The potential to ‘shatter’ the market: Astec Industries

The potential to ‘shatter’ the market: Astec Industries

A regional Victorian company has employed an Astec GT200DF cone crusher and GT205MF multi-frequency screen to process material in their recycling business.

With glass and glass product manufacturers making up nearly a third of the sand and gravel market in 2018-19, producers are increasingly using recycled glass materials in their processes – reducing demand for silica sand from the industry.

As the sector looks into sustainable ways to repurpose waste material – recycled glass is being transformed into a manufactured sand for reprocessing or as a supplement in the construction industry.

The benefits of glass recycling have sustainable and efficient advantages for the environment, saving energy and natural resources.

A glass bottle in landfill, for example, can take up to a million years to finally break down, but a recycled glass bottle takes only 30 days to leave recycling bins and become a new glass container in the supermarket – without loss of purity or quality.

In addition to becoming new glass vessels, recycled glass is being utilised in many other areas such as reflectors in paints, as well as in roads.

Due to the benefits of the process and product, there are an increasing number of sites taking up glass crushing and screening, particularly with suitable mobile equipment to optimise industry.

With a team specialising in crushed glass applications and knowledge, Astec Industries was an exhibitor at the Australian Waste and Recycling Expo in 2019, which featured equipment suitable for crushing glass.

With one of the largest bluestone producers in Tasmania processing glass as a side project at 30,000 tonnes per annum with Astec Equipment, a major recycler in country Victoria has also come to the fold.

This country-based site in Victoria crushes and screens glass bottles in a dry closed circuit at an output of 80 tonnes per hour to produce a manufactured glass sand.

The mobile equipment it is employing in this glass recycling process is an Astec Industries GT200DF featuring a Kodiak K200+ 200HP cone crusher, and a GT205MF multi-frequency screening plant that is equipped with a 20’x5’ multi-frequency screen box – meaning it has a conventional circular motion and uses Astec’s high frequency technology on the bottom deck.

“The high frequency action provides additional frequency directly into the media on the bottom deck, which helps with separation in finer or wetter applications,” an Astec spokesperson says.

The GT200DF at the feed end in the process uses the Kodiak’s chamber profile, clamping force, stroke and shaft speed to optimise the autogenous crushing process that is occurring.

“This is in contrast to a vertical shaft impact crusher which would alternatively shred the material, requiring new tips approximately every four weeks due to wear,” the spokesperson says.

Comparatively, the manganese liners on the Kodiak crusher have worn at a rate of once every 12 weeks. The Kodiak cone crusher is a roller bearing machine.

“This style of crusher gives producers a greater level of accuracy about settings and product specifications with a greater loading capacity than some alternative cone designs,” the spokesperson says.

“Its hydraulic tramp iron relief system would identify an “uncrushable” object, opening up to allow this uncrushable piece to pass and then reset itself.”

The Kodiak’s TIR system eliminates maintenance costs associated with accumulators. Pressure relief valves act as latches, generating minimal back pressure build-up during an overload event.

These valves prevent violent, rapid release of stored hydraulic pressure prevalent with accumulators, whilst reducing maintenance and stress on the machine should an overload event occur.

Finally, plastics, wood and other incompatible materials can be screened off using the top deck of the GT205 multi-frequency screen and the manufactured sand product pass through the media installed on the bottom deck.

The final product can be used as a sand replacement in asphalt, crushed rock products and pipe bedding material.

“From individual machines to complete turnkey solutions, Astec Industries offers creative and accurate solutions from equipment installation to complete turnkey engineered systems with advanced automation controls for the C&D industry.”

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