutions, customers can further improve jobsite safety and operational efficiency. Whether you want to increase production, identify bottlenecks or quickly collect reliable machine and production data, the Japanese off-highway machinery giant says it has the ideal digital solutions.

Thanks to the one-second logger data Komatsu quarry machines collect, a fully configurable dashboard is offered for Komatsu quarry fleets. Using the factory-fit telematics hardware, data collection is made easy.

Figures such as fuel consumption, ton/hr, idling times, error codes and machine health are presented to you when, how and where you want.

Komatsu’s Operator Guidance Monitor (OGM) provides real-time feedback to your operator using an in-cab tablet, which collects data directly from the machine. Applicable for Komatsu's bigger rigid dump trucks, OGM will automatically evaluate major KPIs (key performance indicators), such as payload, cycle times, fuel rate, idling and productivity immediately after each cycle. Operators will get alerts in case of overspeeding, sudden

32

© AGGREGATES BUSINESS September/October 2023

braking or other areas for attention. Komatsu says you will improve your operators' skills and awareness, and the quarry’s safety and overall cost will also improve. Due to a series of back-office dashboards, quarry management can follow up on production, fuel consumption and machine use.

In the coming months, Komatsu will

Komatsu’s Operator Guidance Monitor (OGM) provides real-time feedback to your operator. Pic: Komatsu

introduce Smart Quarry Site, an all-in-one fleet management system for your quarry.

Smart Quarry Site offers a complete package to follow up and control your multi-brand fleet using an in-cab-screen and CAN bus connectivity. Smart Quarry Site offers the flexibility to be used at every company level thanks to a real-time overview of your machines, configurable PDF or CSV reports, API service, and a series of dashboards.

Features such as operator IDs, pre-start checks, overspeed alerts and a mesh network between machines will increase the jobsite safety. Komatsu says Smart Quarry Site will help you understand and control every aspect of your quarry exploitation area. Goals such as CO2 reduction, cost control, saving labour hours, controlled machine downtime and increased production and safety are “within reach”, says the manufacturer.

As part of its commitment to net zero, UK-based Aggregate Industries has deployed its first electric-powered loading shovel.

The LiuGong 856HE wheeled loader is now operating at the Aggregate Industries London Concrete plant in Bow, East London.

The 856HE is claimed to be the world’s first commercially available battery-electric loader and is the first fully electric wheeled loader that LiuGong has supplied in Europe.

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LOADING

Oliver Keates, European product manager for the LiuGong Machinery wheeled loader range, says that more than 2,000 similar LiuGong electric wheeled loaders have already been deployed in China.

He adds of the 856HE loader: "This machine is suitable for a range of functionalities including quarrying applications, batching plants, recycling of materials and hopper loading."

At Bow, the 856HE loading shovel will be used to load aggregates from the site’s railhead and will also be used on the London Concrete Readymix plant to keep the site tidy and to manage stockpiles.

The 21,000kg vehicle has a 423kwh lithium iron phosphate battery with a fast-charging capability of 1.7 hours. The machine has a 160kw engine and 3.5m3 bucket capacity and can operate for more than 11 hours on full charge. The machine can be charged from 20% to 95% in around 45 minutes using the Kempower-supplied charger at the Bow site. Most importantly, it uses zero fuel, has zero emissions and produces low noise and vibration.

It joins London’s first all-electric readymix concrete mixer truck at Bow, a 26-tonne Renault Trucks E-Tech D Wide deployed earlier this year. Electrification of the fleet and plant is central to Aggregate Industries’ wider approach to reach net zero before 2050. Kirstin McCarthy, Aggregate Industries’ director of sustainability, said: “We are delighted to be working with LiuGong and that we are the first customer in Europe to be deploying this all-electric vehicle.

“We have worked closely with the manufacturers to get the specification and testing right and it is routinely delivering a 10-11 hour shift on full-charge and will be a real asset to our operations.

“Aggregate Industries has a clear direction of travel for how we intend to reach zero emissions before 2050, and as a business that has a lot of vehicles and burns a lot of fuel, electrification of our fleet is a key part of that overall strategy.

“Change begins small and then gathers pace, and we will be rolling out further electric vehicles across the business during the rest of 2023 and 2024 as we move towards low- or zero-carbon fuels or energy sources.”

London Concrete and LiuGong representatives with the new LiuGong 856HE. Pic: Aggregate Industries

LiuGong's Keates added: “Working with Aggregate Industries has helped LiuGong to deliver our message of productivity and efficiency with reliability.

“This is a journey that began in 2018 for LiuGong, and we continue to grow and expand our electric fleet of vehicles. More and more companies can now see the benefits these machines bring to businesses.

Through LiuGong’s iLink Telematics, companies are seeing real benefits which are helping them achieve the ambitious targets that have been set by the Government.”

A second LiuGong 856 HE is due to be delivered to Aggregate Industries before the end of the year. The first 856 HE currently operating at Bow will then be moved around other Aggregate Industries sites in the UK. Aggregate Industries launched its Journey to Net Zero Strategy in May this year, outlining how it plans to reach zero emissions before 2050.

Remaining with LiuGong, the manufacturer exhibited its new 52-tonne 952F excavator prototype at the steinexpo quarrying equipment show in Germany.

James Higgs, product specialist at LiuGong Europe, said the machine has

The LiuGong 856HE wheeled loader working with material at Aggregate Industries’ London Concrete plant in Bow, East London. Pic: Aggregates Industries

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been specifically designed for the European quarrying and demolition sectors.

Two prototypes of the 952F excavator are being tested - one at an aggregates recycling facility in Berlin and the other with a LiuGong customer in the UK. In addition to Europe, LiuGong says the machine suits North American customers.

Powered by a 282Kw Cummins X12 engine, the machine could be on the market as early as Q1 2024.

Volvo Construction Equipment (Volvo CE) L60F, L70F, and L90F wheeled loaders for Middle East and Africa customers are being upgraded to the H-Series generation with Tier 3 engines this year, ensuring customers get the same powerful and reliable operation as before but with several additional benefits.

The new models will, says Volvo CE, increase operator comfort, lifting capacity and fuel efficiency while reducing service costs and wear and tear, resulting in a smooth operator experience on almost any job site.

With this series upgrade, the Volvo L60Gz and L90Gz models will be phased out by the end of 2023.

The H-Series wheeled loaders boast a brand-new look and feel and several performance-enhancing upgrades that can be boosted further when paired with a wide range of optional equipment.

Some of the most noticeable improvements are as much to do with the machine itself as they are to do with the experience of operating it.

Those stepping inside the cab are set to enjoy a much more comfortable and productive work environment thanks to new features such as Rimpull Control, which allows operators to adjust the wheeled loaders’ rimpull to match slippery ground conditions, thereby reducing wheel spin and wear and tear, additionally resulting in better fuel efficiency.

The H-Series’ Smart Control also balances the energy flow between the hydraulic and the drivetrain systems, providing the right amount of power for exactly where and when it is needed.

In addition, the upgraded wheeled loaders come with an electrically opened engine © AGGREGATES BUSINESS September/October 2023

33

LOADING

hood, slide-out coolers and quick oil change connectors, providing better access to service points and making maintenance routines simple and hassle-free.

Meanwhile, a new optional lock-up torque converter helps increase productivity and fuel efficiency in load and carry applications while reducing operators' fatigue and increasing site productivity.

Another fuel-saving feature is the Eco pedal. When pressing down on the gas pedal, operators will sense a light pushback, indicating they are at the top limit of the economic working range for the engine rpm. Operators then have a choice to stay in this range – and therefore operate most economically – or push beyond this limit if required.

All these new functions allow operators to work smarter, not harder, all the while ensuring the maximum uptime for site productivity and greater fuel efficiency.

Customers looking for further uptime can choose from Volvo Services, such as On-Board Weighing and Volvo Co-Pilot, which allow the H-Series to perform accurately, productively and safely.

The upgraded wheeled loaders can be fitted exactly to customers’ varying needs thanks to a complete range of options and attachment coverage.

Develon, formerly Doosan Construction Equipment, has completed the launch of the 19-strong latest generation ‘DX-7M’ range of tracked excavators from 2 to 53 tonnes for Tier 2 and Tier 3 markets worldwide. The new excavators are designed for various markets, from construction, rental, recycling, waste processing and utilities to mining and quarrying.

The range models are: the DX27Z-7M and DX35Z-7M 2-3-tonne miniexcavators, DX200A-7M, DX210-7M, DX220LC-7M and DX220AF-7M 20-22tonne crawler excavators, DX225LC-7M and DX225LCA-7M 22-tonne crawler

excavators, DX300LC-7M, DX300LCA-7M, DX360LC-7M and DX360LCA-7M 31-37tonne crawler excavators, DX400LC-7M, DX450LC-7M and DX450LCA-7M 41-45tonne crawler excavators, and the DX490LC-7M, DX490LCA-7M, DX530LC-7M and DX530LCA-7M 49-53-tonne crawler excavators.

From the smallest model in the range, the DX27Z-7M 2.8-tonne mini-excavator, to the largest, the DX530LC(A)-7M excavators, the ‘DX-7M’ models are all said to offer significantly improved performance compared to the previous-generation machines. This is due to many enhancements, including more powerful engines and new higher-flow hydraulic systems.

The DX200A-7M 20-tonne excavator and all the larger excavators from the DX300LC(A)-7M upwards incorporate Develon’s Virtual Bleed Off (VBO) cuttingedge technology. The VBO system utilises an electronic pressure-controlled pump within a closed-centre hydraulic system for claimed productivity increases of up to 17% and claimed fuel-efficiency improvements of up to 32%, depending on the model and the mode selected. The closed-centred main control valve minimises pressure loss, while the electronic pressure-controlled pump manages and optimises engine power more effectively.

Improved feedback to the operator through the joystick results in enhanced machine control and less operator fatigue.

The acceleration and deceleration of the excavator workgroup functions are smoother, allowing operators to perform repetitive swinging and digging motions with less jerking movements.

Another feature of most models from 20 tonnes and above that contributes to decreased fuel consumption is the advanced Smart Power Control (SPC) system from Develon. The SPC system controls engine RPM automatically to supply the appropriate

The Volvo CE L90F (pictured), L60F and L70F wheeled loaders for Middle East and Africa customers are being upgraded to the H-Series generation. Pic: Volvo CE

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© AGGREGATES BUSINESS September/October 2023

An aerial view of BKT’s

torque, depending on workload and speed, to Bhuj facility ensure the best fuel efficiency.

The completely redesigned cabs on the DX-7M excavators provide maximum comfort and total control of all aspects of the equipment. Several ventilation and air conditioning options are offered to meet any additional needs.

Enhanced safety is also ensured by the seat-belt warning alarm system and the AVM (around view monitor) system, designed to prevent accidents caused by blind spots.

Other comfort aspects of the new cabs include a new interior with a dark grey base for a modern look, upgraded heating and ventilation functions for the operator, an eight-inch touchscreen monitor for intuitive operation, a DAB audio (handsfree, Bluetooth), a choice of fabric seat with heating function or leather seat, multipurpose cup holder and storage availability, an ergonomic footrest (reduced ankle fatigue), LED cab lights, and a rear sun visor.

The DX200A-7M and DX220AF-7M models have additional reinforcement for claimed exceptional off-road performance.

Every key component meets Develon’s global standards. In the DX200A-7M, the hydraulic components and the engine tank have been strengthened, and the robust frames and structures are designed to stand up to the rigours of tough workplaces. Similarly, the DX220AF-7M is fully armoured from top to bottom to help maximise uptime on all types of extreme terrain, including forestry work.

Another important feature of the newgeneration Develon excavator range is the installation as standard of the latest version 3.0 of the Develon Fleet Management system, which provides a telematics management system by collecting data from sensors on the machines. The DX27Z-7M mini-excavator is now the smallest model in the DEVELON range with the successful Develon Fleet Management system. AB

The DX530LC-7M is part of Develon’s latest generation of ‘DX-7M’ tracked excavators. Pic: Develon

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HAULING

Driverless hauling passes its close-up test A close-up look at driverless hauling, a mobile haul-road dust-suppression water truck from the world’s biggest off-highway machine manufacturer, and a top articulated dump truck manufacturer is a big draw at a popular industry exhibition. Guy Woodford reports

U

S-based technology company xtonomy says it provides the most advanced next-gen autonomous solution for mining and quarrying. In collaboration with Germany’s Bell Equipment distributor, Kiesel, the firm recently illustrated its claim by demonstrating its fully operational autonomous haulage system (AHS) on a Bell B40E articulated dump truck (ADT) at steinexpo 2023, staged in Europe’s largest basalt quarry in Homberg/ Nieder-Ofleiden in the central Germany state of Hesse. Attendees at the five-day event (24-28 August) watched the articulated hauler making driverless cycles around the Quarry Vision area.

After many years of development, xtonomy AHS for trucks is now transitioning to full production. It is designed for smaller truck fleets that the excavator or loader operator may fully operate. Although the autonomous trucks automatically follow the excavator position on the bench and adapt the queuing position, cusp point and loading position automatically, the operator can adapt all points to assist the process further.

No additional personnel are required to supervise the fleet, as all underlying processes are fully automated. Robust radar onboard mapping and object detection continuously monitor the environment. At the same time, motion planners freely plan the best routes and dynamically react to

changes instead of driving from one fixed point to another on virtual rails. Furthermore, xtonomy AHS handles the interaction of multiple trucks in such unstructured environments. This is only possible, the company says, through autonomy at the highest system levels.

Several safety layers .guarantee dependable operation via radio communications, high-precision GPS, radar and ultra-wideband (UWB) localisation.

Manned machines may be integrated into the ecosystem for safe interaction in complex scenarios.

Furthermore, the xtonomy autonomy system does not require uninterrupted coverage of high-bandwidth comms throughout the mine site. This dramatically reduces the system implementation effort.

Properly watered haul roads directly impact fleet cycle times and the ability to meet production targets. As haul-road dust affects safety and productivity at mines and quarries, the water truck is one of the site's most important support equipment. The new Cat 777 (05) Water Solutions Truck provides an integrated solution to help reduce haulroad dust by solving overwatering and underwatering issues.

The new 777 (05) is built on the Cat 777E truck platform, proven at mine, quarry and construction sites globally. An innovative truck that uses less water for controlling haul-road dust, the design integrates the

truck, tank, and water delivery system, connected with technology. Its Cat Water Delivery System (WDS) combines with Cat MineStar Edge connectivity to help operations manage the site more safely and productively with flexible levels of technology to meet site needs.

Boasting a 75,700-litre Cat-branded water tank, the 777 (05) has a spray system, splash guards, fill chute and rock ejectors. It is powered by the 765kW Cat C32B engine that meets China Nonroad Stage III emission standards, equivalent to U.S. EPA Tier 2.

The new water truck’s exclusive Cat WDS features a self-contained hydraulic system that controls spray patterns independent of engine RPM for consistent watering. Based on the truck’s speed, variable water flow automatically starts and stops when the truck slows or comes to a halt, preventing overwatering and subsequent poor traction at road intersections. The pump features soft startups and automatically shuts off when the tank is empty to prevent system damage.

WDS components include a water cannon, oil cooler, variable displacement pump, hydraulic oil tank, electronic control boxes and hydraulic motor/water pump. Covering up to a 24-metre wide road in a single pass, the system sprays at rates reaching 0.8 l/m² at speeds from 4 to 40kph (3 to 25mph). With its maximum 61-metre-spray distance, the truck’s water cannon offers a maximum flow rate reaching 4732l/min.

xtonomy’s AHS on a Bell B40E ADT at steinexpo 2023.

Pic: xtonomy

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HAULING

Factory-installed, ergonomic water controls are integrated into the truck’s design for convenient operation. Its innovative automated water delivery feature enables the operator to focus on driving and site traffic to enhance safety. Complete with auto shut-off to prevent overfilling, the water tank is filled remotely, allowing the operator to remain inside the cab during the cycle to reduce potential operator slips and falls.

Flexible levels of the cloud-based MineStar Edge technology are integrated with the Cat WDS to collect and communicate machine data, allowing site supervisors to monitor the water truck to know where and when it’s spraying water. Asset management options include productivity, water usage, fuel and water tank levels, when and where to apply water, geofencing, asset location, and remote management of water distribution.

Providing tracking capabilities without infrastructure investment, Edge Equipment Tracking delivers basic connectivity without interfering with existing fleet management systems. Helping to achieve a lower total cost of ownership, Equipment Tracking provides insights to help mines better manage their assets. It features service meter readings, fuelling and recording data, location accuracy and replay, time utilisation tracking with downtime and operator tracking, automatic stoppage measurement, and health event recording.

Paired with Equipment Tracking, MineStar Edge Production Recording delivers premium connectivity with an accurate and automated near-real-time measurement solution that reports on every aspect of the watering cycle without requiring operator input. Giving visibility to the entire operation it helps to discover opportunities for improving productivity. This premium package also includes water usage by truck/fill station, volume and rate of water put down over time and area covered, water delivery system setting by location, truck, and conditions, activity breakdown with time and distance – watering, not watering, stopped, etc.

The Cat dealer and parts network fully supports this integrated system with Cat-branded tank options. Covered by the Caterpillar factory standard warranty, the water truck, including the tank and components, is eligible for Cat equipment protection plans (EPP) and customer value agreements (CVAs). Cat dealer installation of the integrated system is available, and retrofit kits for existing Cat 777E truck platforms in the field have planned availability in the future.

Rokbak’s RA40 articulated hauler was showcased at this year’s Maxpo (31 August – 2 September), Finland’s largest exhibition of land construction and environmental maintenance machinery. Visitors got a close-up look at the RA40, courtesy of Kivisampo, Rokbak’s trusted dealer in the Nordic nation.

As a biennial global exhibition, Maxpo presents ‘the biggest and greatest machines’

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to almost 10,000 visitors at Hyvinkää Airfield, approximately 40 miles (60km) north of the Finnish capital Helsinki.

Kivisampo has been attending Maxpo for two decades. This is the first time a Rokbak hauler has been exhibited at the event since the rebrand in September 2021. The rebrand followed huge investments and improvements after the Volvo Group’s 2014 acquisition.

“For us, Maxpo is a big deal,” explains Kivisampo sales director Sakari Rantanen.

“It’s the time of the year when the customers come to you instead of the other way around.

We’re delighted to present the truck to the masses. Rokbak is still a relatively new brand, but, especially in the Nordic countries, Volvo is a name on everyone’s lips, and the truck’s Scania engine is very well-liked.”

In the first half of 2023, the Nordics accounted for 16% of the European market for ADTs. This is a 52% increase in share compared with 2022. In the Finnish market, the over 35-tonne class is the largest sector.

The RA40 has been on demonstration in Finland and was introduced to the wider market at Maxpo. Arriving in a straightto-the-point sand-coloured palette, the 38-tonne RA40 is a heavy-duty articulated dump truck that makes light work of largescale quarry, mine and construction jobs.

Offering reliability and performance, the RA40 delivers cost-effective productivity in the toughest conditions and roughest sites, from quarries and infrastructure developments to commercial construction projects. AB

Featuring a 75,700-litre Cat-branded water tank, the Cat 777 (05) has a spray system, splash guards, fill chute and rock ejectors. Pic: Caterpillar

Rokbak’s RA40 has been on demonstration in Finland and was introduced to the wider market at Maxpo. Pic: Rokbak

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DRILL RIGS, BREAKERS & HAMMERS

Michele Vitulano, Indeco’s global sales and marketing manager. Pic: Indeco

A growing attachment to the new marketplace Italian attachment specialist Indeco is adapting to a changing construction and quarrying industry marketplace with big growth plans for its product range and customer support.

Aggregates Business editor Guy Woodford caught up with Michele Vitulano, Indeco’s global sales and marketing manager, at this year’s SaMoTer and co-located Asphaltica exhibition in Verona to get the full picture

M

ichele Vitulano is his usual quick-witted and colourful self as we sit down to talk during the early stages of the 31st edition of SaMoTer and co-located Asphaltica (3-7

May 2023).

He highlights a growing demand for attachment products compatible with smaller-sized excavators, with the company looking to increase its range in response to this market trend. “We already have breakers from 60 kilograms to 11,000 kilograms, so we are talking about pulverisers, demolition crushers, mulching heads, and grabbers. We are growing these ranges going down and are very close to launching a 150-kilogram grabber. We will also have 900-kilogram and 500-kilogram demolition crusher attachments out very soon.”

Vitulano notes that Indeco benefited from a particularly strong performance in North America in 2022, where the Bari, Puglia-headquartered company enjoyed its best-ever sales year at just under $50mn.

Indeco North America is now looking to expand its Milford, Connecticut facility to

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meet the strong demand for equipment. The site also manufactures several items, such as mounting brackets for hydraulic hammers and compactor attachments.

“Our Milford premises is huge, and from it, we can deliver 98.5% of requested parts within 24 hours,” emphasises Vitulano.

“We can also deliver spare parts from there to customers in Canada, Mexico, Peru, Colombia and Chile.”

Vitulano says he is also looking for a suitable business to add to Indeco’s portfolio.

“We are looking to add another product to our basket. The choice is always to start the product from zero like we did with our steel shears or buy a company already producing them as we did with our mulching heads.

We are watching some European and US companies and have our eye on several possibilities.

“Indeco is financially really strong. That is why we don’t use any bank financing. We reinvest all our profit as we are doing with our new €8 million Bari production plant.

It will be used for welding and cutting of what we call silent demolition tools, like pulverisers and steel shears. It will also be used to produce the casings for our hammers.

This plant will easily double our production

Michele Vitulano next to an Indeco HP 2500 hydraulic hammer at SaMoTer 2023

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DRILL RIGS, BREAKERS & HAMMERS

capacity. We will take on more people and have more robot stations for better efficiency.

The space used before in our main premises for metal carpentry will increase our semifinished and spare part inventories. The latter will help our dealers offer even better service to customers. I hope this new plant starts operating in June.”

A global employer with 240 employees worldwide, Vitulano says that in December 2022, Indeco responded to its workers’ concerns over rising energy and other living costs by raising salaries by around 10%. “At the end of the day, a company succeeds through the efforts of its people,” he stresses.

Indeco has made its first sales of breakers in Japan, a significant success given the strength of Japanese hydraulic breaker firms in the home market. Improving construction and mining customer demand in Australia is also good news for the company, which has distribution and service premises in Melbourne and Sydney.

The first manufacturer to launch the smart hammer on the market in 1985, Indeco is among the first to offer a range of hydraulic attachments with 4.0 technology. This is thanks to the new remote-monitoring system Indeconnect, based on the principles of the Internet of Things, to prevent equipment obsolescence and maintain optimum performance over time.

Indeconnect consists of a proprietary device to be mounted on various equipment, provided with 4G technology for wireless interconnection to the network and a cloud-based web platform accessible from mobile (via app) or PC, with which to consult the data transmitted in real time by each installed device: hours of work performed, working position in space, hydraulic oil temperature, ambient temperature, and GPS location.

Returning to Indeco’s trading priorities, Vitulano says: “The challenge over the next year will be to increase our attachment product efficiency even further as construction machines become increasingly electric powered. Our hammers have a fuelsaving system. Our hammers require 18-19% less oil than comparable attachments to do the same work on the same excavator.

A gas-powered hammer has an efficiency of 55%; our hammers have an efficiency of between 65 and 70%. If a hammer requires less input energy from the machine carrier, then greater output energy can be generated by the hammer. It lowers the carrier machine’s engine RPM, reducing gas consumption and customer fuel costs.

“An excavator’s fuel cost, right now, is a lot of money. We were doing some calculations at a huge quarry in India that primarily treats construction and demolition waste and turns it into gravel. We reviewed the customer’s 100-tonne excavator and hammer operating and maintenance costs, then looked at the fuel cost and said, ‘My goodness. It is five to six times all the other costs.’ Talking to your customers and learning from your markets is important.”

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Commenting further on Indeco’s key sales markets, Vitulano says: “We generate most of our sales in Europe and the US, so we are reinvesting some of our profit into offering even more to customers in those markets. For instance, I remember years ago when we invested significantly in Indeco UK, near Manchester in England. A colleague expressed concern over the investment size, but I said, ‘No, we must invest to employ more people and to have a better workshop and offer a better service.’ It is important for a company to put money back into the markets that have enabled it to grow. We put passion into what we do and love our customers.”

Vitulano comments on Indeco’s trading in China and Southeast Asia: “We sell big steel shears and hydraulic hammers in China. Unlike in China and South Korea, the European community has no agreement with Southeast Asian countries regarding zero [export and import] duties.

A hammer going to Indonesia from Europe has 14% more duty to pay than if it was imported from China or South Korea. That means selling our products in Indonesia and other Southeast Asian countries costs much more. We are trying to do business in important markets like that, but it is difficult.” AB

An Indeco HP 5000 hydraulic hammer at work. Pic: Indeco

“It is important for a company to put money back into the markets that have enabled it to grow” Michele Vitulano, Indeco

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DRILL RIGS, BREAKERS & HAMMERS

Czech mate to Epiroc A surface drilling team in the Czech Republic provides first-class drill and blast services to quarries nationwide after purchasing a new fleet of Epiroc equipment. Guy Woodford reports

S

ome years ago, the Fospol division of Explosia decided to renew its fleet and has since been continually phasing out its older drill rigs and replacing them with modern equipment. The company currently has six drill rigs, three of which are from Epiroc, including the top-ofthe-range SmartROC D50 MKII. It aims to boost its capacity to five Epiroc rigs by yearend 2023.

These SmartROC T40 MKII rigs are equipped with the Hole Navigation System (HNS) and are expected to be delivered in the second half of 2023. In addition, the whole fleet will be backed up by Epiroc’s ROC Care service and maintenance contract, which includes regular service inspections using Epiroc’s RigScan scanning technology.

Přemysl Gromada, head of the FospolExplosia Drilling Group, points out that when the first SmartROC D50 arrived in the Czech Republic, it represented a milestone for Explosia.

“It was a DTH [down the hole] rig unlike any other in the whole country, and it was a great success for our company,” he says.

“It felt like a reward for a job well done in terms of the company’s modernisation and investment plan.

"Since then, we have increased our productivity by about thirty per cent, not only due to the modernisation of the fleet but also to the replacement of personnel in drilling positions."

The Epiroc fleet performs well in the hard rock quarries of Litice-Plzeň, achieving penetration rates of 0.3-0.5 m/min, as well as in the softer limestone quarries of Velké Hydcice, where the average penetration rate is 1.3 m/min.

With tophammer drilling, the rigs drill 89, 95 and 102 mm diameter holes and 100 and 105 mm diameter holes with DTH drilling.

The holes are normally drilled to depths of 15–20m.

Explosia has three Epiroc drill rigs, including the top-of-the-range SmartROC D50 MKII. Pic: Epiroc

Gromada says a hole of 15–29 metres is completed in 30-60 minutes, much to the drillers’ satisfaction.

He continues: “As our previous rigs were about 15 years older than the latest models, our drillers see improvements on almost every level. But they probably most value the automatic processes, such as full drill cycle automation DTH, tophammer rod extraction assistance, remote control and the Hole Navigation System.

“This high level of automation eliminates interventions by the driller and accelerates the whole drilling process.”

The drillers look forward to achieving efficiency gains with features such as one-hole automation and the Hole Navigation System (HNS). However, the company says it is early days, and the full

benefits will not be fully realised until 2024.

However, performance monitoring using the Epiroc Certiq system has already proven its worth.

Gromada says: “We have been using Certiq since the autumn of 2021 when we purchased the Epiroc SmartROC T40 and T45 drilling rigs, which was a big change for us. It was a move towards more efficient monitoring of production and simplification of records.

“This gave us a much better overview of inputs and outputs of individual drilling rigs, which made calculations easier for us.”

The same can be said of the My Epiroc application, which Explosia also adopted into its drilling operations in the second half of 2020. This tool, Gromada points out, has been particularly helpful in production

Exploisa says its Eprioc drill rigs are ultra-fuel efficient and highly productive. Pic: Epiroc

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DRILL RIGS, BREAKERS & HAMMERS

monitoring and planning of regular service activities.

In addition, the company has noted significant improvements in overall fuel consumption. The average consumption of diesel using the previous Epiroc ROC L6 drill rig was approximately 1.9 litres per drill metre.

With its replacement, the Epiroc SmartROC D50 MKII, its 2023 fuel consumption averaged 0.96 litres per drill metre – almost half.

Currently, the monthly savings on diesel average about 3,000 litres.

In the past, due to its ageing fleet and lack of repair and maintenance services, Explosia has urgently and regularly had to request assistance from its competitors to complete drilling projects, but not anymore, explains Přemysl Gromada.

“The situation has changed significantly over the last three years, and this is the first year that we can offer drilling work to companies in the Czech Republic who unexpectedly get into a situation where they cannot meet deadlines.

“Fortunately, Explosia realised in time that without modernisation and investment, it would not be possible to continue fulfilling our existing or future obligations, let alone be a full-fledged competitor to other companies in the drilling business. The drilling quality is completely different now and much better.”

In terms of all its operations, Explosia is a company with a comprehensive sustainability policy. By commissioning the new Epiroc

Přemysl Gromada, head of the Explosia Drilling Group. Pic: Epiroc

“The drilling quality is completely different now and much better” Přemysl Gromada, Fospol-Explosia Drilling Group

drill rigs, the drilling team has reduced fuel consumption by 30-50%.

“Whether it concerns raw materials, energy, production or any other resource, sustainability is important for everyone,” continues Přemysl Gromada, who proudly claims a strong personal commitment to environmental protection.

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“Epiroc has helped us by significantly reducing exhaust fumes, primarily as the new rigs have better fuel consumption than the old ones, and lowering emissions further through AdBlue. So, I can see that over the last four years, Explosia has significantly shifted ecology towards conservation and more consideration for nature.” AB

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TYRE TECHNOLOGY

An aerial view of BKT’s Bhuj facility

BKT invests in its confident growth vision Indian off-road tyre giant BKT, Balkrishna Industries, recently invited the world’s trade media to its state-of-the-art site at Bhuj in Gujarat to showcase the group’s exciting plans for the future.

These include a doubling of the company’s turnover to US$2bn by 2026 and an increase in annual tyre production to 600,000 tonnes. Guy Woodford reports

S

peaking at BKT’s newly acquired 65-acre site, just a short distance from the company’s main site at Bhuj, marketing and communication manager Gabriella Usiello outlined the company’s plan of action.

This will include a second carbon-black production facility dedicated to external sales, a second power plant to supply the significantly enlarged operation and an assembly line making rubber tracks for agricultural machinery.

“We are incredibly proud of this new acquisition and the growth opportunities it offers BKT. We are constantly looking for ways to improve and grow. This additional land is going to be another game-changer for us, giving us more room to expand our production capabilities and take our operation to the next level,” she said, adding: “We are confident that with this new site, we will continue to produce the highest quality products and meet the demands of our customers.”

Usiello’s speech followed an extensive tour for the assembled media of the facility which will employ more than 4,770 workers.

The vast site is more like a village, complete with growing onsite accommodation for employees and their families. There are shops, a school, medical services, and sports and other recreational facilities. By the end of next year, 1,240 employee families and 400 single men will be living at BKT Bhuj. Work on the site is expected to be completed in 18 months to two years.

Day two included a press conference at The Trident Hotel in Mumbai focusing on the trip’s theme, Enter the Future. The media party heard from a number of top

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BKT executives, including chairman and managing director Arvind Poddar and joint managing director Rajiv Poddar.

“In our future, BKT will double its turnover. In our future, the combination of production, distribution and brand promotion will allow us to achieve new standards,” said Arvind Poddar.

“People have asked me if all this was really necessary … so much in such a short time. The goals we set ourselves when we decided to open the Bhuj site were proportional to the financial solidity of the time but above all to a vision which is as great as it is concrete,” said Rajiv Poddar.

“Growth has always been in step with demand. Global tyre demand is growing, and

we see no signs of it slowing down over the next five years. This demand started to rise during the 2020 pandemic, which today is above pre-Covid levels.

“The journey we started out on at Bhuj in 2012 was never a return journey, but one to prepare ourselves to discover the future.”

BKT’s 25” to 57” off-the-road (OTR) tyre range supplies many industries, including construction, quarrying, mining, industrial, earthmoving, ports and agriculture. The company has more than 10,000 employees and offers a staggering 3,200 products in 160 countries across five continents. With its global headquarters in Mumbai, the company has three subsidiaries: BKT Europe in Seregno, near Milan, Italy – which has a

BKT’s carbon-black plant at its soon-to-be-expanded Bhuj facility

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TYRE TECHNOLOGY

10% share of the continent’s OTR tyre market; BKT USA in Copley, Ohio; and BKT Tires in Toronto (Canada). There are six production sites in India, one in Bhiwadi, Chopanki, Dombivli and Bhuj, and, since autumn 2021, two in Waluj, a large village located to the west of the city of Aurangabad in the central part of Maharashtra state.

BKT’s consistent investment in digitalisation and automation at its current Bhuj site has increased production speed, volume and final-product quality. The amount of product discarded has been reduced, increasing the sustainability of the manufacturing process and reducing production costs.

Processes are also becoming increasingly reliable, and most importantly for BKT, occupational health and safety risks have been drastically reduced, and worker comfort improved.

The extended facility, including the new fully digitalised carbon-black plant dedicated to external sales and the stateof-the-art rubber-tracks assembly line, will meet significantly increased market demand for these products. It is anticipated that 5% ($100mn) of BKT’s targeted $2bn annual turnover by 2026 will be generated by carbon-black sales with the 198,600 tonnes earmarked for tyre tread production in 2023 predicted to rise to 500,000 tonnes per year by 2026.

Moving the rubber-tracks assembly to a new purpose-built site will free up space to allow BKT to increase its off-the-road tyre output at times of higher customer demand.

Carbon black is produced by a hydrocarbon fuel [gas or oil] reaction to limited combustion air at temperatures of 1320 to 1540°C. The unburned carbon is collected in an extremely fine, fluffy, black particle, 10 to 500 nanometres (nm) in diameter, and this ‘carbon black’ is used to strengthen the tyre rubber compound.

BKT Bhuj’s carbon-black plant began operating in 2017 with 65,000 tonnes of hardgrade carbon black for tyre treads produced in that year. In the following year, production increased to 110,000 tonnes. The production of soft-grade carbon black started in 2018.

This is used in the casing compound to improve strength and durability, generating less heat. In 2021, the total production of the two types of carbon black reached 138,000 tonnes per annum, while last year, it rose to 165,600 tonnes. The goal for 2023 is 198,600 tonnes. BKT Bhuj’s research and development centre plans to add a third ‘speciality’ type of carbon black, which has different properties to the carbon black used in rubber compounds. These properties offer high resistance to colouring, a high purity level, a low ash level and a very low level of PAHs. This makes speciality carbon black suitable for specific applications such as paints, plastics and inks.

BKT has also introduced a new approach to carbon-black production, making the whole process more sustainable. For carbonblack transportation, BKT substituted

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bulk bag containers with mobile silos.

This means that the tyre-production plant receives the carbon plant using mobile silos transported pneumatically to the storage.

This will eliminate the need for BKT to use 100,000 bulk bags over the next few years. Furthermore, the whole transport system is designed to reduce energy usage and consumption. Every transfer system is controlled by weight and energy used – with BKT aiming to reduce energy consumption by up to 70%. This will save more than two million kilograms of CO2 emissions annually, comparable to the emissions rate of 5,000 100m² apartments.

At the same time the gas used to manufacture carbon black is now ending up in a co-generation plant able to reuse 75,000m³ of gas per year. This saves 215,000 tonnes of coal per year.

BKT Bhuj’s power plant became operational in 2013, giving the site a reliable and controlled source of electricity. Today, solar panels and the cogeneration plant allow the facility to produce its own energy. Last year, the cogeneration plant was expanded from 20MW to 40MW per year, and work is underway to increase the power generated by self-produced renewable resources.

Water is also at the heart of BKT Bhuj’s power-plant sustainability. Since 2019, a zero-liquid discharge (ZLD) principle has been adopted, meaning no liquid waste is released outside the plant. All water used in the plant is treated, purified and reused. The objective of the ZLD principle is to conserve water resources, reduce the environmental impact of wastewater discharge and improve the plant’s overall efficiency and sustainability.

When the first tyre rolled off the Bhuj production line in 2012 following a $500mn investment, the plant was located across 123 hectares. Before starting the works, the landscape was completely arid with neither water nor electricity. After laying many kilometres of drinking-water pipes and power lines the site grew exponentially: 126

hectares in 2016, 131 in 2019, 137 in 2021, and 258 in 2022. By the end of 2023, it is forecast to reach a total surface area of 323 hectares, of which 283 acres have already been acquired.

More space provides the possibility to install new machines, accommodate more test areas, and increase volumes and all that goes with it. From 92 tonnes of daily production in 2015, BKT Bhuj ended 2022 with its best result ever - 436 tonnes daily. This is timely as BKT’s business has, as Rajiv Poddar noted in the Mumbai press conference, increased by 49% compared to the pre-pandemic period. This remarkable achievement reflects the Indian multinational’s readiness to embrace new opportunities and challenges.

BKT spends 3.5% a year of the company’s turnover on research and development (R&D). Its R&D Centre is said by the company to be the “cradle which allowed the Bhuj site to grow into what it is today”. Established in 2017, this hub develops products and processes to ensure BKT can maintain its leadership in the international off-the-road tyre market. Led by a specialist team of researchers and analysts, it remains one of the world’s most important and up-to-date tyre research centres.

Finding the right solutions requires testing. For this reason, a special test track was inaugurated in the R&D centre’s first year. With six different tracks, this circuit includes tracks for tyre-performance tests in both dry and wet conditions, an asphalt track and a sloping concrete track. Thanks to a wide variety of tests, many important characteristics such as traction, handling, comfort, soil compaction, and much more, can be measured here, thanks to highprecision devices and instruments.

Having seen the vast BKT Bhuj site firsthand and after listening to BKT’s senior management team lay out the company’s hugely ambitious plans for growth, few would bet against such a vision becoming a reality in 2026. AB

A BKT employee inspecting a giant BKT off-the-road tyre at the company’s state-of-the-art facility in Bhuj, Gujarat

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WATER RECYCLING, MANAGEMENT AND FILTRATION

The Tecnoidea soil-washing plant operated by Italian construction materials company Beton Lana

Getting the full automated soil- and water-treatment plant Italian companies Tecnoidea and Ma-estro have collaborated on the new W-Portal automated control system for water- and sludge-treatment plants, which enables both increased sustainability and cost savings. Liam McLoughlin reports

T

ecnoidea Impianti SRL has developed a new automated production control system for water- and sludge-treatment plants in collaboration with fellow Italian company Ma-estro. The system, which is a Tecnoidea product powered by Ma-estro, is to be called W-Portal – with the W standing for Water. It features a web app and portal where both Tecnoidea and the plant operator can log in to check and extrapolate all the plant data.

“The system enables the complete control of the treatment plant by maximising production efficiency and minimising production costs,” says Marco Doniselli, project engineer at Tecnoidea.

He adds that the two main aims of the automated control system are to enable increased sustainability and cost savings.

“These aims are reached by tracing process parameters (energy consumptions, CO2 emissions, environmental data) and implementing automatic actions,” he says.

“For example, based on the quality of the input material you can adjust water flows, and therefore save energy.”

The system is designed to enable predictive maintenance and the optimisation of spare parts use with less wastage. It also provides the ability to do scheduled, and therefore less frequent, planned downtimes.

Doniselli says that the soil-washing and water-treatment processes are often regarded as being two different entities which are unrelated and unable to communicate.

“We believe the innovation in our new system is that it treats these two processes

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© AGGREGATES BUSINESS September/October 2023

as more of one single 360-degree industrial process,” he adds.

Both companies are bringing specific quarry-industry expertise to their collaboration. Ma-estro has developed an advanced system for tracing, managing and controlling entire plant processes at quarries.

It provides its quarry customers with tools for identifying plant inefficiencies. Tecnoidea has strong expertise in enabling water- and sludge-treatment turnkey solutions.

“Together our combined expertise enables water- and sludge-treatment plants to be capable of achieving 100% of their operating performance and optimising production costs,” says Doniselli.

The two companies have previously worked on several projects, but the first

German company Anton Eireiner has deployed a Tecnoidea soil-washing plant

prototype of the integrated system has been developed for Beton Lana, a constructionmaterials company in northern Italy. The washing plant handles 220 ton/h input material, with 400 m3/h water and 15 ton/h dry solids to the filter press.

The new automated production control system will be available as an add-on package to new and existing Tecnoidea plants. The system will be able to communicate with the PLC (Programmable Logic Controllers) of the washing plant when this has been designed by Ma-estro.

The system is currently undergoing testing, and the plan is to go live with making it available globally to customers in January 2024 in any location that has an internet connection.

Tecnoidea was founded in 1981 and since then has deployed around 2,000 water- and sludge-treatment plants around the world, with more than 1,000 of these being at quarries. “Quarrying is the most important part of our business,” Doniselli says.

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WATER RECYCLING, MANAGEMENT AND FILTRATION

Tecnoidea’s plants are also used beyond the quarrying sector. One of the most eye-catching projects it is involved in is connected to the 2026 Winter Olympics which will be held in Milan and Cortina d'Ampezzo.

As part of the construction project for the event, Tecnoidea has provided a soil-washing plant in the Santa Giulia district of Milan.

This is improving the poor soil quality in the area by washing a total of 1,000,000-tonnes over the next three years and restoring it into the ground to enable new building to take place. Santa Giulia is the location for a new 16,000-capacity area where the ice hockey tournament will take place. Poor soil quality in the area has previously been a barrier to new buildings being constructed.

The washing plant handles 200 ton/h input material, with 600 m3/h water and 40 ton/h dry solids to the filter press.

Europe is the main market for Tecnoidea’s plants - specifically central Europe including Italy, Switzerland, Germany and Austria with the support of the company’s strategic partner metcam. Swiss-based metcam has played a major role in the deployment of a Tecnoidea mud-slurry treatment plant at the Gloggner company in Perlen, Switzerland.

The washing plant (2 lines) handles 20 ton/h drilling mud and 15 ton/h road-sweeping material, with 150 m3/h water (each line) and 10 ton/h dry solids to the filter press (each line). Tecnoidea plants have also been deployed in France, the UK and other countries around the world.

In terms of the company’s future plans and innovations, Doniselli says: “A lot of

A Tecnoidea polluted soilwashing plant is enabling building work in Milan for the 2026 Winter Olympics

things are always going on at Tecnoidea and we do not stand still. We are always trying to improve our machines and products.

An important new feature of 2023 is the new pump-testing facility where the most advanced technologies have been employed to test our ABRA POMPE with the aim of granting the highest performance.

“In my three years at the company I have seen its plans getting bigger and

more complex, but to the end customer the products and the PLC architecture seem even simpler.

“In between there is a lot of work around automation. We are trying to introduce automation even into the sub-features of our machines because we don’t want the operators to bother about anything, just to be concentrated on the final aim and let the machine do the rest.” AB

TWS plant helps improve water treatment at Welsh quarry A newly-deployed Terex Washing Systems (TWS) filterpress is improving the quality of water treatment and water recycling at a quarry in North Wales

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he Aberdo quarry at Pentre Halkyn is owned by CCP Building Products and produces quality limestone aggregates that supply the markets of North Wales, Cheshire, Lancashire, Liverpool and Manchester.

In late May this year the quarry started operating a Terex WS FP215 filter press, which features 1.5m x 2m filter plates, and an automated control system.

CCP Building Products says the TWS-supplied wash plant doubles the output from its quarry operation, working alongside the quarry’s current crushing process.

The washing plant allows the quarry to produce high-quality premium limestone aggregates in 10mm, 20mm, 40mm and 4/20mm sizes. The wash process also produces a quality manufactured 0/4mm

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limestone sand that can be used in concrete production. Much of that material production is currently generated from the years of quarry overburden which had been stockpiled onsite as a ‘waste’ material and which the plant was designed to process.

Terex Washing Systems describes the installation at Aberdo as ‘Feeder to Filter press’ because all the wash-plant machinery and crushing and screening equipment at the site is designed, manufactured and supplied from Terex Washing Systems and its other sister brands. These include a Powerscreen Metrotrack jaw crusher at the front end, a Powerscreen Warrior 2100 scalping screen, a Powerscreen Premiertrack 1150 cone crusher, a TWS AggreSand 206 sand-washing plant, a TWS AggreSand 150 scrubbing plant, a TWS FDU (flocculant dosing unit) 5000,

TWS Rake thickener, buffer tanks and the FP215 Filterpress.

Fergal McPhillips, global business development manager for TWS, says that having all the plant from Terex-owned brands is a major benefit for the operator from a servicing and parts perspective as it is a ‘one-stop shop’.

“There is a lot of interest in this deployment around the filter press itself,” he adds. “Health and safety is very high on the priority list for our filter presses. It has stainless steel sliding isolation doors, and the automated maintenance and control system means it is user-friendly.”

More than 95% of the water in the watertreatment process at the quarry is recycled by the Terex WS system. The filter press and washing plant produce 20-tonnes of dry filter© AGGREGATES BUSINESS September/October 2023

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WATER RECYCLING, MANAGEMENT AND FILTRATION

cake waste product which is put back into the quarry.

“The filter press is in place to recycle the maximum volume of water, minimise the water usage, and produce a dry filter cake that is easy to transport,” McPhillips says. “The recycled water is fed back into the washing process.”

CCP Building Products says that, from render and floor screeds to concrete materials and paving courses, the washed aggregates that the quarry produces have an array of uses.

“Their versatility, high quality, strength and workability make them ideal for all kinds of projects and uses, including the production of concrete, asphalt, drainage and landscaping projects to name just a few,” it adds.

Washed aggregates undergo a specialised process to remove impurities, such as clay, silt, dust and other unwanted particles, which can have a negative impact on the strength and workability of concrete, one of their key uses. The washing process also eliminates sulphate and chloride to meet the specifications for the British standard of sand used in concrete. By ensuring cleanliness and adhering to quality standards, washed aggregates provide numerous advantages over non-washed.

Terex Washing Systems has a history of deploying similar filter presses across Europe and the USA, designed and manufactured at its HQ in Dungannon, Northern Ireland.

Turkish concrete producer Boǧçziçi Beton has commissioned a new CDE wash plant to increase its output levels.

Established in 1997, Boǧaziçi Beton has 28 separate concrete batching plants in Turkey pouring six million m3/year. In total, the firm has poured some 35 million m3 of concrete which has been used in major construction projects in Istanbul, including the new central bank, metro construction projects, highways and viaducts and high-rise buildings in the financial district.

Aberdo limestone quarry has deployed a Terex Washing Systems FP215 filter press, which features an automated control system

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© AGGREGATES BUSINESS September/October 2023

An aerial view of BKT’s Bhuj facility A CDE EvoWash plant is improving output at Turkish concrete producer Boğçziçi Beton

The firm took over a 50-acre quarry in the Kemerburgaz-Cendere region in 2015 to begin processing crushed sand and aggregates for its own concrete production.

The following year, Boǧazççi Beton increased crushing-plant capacity at its Cendere quarry to 2,000tph, enabling the firm to process up to six million tonnes of crushed material annually.

In Kemerburgaz, where Boǧçziçi Beton’s site is located, all quarries have natural sandstone which has a major waterabsorption problem in crushed sand.

With approximately 15-17% of 0–63micron content after crushing, Boǧazççi Beton was producing methylene blue test results above the acceptable limits which resulted in higher production costs due to the need to add additional cement to the concrete mix.

Seeking to address this, Boǧçziçi Beton engaged with wet-processing experts CDE to design and commission a plant to remove excess fines content in its sand and decrease

water absorption with the aim of achieving a lower methylene blue result in line with industry standards.

The issue central to Boǧazççi Beton’s high methylene blue values is the integration of bucket wheels in the existing plant, which increase water absorption.

CDE commissioned a 220tph EvoWash 251 to help improve the quality of the product whilst also increasing outputs.

A compact, modular sand-washing system, CDE’s EvoWash screens and separates the smaller sand and gravel fractions through an integrated highfrequency dewatering screen, the hydrocyclone technology provides unrivalled control of silt cut points and eliminates the loss of quality fines.

The feed material is delivered to the plant dry, before being adequately fluidised. From here it is pumped to dual 500mm cyclones via an integrated slurry pump to remove minus 63-micron fines away from the product.

By removing the fines, the product has a maximum of 3% 0–63-micron content which dramatically changes the methylene blue quality measure of the material, aligning it with industry standard.

The EvoWash 251 was seamlessly integrated to efficiently process the fines material. The resulting output contains a

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WATER RECYCLING, MANAGEMENT AND FILTRATION

Tsurumi has launched the AVANT MY Series of wastewater submersible pumps

maximum of 2.5%–0–63-micron content, down significantly when compared to the output of the dry crushing process.

Japan-based water-pump manufacturer Tsurumi Pump exhibited a major display of its latest pumps, technologies and services at WEFTEC from October 1–4, at McCormick Place in Chicago.

Tsurumi displayed its newest line of wastewater submersible pumps, the AVANT MY Series, to the public for the first time. These pumps are built to the same standards under the Tsurumi AVANT™ line of explosion-proof, FM-approved submersible pumps. These durable pumps feature multiple impeller options and have an accessible price point.

“The MY Series is more of an on-the-shelf option and is designed for industrial and smaller municipal applications,” said Chris Bristol, municipal product sales manager at Tsurumi. “It’s an economic option for smaller manufacturing and municipal wastewater facilities. Our pumps are known to be very reliable and last for many years, but it’s good to know that on-the-shelf availability means quicker turnaround times for customers.”

Along with the MY Series, Tsurumi is introducing new FM-approved MMR Series submersible mixers, which feature built-in IE3 premium-efficiency motors.

Submersible mixers are the most practical and efficient solution for mixing, agitating, homogenizing and equalizing wastewater at treatment facilities. They are used in aerobic as well as anaerobic and anoxic stages of wastewater treatment processes to prevent sedimentation and maintain constant concentration levels in the tanks.

US-based McLanahan has analysed which type of dewatering equipment is best for the management of tailings: a decanter centrifuge, a belt press, or a filter press.

All aggregate and mining operations with a wet-processing plant will produce a waste stream. This waste stream consists of tailings – the process water and fine solids, clay and other deleterious material removed during the washing process. Traditionally, these

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tailings are sent to a settling pond or lagoon to separate the solids from the liquid in the waste stream.

However, McLanahan says settling ponds can be time-consuming and expensive to maintain, take up valuable land space and/ or cover up mineable reserves. They are not the best method for tailings management, especially when mechanical dewatering options are available.

It adds that mechanical dewatering equipment improves tailings management by separating the solids from the liquid to produce a solids product that is suitable for mechanical handling.

When it comes to tailings management, the best equipment for one site may be different than the best equipment for another site. Decanter centrifuges, belt presses and filter presses are all suitable choices for pond reduction/elimination, so the best one depends on the tailings management goals of the site.

The main thing to consider is the type of material being dewatered. Decanter centrifuges work best with material that has a larger particle-size distribution and is more easily dewatered. They are also ideal for material with low clay content, and they are less sensitive to changing feeds.

Belt presses can be used to dewater a variety of different slurries in a wide range of applications, but they don’t perform well with varying feed conditions.

Filter presses are ideal for dewatering tailings from mineral and aggregate wash plants, mineral concentrates and most underflow slurries coming from a thickener or clarifier. However, the feed percent of solids and particle-size distribution does have an effect on the overall dewatering efficiency of a filter press.

In terms of operational costs, decanter centrifuges and filter presses are fully automated, whereas belt presses require an operator.

Filter presses do not require the addition of chemicals to aid in dewatering, while belt presses do. Decanter centrifuges may benefit from the use of chemicals, but that depends on the material being dewatered.

In terms of capital cost, belt presses are generally less of an upfront investment when compared with centrifuges and filter presses. Additionally, filter presses require ancillary equipment, such as a surge (or buffer) tank.

Maintenance costs are higher with belt presses because maintenance intervals are more frequent than centrifuges and filter presses. Belt presses require frequent belt washing, and the rollers and bearings are known for requiring frequent replacement, which means more downtime to perform maintenance.

In terms of footprint, belt presses and centrifuges take up less space than filter presses.

McLanahan states: “When determining which solution is right for handling your tailings, make sure you consider the type of material the equipment will be processing as well as the initial investment and long-term operational and maintenance costs.” AB

A McLanahan centrifuge that is used for dewatering

© AGGREGATES BUSINESS September/October 2023

47

BLASTING & ALTERNATIVES

Bringing digitalised capabilities to quarrying Developing technologies and software solutions are making quarrying operations leaner and safer, and companies are bringing value-adding services to their digitalised solutions for blasting operations in the sand and gravel sector. Liam McLoughlin reports The data can also be used to conduct safety telematics and ensure compliance, study interactive 3D models, utilise distance and height-measurement tools and support quarry development planning.

“There are currently 36 Civil Aviation Authority (CAA) qualified drone pilots within the EPC-Metrics team,” Ryan continues, “with the skills to operate drones nationwide, including a WingtraOne Professional vertical take-off and landing (VTOL) fixed-wing drone from within a modern fleet. The drones are used to safely capture data from any area of a quarry which is then used, in conjunction with photogrammetric techniques, to create highly accurate, fully geo-referenced 3D models, from face profiles to full quarry maps, which can be regularly recreated as a quarry environment changes.

“The technology we’re bringing to the field is also enabling EPC Metrics to perform

Design #6

fully remote, environmental monitoring on site,” Ward says. “Through our partnerships with leading system manufacturers we can measure noise, vibration, air over-pressure and environmental conditions. As most drilling and blasting operations must adhere to strict, site-specific planning regulations, including noise restrictions, we’re working to make sure that activities, including those relevant to sand and gravel processes, remain compliant. We use, and can hire out, permanent fixed monitoring stations to gather event data and real-time results in the field. These results can then be fed back to an online platform, reviewed and analysed, then easily communicated to relevant parties.”

Using its drone technology, EPC Metrics has supported digitalised quarrying processes at several quarries across the UK, recording and analysing the data gathered, and safely optimising aspects of mineral-extraction

Design #5

Design #4 Design #3

High vibration

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PC-UK successfully launched its subsidiary company EPC Metrics last year, and with it a team of experienced engineering specialists capable of offering technical support and services to improve blasting, site mapping and monitoring within quarrying operations.

Ryan Ward, commercial manager at the UK-based commercial explosives and drilling & blasting services provider, says that the technical and consultancy services provided

by EPC Metrics are increasing the quality of data available to make informed decisions within the quarrying industry.

“This enables us to support and improve a cross-section of quarrying disciplines utilising state-of-the-art drone-mapping services to help sand and gravel production become increasingly efficient,” Ward adds.

“EPC Metrics’ additional specialisms of noise monitoring, vibration-monitoring equipment provision, hire and calibration, and engineering consultancy can also realise a series of problem-solving solutions related to the sand and gravel field.”

By drone mapping a site and processing gathered data for examination within an interactive software platform, sand and gravel operations can have digitalised access to information detailing their haul-road gradients, bund-height calculations, stockpile surveys, and volumetric analysis, as well as project tracking.

Design #2

Design #1

Bad fragmentation

© Robin372/Dreamstime.com

ABOVE: Maptek’s BlastMCF software offers comprehensive blast design and analysis BELOW: Blast-design and analysis software can guarantee improved productivity and safety in quarry blasting operations

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© AGGREGATES BUSINESS September/October 2023

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BLASTING & ALTERNATIVES

performance.

By combining advanced photogrammetry techniques and browser-based 3D surveys, EPC Metrics has helped to prioritise the quarries’ operational safety and enhance site efficiencies, development and mineralextraction planning. By improving data accuracy, using highly detailed imagery from a 42-megapixel camera, advanced data analysis from volumetric cut-and-fill measurements has been made possible. This has enabled EPC Metrics to progress its work in safety analytics, face height and distance measuring. Furthermore, as the information can be geo-referenced using GPS, EPC Metrics’ surveying practice has been made more accurate, cost-effective, and reliable.

Automated drill and blast design can significantly improve the efficiency, safety, and cost-effectiveness of quarry operations, according to US-based Maptek, which provides software, hardware and services for the mining and quarrying industries Maptek BlastMCF is a software solution offering comprehensive blast design and analysis, which can guarantee improved productivity and safety. The company says this is particularly relevant given that engineering-intensive methods are impractical for lean operations.

Safety is a paramount concern in the quarry industry. Automated drill and blast -design tools allow for better control over blast patterns and sequencing, reducing the risk of accidents and hazardous situations for quarry personnel.

With the BlastMCF automation approach, Maptek says operators can easily generate scenarios that help them understand the interrelated factors that influence blast performance.

Quarry operations often need to adhere to environmental regulations and minimise their impact on the surrounding ecosystem.

Automated blast-design software can help optimise blast patterns to reduce vibration, dust, and noise, thus aiding compliance with environmental standards.

Efficient blast designs can improve the overall productivity and throughput of a quarry. By automating the design process and optimising blast parameters, quarries can increase production rates and meet market demands more effectively.

They also lead to significant cost savings in terms of reduced drilling, blasting and material-handling expenses. By automating the design process, quarry operators can identify the most cost-effective blasting strategies and minimise resource wastage.

BlastMCF can generate precise and accurate blast designs based on geological data, quarry layout and other critical parameters. This reduces the chances of over-blasting or under-blasting, which are known to lead to wastage of resources and increased operational costs.

Controlling the fragmentation size of the blasted material is crucial for quarry operations. Automated design software can optimise blast patterns to achieve the desired

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EPC Metrics technology enables remote environmental monitoring

fragmentation, which in turn improves downstream processing, reduces wear and tear on equipment, and enhances the quality of the final product.

Maptek’s BlastMCF allows for the integration of various data sources such as geospatial data, drilling data and geological models. This integration helps quarry operators make informed decisions and adapt to changing conditions in real time.

A generic algorithm enables faster, easier scenario analysis to objectively validate and verify design concepts quickly. This allows operations to benchmark the critical factors that impact blast performance specific to their site conditions.

A significant advantage of BlastMCF is the automated generation of drill pattern, per -hole charge plan and timing in a single step.

Detailed reporting and analysis capabilities allow quarry managers to track performance, make data-driven decisions, and continuously refine blast designs for ongoing improvements.

Mark Roberts, global product strategy manager at Maptek, says that BlastMCF automated drill and blast-design tools play a crucial role by enhancing safety, precision, cost-effectiveness, and environmental compliance. The combination of online subscription licensing, machine learning and cloud processing can save thousands of dollars per blast, to help quarry operators optimise their blasting operations, resulting in improved overall efficiency and profitability.

Australia-based multinational Orica has released a new integrated digital solution for the quarry market to streamline and optimise blasting operations.

BlastIQ Quarry is a smart solution that harnesses the power of digital technologies to help quarry operators optimise their

drill and blast activities in near real-time.

Developed by Orica Digital Solutions, BlastIQ Quarry allows quarry operators to design blasts according to performance objectives and presents drill and blast insights for continuous blast optimisation.

Developed with customer feedback and deep blasting experience in quarry operations, the smart digital blast-optimisation platform provides a single source of truth and delivers instant pre- and post-blast insights. Instead of manually handling paper-based information, operators can now also collate their data digitally and derive insights to inform their drill and blast performance.

Head of blast design and execution for digital solutions at Orica, Cu Luu, details the key benefits of the new blast-control solution, saying: "Overall, BlastIQ Quarry is a powerful and comprehensive solution that can help quarries improve the efficiency of their drill and blast operations, reduce overall cost, ensure data accuracy, drive productivity, and maintain regulatory compliance. Its integrated and connected components provide a complete solution that delivers real results and drives continuous improvement for the industry."

Complementary applications to enable a synergistic workflow include the SHOTPlus blast-design and modelling software; BlastIQ Mobile Lite which places blast designs and hole conditions in the palm of operators’ and engineers’ hands; and BlastIQ Insights which enables the tracking of key performance indicators and comprehensive document storage. These technologies work together to offer customers improved productivity with blast-loading instructions and rules being instantaneously and digitally communicated to field operations to ensure the right explosive product and quantity is used at the right place and initiated at the right time. AB © AGGREGATES BUSINESS September/October 2023

49

EVENTS | FOR A FULL LIST OF EVENTS VISIT WWW.AGGBUSINESS.COM/DIARY

2024 JANUARY 23-25 World of Concrete Las Vegas, NV Organiser : Informa Tel: +1 212 600 3525 registration@worldofconcrete. com https://www.worldofconcrete. com/en/attendee.html

JUNE 15-17: Hillhead 2024 Hillhead Quarry, Buxton, UK Organiser: QMJ Tel: +44 (0)115 945 4367 Email: hillhead@qmj.co.uk www.hillhead.com/

OCTOBER MARCH 25-27 AGG1 Nashville, Tennessee Organiser: NSSGA Tel: +1 (800) 867 6060 https://www.agg1.org

APRIL

MAXimise your results!

24-27 INTERMAT Paris 2024 Paris, France Organiser: Comexposium Email: laura.sanchez@ comexposium.com https://paris-en. intermatconstruction.com/

SIM 2024 (dates TBC) Bordeaux, France Organisers: Exposition SIM https://www.expositionsim.com/ en/index.htm

These dates were correct at the time of going to press, but please note that the COVID-19 pandemic means some events may be rescheduled with little advance notice

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UNCERTAINTY AFTER RECORD-BREAKING YEAR l DIGITAL CONSTRUCTION WORKS l CHANGE DRIVES HEAVY LIFTING INNOVATION l FUELLING THE FUTURE IS A GAS, SAYS CUMMINS l EXOSKELETONS THAT FIT LIKE A GLOVE l METSO SWITCHES ON SUSTAINABLE CRUSHING l FOCUS: WEST AFRICA, PHILIPPINES, INDONESIA l APPLICATION EXPERTISE FROM FAYAT l BUILD BACK BETTER MAKES A REAL DIFFERENCE

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“It’s been a real game-changer for us.

We’re now producing aggregates and sands that are 10% derived from recycled concrete from demolition waste.”

MCLANAHAN ULTRAWASH McLanahan UltraWASH Modular Washing Systems offer the same world-class washing technology we’ve been supplying since 1835, but in containerized modules for shorter lead times, quick setup and ease of transport if producing at multiple locations or one very large site.

Whether processing natural or recycled aggregate, McLanahan offers a complete modular product line.

From crushing and screening to washing and water recycling, McLanahan provides a start-to-finish solution for your operation.

WASHING // SCREENING // SCRUBBING // CLASSIFYING // CRUSHING // FEEDING // TAILINGS & WATER MANAGEMENT ASIA | AUSTRALIA & ASIA PACIFIC | EUROPE | LATIN AMERICA | NORTH AMERICA

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