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Modular Wash Plant

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Specialists in Modular Wash Plant

Due to increased demand for waste transfer and material recycling in the North West of England, the Ruttle Group were one of the first suppliers in the region to commission an aggregate wash plant to ensure consistency and reliability in processed materials.

The wet processing solution, co-designed by Ruttle and CDE Group, is an investment which diverts and recycles thousands of tonnes of material a year destined for landfill. The plant is able to process up to 120t/hr of raw material, producing 5 high-quality products for re-sale and re-use.

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How it Works

In the first stage of the process, material is passed through CDE’s patented R4500 screener. This removes oversized rock and demolition waste from the raw material for further processing, and can separate heavily clay-bound rocks and gravels with its high-energy processes. Screened material is then sent to the AggMax™ Logwash for scrubbing and classification. The washed material is automatically separated into three different sized products, which can then be stockpiled ready for re-sale.

Fines from the first stage are passed to the EvoWash™ unit, a high-frequency dewatering screen with hydrocyclone technology, efficiently separating sands from the slurry produced by the AggMax™ process. The EvoWash™ unit separates these sands into two sizes which are then dried and stockpiled in a storage bay.

Left over water is then recycled through the A400 AquaCycle™ thickener, ensuring up to 90% of the processed water is recirculated back into the system offering a fully integrated primary water treatment solution. The AquaCycle™ uses a flocculant additive to separate clean water from the solid particles which are then processed further to reduce waste.

The remaining solid particles form a sludge which is finally de-watered in the Filter Press, the final stage of the process. The Filter Press recovers any remaining water and creates a dry filter cake that can be used for pipe bedding, landfill capping and general class 2A fill material.

Efficiency Upgrades

Following increased demand for recycled materials, the plant was upgraded by adding a 28t lime dosing unit. This speeds up production times by allowing the filter-cake to de-water much more efficiently, reducing plant downtime and increasing processing capacity. The EvoWash unit was also upgraded to a 250t/hr unit, allowing faster separation of sands from the fines produced by the AggMax™ Logwash.

These upgrades meant that the total production capacity could increase from 80t/hr to 120t/hr, ensuring that the plant can keep up with our clients needs whilst avoiding the environmental impacts of landfill and first life aggregates.

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