The very foundation of The HAZEMAG Company started with the processing and recycling of rubble. Our founder, Dr. Erhard Andreas developed and introduced the Andreas Impactor, the very first mill of its kind that was utilized, post war, for the processing of the massive amount of waste and debris was dominate throughout many cities in Germany. Rubble recycling as we know it today, began with this highly successful introduction of the HAZEMAG Andreas impactor. Now, some 70 years later, this recycled and acceptable resource is being used and enjoyed in many aspects of our daily lives; benefiting all of us while giving life to a previously used and valuable resource once again.
With its process know-how, high quality - reliable machines and services, HAZEMAG plays an important and highly contributing role in the crushing and recycling of materials such as rubble, concrete and asphalt; resulting in a proven component that can be utilized in a wide range of construction sectors.
Perhaps more than many other industries, the success of the recycling group is highly determined by the control and management of the raw, available materials. To achieve this, the processing system must offer a very high level of flexibility, extreme ruggedness, high technology and the ability to adapt to an extensive variation range in the raw materials. The decision between a fixed/stationary plant versus a mobile plant are solely determine by the availability of raw materi-als, annual projected production rates and the local demand for the recycled products. Under the correct management controls, the success and profitability of a recycling facility can easily be realized.
Quality control, raw material management and the needed processing methods are realized in a variety of ways, such as:
· selective demolition of buildings
· inspection/monitoring of the incoming material
· raw material stockpiling according to its makeup/mixture
· material preparation: pre-sizing, sorting and removal of larger tramp irons
· raw material identification, classifying and selective sorting
· metal identification, preparation and possible removal
· sorting out of non-mineral fractions
· separation of light materials
In any recycling facility, the design of the processing plant will be defined by the makeup and characteristics of feed material. The flexibility and components that make up the plant must be capable of processing a raw feed material that can range from clean building rubble, mixed building rubble and large concrete products; all of which can potentially contain large amounts of tramp irons.
The requirements on the finished product; defined as the grain size and needed distribution of each, product shape requirements, material composition and perhaps most important its quality in regard to purity, clean materials, will define and reflect the plants level of technology and automation.
The successful processing of a wide range of demolition and construction debris into an acceptable, saleable product is the target of processing. This is particularly relevant in the business of rubble processing, where crushing and screening plants are commonly employed.
· Define the feed material (building rubble)
· Define the size of the feed materials
· Define the composition of the finished products
· Define the needed purity of the finished products
· Define the required plant throughput rate
· Define/project the amount of waste that will be generated
· Define the required land area
· Define permitting requirements associated local codes
For the processing of building rubble, the availability of proven machines and technology is certainly known. Although the overall design and selection of the ancillary machines can vary, the heart and key component of any recycling plant is found in its crushing unit; which without any doubt will help determine the success and profitability for any operation. Beyond the crushing unit, the typical ancillary units are:
· Crusher feed unit
· Under crusher discharge pan
· Material transfer conveyors
· Screening system
· Magnet for the removal of tramp irons
· Chutes and skids
· Dust suppression: spray or filter system
· Air systems
· Finished product stacking conveyors
Building rubble in itself presents a difficult task. Add the presence of basic tramp iron to the mix and it becomes very clear that the crusher must be designed and constructed in a manner that can take a high level of punishment. Add rebar; metal that can vary in length from short to excessively long, now the design of the plant must take into consideration the absolute need to maintain a uniform, unrestricted flow for the material otherwise production stoppages and potential equipment damages are certain to occur. The key or target is to ensure that the design of the plant is robust and very well engineered in regard to accepting the raw material variation; ensuring a consistent, uninterrupted product flow and trouble free operation. In this regard, years of experience, trial and error and a solid learning curve have produced concepts; system designs that have been proven time and time again.
1) Horizontal Crushing: The HAZEMAG impact roll crusher, model HHI, provides an uninterrupted material flow from the raw feed to the crushed product, including the removal of tramp irons facilitated by the use of an inline belt magnet.
2) Pointing The Way: The HAZEMAG primary impact crusher, model HPI, provides an excellent solution for processing rubble. “Pointing The Way” ensures that the material flow through the crusher is not interrupted by its discharge system; thus the discharge vibrating pan is positioned in a manner that continues this uniform flow process. This common sense approach continues throughout the complete processing system; resulting in its trouble free operation, reduced downtime and a consistent product flow; crushed product and the removal of tramp irons.
The proven success of the HAZEMAG primary impact crusher, model HPI, is realized in high automation, proven reliability and its ability to selectively crush; a process where the concrete is crushed to a desirable product while its internal tramp iron is freed and removed in a very efficient manner. Due to its rugged design, proven reliability and highly automated, hydraulically apron adjustment control system, the HPI impactor has earned its title; the heart of the recycling system.
HAZEMAG HPI Crusher: Design, Technology & Proven Advantages
· Material reduction facilitated by an extra heavy duty primary rotor
· Ability to process higher strength materials; up to 300 MPa
· High crushing degree: up to 1:20
· Excellent, uniform product gradation; 0 – 56 mm is typical
· High quality finished product: cubical, increased soundness
· True selective crushing: metal is clean and free of concrete
· Resistance against wood and metal
· Extreme flexibility: simple adaptation to different feed materials
· Excellent product size control: influenced as you wish
· Automated, hydraulic apron adjustment and automatic reset system
· Hydraulic apron “back pressure”: continuous positioning with the rotor
· Large inlet opening / moveable base: reducing the potential for blockages
· Interchangeable spare parts: standardized impact aprons & housing liners
· User friendly: fully automated, safe operation and consistent product control
· Reduced noise development
The impact aprons are retained in position by hydraulic cylinder, allowing adjustment and securing at the touch of a button. The instant a pre-set limiting value is overstepped in the crushing chamber, the impact apron retracts in a controlled manner. As soon as the load value returns to normal, the impact apron resumes its pre-set position, and operation continues without interruption.
The rotor discs are welded together with rugged holding beams to provide the backbone for the blow bars. The blow bars themselves are secured to the holding beams by means of wedges, which are easily removed for blow bar changing.
Should overloading, power failure, etc. cause material jamming in the crushing chamber, the impact aprons can be raised hydraulically, allowing the material to pass through the gap thus enlarged. The gap then reverts automatically to its original setting.
The inlet base section is also installed as an impact element; consequently, if jamming does occur in this area despite the generously-sized inlet cross-section, the hydraulics can be utilized to eliminate such problems with minimum effort.
Beyond the crushing process, the plants technology must also serve the need to process, separate and remove light-weight materials, such as; paper, wood, plastics and other foreign items that are often associated with the processing of demolition debris. Due to its potentially high level of contamination, the consideration for manual sorting and removal is not practical and certainly uneconomical.
For this task, HAZEMAG has developed an air classifier system for the efficient, highly effective removal of light-weight materials to the highest possible degree. The air classifying system utilizes the basic principle of separating materials by the size, density and weight. This is accomplished by passing the flow of mixed material (stones, wood, paper, etc.) in front of the air classifier where a certain volume of air is being discharged. The air is passed through the stream of material in a transverse direction, permitting its ability to move the lighter particles away from the heavier stones. Once this separation occurs, we now have the ability to direct the light particles in one direction and the heavier stones in another direction. Although this system cannot reach a separation rate of 100 %, it does offer an excellent, proven manner of effectively producing a clean stone product that has been accepted for many uses. The complete system is self-contained, thus reducing concerns that may be associated with dust, noise and the environment.