Case Study AAL Recycling plant

Plant Data

Answering the needs: AAL Recycling

AAL Recycling Ltd established in 1992 on the Isle of Jersey, is now one of the largest demolition, transport, recycling and excavation companies in the Channel Islands, employing over 85 people and with a fleet of more than 70 vehicles.

AAL currently runs the recycling centre for commercial and household construction waste at La Collette, supporting the island’s sustainability project. The demolition and excavation area is the company’s fastest growing, having taken over some of the most complex projects developed on the island in recent times.

Given the huge growth of AAL Recycling, Alan Langlois CEO, approached Matec Industries to find innovative and technological solutions, which would allow them to process up to 150 tonnes/hour of recycled material, with a water consumption of less than 25 m3/h.

The plant would have to comply with all current regulations, guarantee low energy consumption, and maintain high performance in washing and sorting the treated material.

Log Washer: what is it?

A log washer is a special machine consisting of 2 rotating vane shafts. It is used to treat rocks that are particularly difficult to wash with the simple high-pressure nozzles on our Screentec. It is mainly used to remove clay or silt from the treated rocks by generating intense rubbing between them in addition to friction with its rotating paddle system. The two central shafts, rotating the blades in opposite directions from each other, rub and transport the material along the machine until it is discharged. Meanwhile, the dissolved clay and muddy contaminants overflow into a suspension of water.

Matec’s solution for AAL Recycling

In order to meet the customer’s needs and guarantee the expected results, we installed a complete aggregates, sand and gravel treatment plant with an adjoining sludge and wastewater treatment plant.

Sludge and waste water treatment plant

The system includes a 1500×1500 filter press with 170 plates with a TT quick opening system to ensure an efficient filtration process. Next to this, we find the 100,000-litre Bifang sludge homogenisation tank, essential for maintaining the correct sludge density.

A Vertical Thickener with a capacity of 220,000 litres is an integral part of the system, helping to separate solid particles from the water. For the efficient transfer of treated water, there is a 6,000 Lpm Booster Pump.

The system includes two dedicated clean water tanks, of 100,000 and 40,000 litres respectively, to ensure an adequate reserve at all times. In addition, the system includes the Bifloc automatic device for optimal flocculant management, improving overall efficiency.

An Alfa Centrifugal Pump, with a capacity of 6,000 lpm, is designed to load the Vertical Decanter. A 50,000 litre turbid water tank and all pumps and piping necessary to ensure smooth operation of the entire system complete the picture.

Washing and Screening Unit

For the washing and screening part of aggregates, sands and gravels, we supplied an Aggretec 150 assisted by a Scrubtec system capable of effectively selecting gravels of different grain sizes, fine and coarse sands and guaranteeing a complete removal of silt and clay from all final products.

Aggretec is the modular washing and sorting plant with quick installation that is easily transportable and therefore also ideal for working on construction and demolition sites.

The system comprises 3 conveyor belts for handling different grain sizes (0-2mm, 2-4mm, 25-40mm), equipped with a sand recovery unit with hydrocyclones, a 3 deck vibrating screen, a magnetic belt separator, a screen feeder and a loading hopper.

Scrubtec, on the other hand, is a key component in construction and demolition waste recycling systems ideal for aggregates and mining materials with a high clay and silt content.

The plant includes a log washer (or Scrubtec) for deep cleaning of the stones, a trash screen for separating impurities and a dryer/finishing screen for the drying phase. In addition, there are 3 conveyor belts dedicated to different grain sizes (4-10mm, 10-16mm, 16-25mm).

Result acheved in the plant

Thanks to the technological solutions provided by Matec, AAL Recycling can now successfully handle a volume of recycled material of up to 150 tonnes per hour. This outstanding result not only fully meets the customer’s expectations, but also results in significant savings in time and resources.

Our commitment to a green and sustainable approach is evident at every stage of the process. The combination of operational efficiency and ecological practices results not only in a reduced environmental impact, but also in a significant contribution to the promotion of a circular economy. In this way, Matec and AAL Recycling work synergistically, demonstrating that sustainability can go hand in hand with efficiency and operational excellence.