HAZEMAG manufactures the largest rubble recycling plant in the world for EMIRATES RECYCLING LLC
In the United Arab Emirates, records are being broken continually in connection with the height and size of new high-rise buildings; a consequence of this construction boom, however, is the enormous amount of building rubble resulting there from. Due to the serious lack of available building land, not only are old buildings being demolished, but also relatively new structures have to make way for more modern, more efficient and more profitable architectural gems. Up to now, building rubble has generally been dumped on huge tips in the desert. The leading policy makers in one of the emirates, Dubai, have now recognised that this method of “disposal“ is extremely damaging to the environment and creates further problems for future generations. As environmental planning and creating sustainable +development projects has become a priority within Dubai it was decided that all waste material should be recycled. Pursuant to this aim, an agreement was signed between the Dubai Municipality, Government of Dubai and Messrs. EMIRATES RECYCLING LLC – a member of the well-known and respected AL ROSTAMANI Group – according to which, with effect from January 1st, 2008, the said company will accept and recycle the incoming construction and demolition material. It is proposed to recycle the material into road base aggregate and material which could be used for non-structural purposes.
During the search for a competent partner to provide the necessary technology and know-how for this purpose, the name of HAZEMAG & EPR GmbH in Dülmen came automatically to the forefront. This world-renowned company and manufacturer of large-scale crushing plants for the raw materials, non-metallic minerals and cement industries had already supplied in 2003 the world’s then largest rubble crushing plant to Messrs. BENTUM RECYCLING CENTRAL B.V. at the port of Rotterdam. In this plant, more than 1,000 t/h concrete (also containing re-bars) and broken asphalt road paving can be processed.
Following a fact-finding visit to the plant in Holland, the owners and management of EMIRATES RECYCLING became immediately aware that the design and layout of the Dutch plant would be ideal for the task in hand in Dubai, where rubble of up to 1.5 m edge length could be processed with minimum pre-treatment, coupled with optimum plant availability.
After the visit, HAZEMAG & EPR GmbH, together with the owner, evolved a concept with the necessary infrastructure which not only suited the immediate task in hand but which also took into account the rapid capacity build-up. The plan comprises two planning stages:
1.The supply of two semi-mobile recycling plants each with a capacity of 280 t/h
2.The delivery of a stationary plant to handle 1,300 t/h.
In both systems, a product of at least 95% <60 mm will be generated, which is very marketable as a high-quality building material. Particularly significant is the use of impact crushers for the comminution process; these impact crushers achieve a high crushing ratio and can also handle and separate the re-bars in the reinforced concrete without any problems. Thus, the crusher product not only generates a high-quality construction aggregate, but also a considerable amount of valuable, marketable scrap metal, which is cleanly separated from the crushed rubble.
The 2nd planning stage includes the use of the world’s largest impact crusher with a GSK-type rotor 2.5 m in diameter and 3 m wide. Upstream of the impact crusher is a pre-separating screen, by means of which the fines are removed from the material flow prior to entry into the impact crusher. The screen receives the material via an apron conveyor which extracts it from the feed hopper. Downstream of the impact crusher, the crushed material is conveyed further via two vibrating feeders installed in line. At this point is a magnet separator for the removal of the ferrous material.
Thanks to the size and ruggedness of the HAZEMAG impact crushers, the wear rates are extremely low, reducing downtime for maintenance and for spare parts replacement to a minimum. In addition, special mechanical aids are provided to reduce the time and effort in spares changing.
The contract between EMIRATES RECYCLING LLC and HAZEMAG & EPR GmbH was signed in Dubai in December 2007 (see photo below), and the first planning stage is due to go into operation as early as March 2008. The second stage is planned for later, in May 2009. There is also an option on the table for a 3rd stage, which is identical to Stage 2.
According to the latest figures, huge quantities of building rubble (up to 3,000 t/h) can be expected, the equivalent of 150 trucks per hour. This is also a record figure calling for a very sophisticated logistical system.
The contract signing with Mr. Hassan Al Rostamani (front, left), Vice-President of the Al Rostamani Group, and Mr. Klaus Beer (front, right), CEO HAZEMAG & EPR GmbH. At the rear Dr. Armin Greune, HAZEMAG Division Manager, and Dr. Michael Mutz, HAZEMAG Area Sales Manager, Middle East.
Largest Recycling Plant
HAZEMAG manufactures the largest rubble recycling plant in the world for EMIRATES RECYCLING LLC
In the United Arab Emirates, records are being broken continually in connection with the height and size of new high-rise buildings; a consequence of this construction boom, however, is the enormous amount of building rubble resulting there from. Due to the serious lack of available building land, not only are old buildings being demolished, but also relatively new structures have to make way for more modern, more efficient and more profitable architectural gems. Up to now, building rubble has generally been dumped on huge tips in the desert. The leading policy makers in one of the emirates, Dubai, have now recognised that this method of “disposal“ is extremely damaging to the environment and creates further problems for future generations. As environmental planning and creating sustainable +development projects has become a priority within Dubai it was decided that all waste material should be recycled. Pursuant to this aim, an agreement was signed between the Dubai Municipality, Government of Dubai and Messrs. EMIRATES RECYCLING LLC – a member of the well-known and respected AL ROSTAMANI Group – according to which, with effect from January 1st, 2008, the said company will accept and recycle the incoming construction and demolition material. It is proposed to recycle the material into road base aggregate and material which could be used for non-structural purposes.
During the search for a competent partner to provide the necessary technology and know-how for this purpose, the name of HAZEMAG & EPR GmbH in Dülmen came automatically to the forefront. This world-renowned company and manufacturer of large-scale crushing plants for the raw materials, non-metallic minerals and cement industries had already supplied in 2003 the world’s then largest rubble crushing plant to Messrs. BENTUM RECYCLING CENTRAL B.V. at the port of Rotterdam. In this plant, more than 1,000 t/h concrete (also containing re-bars) and broken asphalt road paving can be processed.
Following a fact-finding visit to the plant in Holland, the owners and management of EMIRATES RECYCLING became immediately aware that the design and layout of the Dutch plant would be ideal for the task in hand in Dubai, where rubble of up to 1.5 m edge length could be processed with minimum pre-treatment, coupled with optimum plant availability.
After the visit, HAZEMAG & EPR GmbH, together with the owner, evolved a concept with the necessary infrastructure which not only suited the immediate task in hand but which also took into account the rapid capacity build-up. The plan comprises two planning stages:
1.The supply of two semi-mobile recycling plants each with a capacity of 280 t/h
2.The delivery of a stationary plant to handle 1,300 t/h.
In both systems, a product of at least 95% <60 mm will be generated, which is very marketable as a high-quality building material. Particularly significant is the use of impact crushers for the comminution process; these impact crushers achieve a high crushing ratio and can also handle and separate the re-bars in the reinforced concrete without any problems. Thus, the crusher product not only generates a high-quality construction aggregate, but also a considerable amount of valuable, marketable scrap metal, which is cleanly separated from the crushed rubble.
The 2nd planning stage includes the use of the world’s largest impact crusher with a GSK-type rotor 2.5 m in diameter and 3 m wide. Upstream of the impact crusher is a pre-separating screen, by means of which the fines are removed from the material flow prior to entry into the impact crusher. The screen receives the material via an apron conveyor which extracts it from the feed hopper. Downstream of the impact crusher, the crushed material is conveyed further via two vibrating feeders installed in line. At this point is a magnet separator for the removal of the ferrous material.
Thanks to the size and ruggedness of the HAZEMAG impact crushers, the wear rates are extremely low, reducing downtime for maintenance and for spare parts replacement to a minimum. In addition, special mechanical aids are provided to reduce the time and effort in spares changing.
The contract between EMIRATES RECYCLING LLC and HAZEMAG & EPR GmbH was signed in Dubai in December 2007 (see photo below), and the first planning stage is due to go into operation as early as March 2008. The second stage is planned for later, in May 2009. There is also an option on the table for a 3rd stage, which is identical to Stage 2.
According to the latest figures, huge quantities of building rubble (up to 3,000 t/h) can be expected, the equivalent of 150 trucks per hour. This is also a record figure calling for a very sophisticated logistical system.
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Photo:
The contract signing with Mr. Hassan Al Rostamani (front, left), Vice-President of the Al Rostamani Group, and Mr. Klaus Beer (front, right), CEO HAZEMAG & EPR GmbH. At the rear Dr. Armin Greune, HAZEMAG Division Manager, and Dr. Michael Mutz, HAZEMAG Area Sales Manager, Middle East.
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