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In the wet processing and classification market, an understanding of the specifics of the feed material is critical to the delivery of a successful project.
In the wet processing and classification market, an understanding of the specifics of the feed material is critical to the delivery of a successful project.
 










Co-creation: A means of delivering efficient plant design

As demands on quarry operators for productivity and efficiency rises, plant selection and design becomes critical – and, as Peter Craven explains, so does the input the operator provides to the manufacturer to design the best plant possible.

In recent years, issues of productivity and efficiency have risen to the top of the agenda in the global materials processing industry.

There has been a shift in emphasis from one founded on the principle of “more capacity” to one that seeks to ensure every individual operation is extracting maximum value from the material being processed.

This presents a new challenge for most equipment manufacturers which will now have to go beyond their previous self-imposed boundaries and get closer to the customer to ensure the equipment they provide meets the productivity and efficiency requirements now driving investment decisions.

Every application has its own unique challenges, and in order for equipment manufacturers to provide fit for purpose processing systems, they need to ensure these challenges are at the very centre of the discussion.

This is especially true in the wet processing and classification market where understanding the specifics of the feed material is a critical factor in the delivery of a successful project.

The change in emphasis from “capacity” to “productivity” has sharpened the focus on every processing phase, as operators seek to identify where inefficiencies lie and put a plan in place to address them.

The change in emphasis from “capacity” to “productivity” has sharpened the focus on every processing phase.
The change in emphasis from “capacity” to “productivity” has sharpened the focus on every processing phase.

The change in emphasis from “capacity” to “productivity” has sharpened the focus on every processing phase, as operators seek to identify where inefficiencies lie and put a plan in place to address them.

This increased focus can reveal an array of process issues that previously went unnoticed – unnecessary material spillage, inefficient separation systems that result in poor quality final products and good quality material being lost to the water treatment or waste management phase.

Any processing plant including several different processing phases must be more than a number of individual equipment items in sequence. To deliver on the industry’s productivity and efficiency requirements, a robust plant design process requires a considerable level of consultation between manufacturer and customer. It is only through this approach that a full understanding will exist of the project requirements.

This process should take account of a number of issues and ensure the plant is configured to ensure delivery of the most efficient processing system. These issues include material testing and analysis, space restrictions, civil design, proximity to waste storage areas, transfer point technology, water management and maintenance access.

CDE’s experience in the design and delivery of successful materials washing projects has been built on the theory of co-creation – a partnership between the supplier and the customer to understand their objectives, address the issues they are facing and ensure the processing system is designed with the in-built flexibility to ensure any future changes in their requirements can be accommodated with the least amount of disruption.

A successful materials washing plant is built on a detailed understanding of the customer’s project as something unique, and the design and specification of appropriate technologies to ensure their objectives are met. To achieve this with a limited range of standardised, mass produced equipment is not possible – and the success CDE has enjoyed in the materials washing arena over the past 20 years is testament to this.

MAXIMUM PRODUCT YIELD
By conducting extensive material testing and analysis in CDE’s own laboratory, a full understanding of the nature of the feed material is gained.

While testing will indicate whether the final product specifications desired by the customer can be achieved, it is further detailed analysis of these results that will potentially reveal opportunities to maximise product yield from the feed material.

It may be possible to look at production of additional sand specifications that will not only reduce waste volumes but also
provide an additional revenue stream.

This will often require the introduction of more complex processing systems if a specialist sand can be produced – sports sands, filter sands and foundry sands, for example.

While this will require additional investment, the return on investment argument is compelling given the potential to
create a product for one of these high value applications.

By conducting a process audit on existing sites, CDE can focus on the areas where specific actions are required to improve efficiencies. This will help CDE identify important issues to the customer in that specific situation, and ensure any new processing system is built to tackle these issues and deliver on their requirements for increased process efficiency, productivity and plant availability. 

According to CME, a successful materials washing plant is built on a detailed understanding of the customer’s project as something unique.
According to CME, a successful materials washing plant is built on a detailed understanding of the customer’s project as something unique.

By conducting a process audit on existing sites, CDE can focus on the areas where specific actions are required to improve efficiencies. This will help CDE identify important issues to the customer in that specific situation, and ensure any new processing system is built to tackle these issues and deliver on their requirements for increased process efficiency, productivity and plant availability. 

A key element of the co-creation process is CDE’s design workshops, which typically involve a number of representatives from the customer – operations personnel as well as senior management – and an extensive project team from CDE.

This team will include a senior technical engineer, who will be involved to discuss plant specification in detail with the customer and ensure there is clarity around the site infrastructure (civil design, water requirements, power requirements).

As well as dealing with these pre-sales elements, CDE’s design workshops also introduce customers to the delivery processes CDE has in place to ensure project delivery goes to plan.

This is an area that is often overlooked, with the costs of poor delivery underestimated.

CDE’s washing-centric ProMan system has been proven to deliver hundreds of materials washing projects successfully, and the design workshop will involve meeting the individual project manager who will take ultimate responsibility for the delivery of the project and act as a single point of contact until project completion.

The customer will also be introduced to all other elements of CDE’s project delivery process and meet the team of people involved in the project – logistics, design, install and commissioning, post-commissioning support, training, etc.

In summary, mass produced and standardised equipment is designed around the principle of making a production facility efficient rather than delivering successful materials washing projects.

The success CDE has enjoyed in the global washing sector is evidence that successful plant design and delivery involves a high level of direct contact be



















Monday, 24 September, 2018 11:47pm
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