Case Study IPS plant | Matec Industries

Plant Data

Answering the needs: IPS – Industria Produzione Semilavorati

IPS S.r.l. is a leading company in Campania in the recovery of aggregates construction and demolition waste, also specialising in the treatment of excavation soil and rocks and asphalt milling.
Based in San Martino V.C. (AV), it is strategically positioned to serve all the provinces of the region.
The granulates are mainly composed of fragments of concrete, bricks, masonry, plaster, cement mixes, road or railway structures, screeds, coatings and ceramic products.
The minimum and maximum granule size is determined by the type of screens installed in the plant. In terms of potential areas of application, recycled aggregates are generally used in: civil engineering works, road and railway construction, mainly for road, railway and airport sub-bases, fills and foundation layers of transport infrastructure.
In road works, the use of recycled aggregates can have widespread application, bringing two important environmental benefits: saving natural resources and reducing the amount of inert waste sent to landfills.

The Matec solution for IPS plant

Matec Industries for the IPS plant has adopted 4 different types of treatment to succeed in resource recovery and reduce environmental impact.

Soil washing plant capacity up to 50 tph
Water treatment plant capacity 120 m³/h
Chemical-physical treatment plant with a capacity of 10 m³/h
Extractor screw and water treatment capacity 30 m³/h

Tipologia 1: Soil Washing

The soil washing plant treats contaminated waste through a washing and separation process. It consists of two waste receiving groups. The first group handles waste from excavations, while the second group treats waste from road sweeping.

For sweeping waste, operators use a disc screen that separates the volatile dry parts, allowing efficient handling of the materials. Next, workers direct the remaining material to the washing section, which includes two screening machines and a vibrating screen. Here, the plant recovers gravels through the vibrating screen, while the wastewater containing sand goes for further disintegration treatment.

After this stage, light fractions are removed, and workers finally recover sand by hydro-cycling. They store the recovered sand and gravel, while sludge-containing wastewater gets sent to the treatment plant for purification.

With this system, the soil washing plant effectively recovers resources from waste and manages wastewater sustainably, ultimately aiding environmental protection.

Type 2: Water Treatment

A clarification and filtration plant treats sludge-laden wastewater and separates excess solids from the water. This process allows resource recovery and waste reduction. First, the process starts with a decanter silo, where heavier solids settle out and separate from the liquid. Next, operators transfer the concentrated sludge to a homogeniser tank. This tank ensures uniform distribution of solids, avoiding lumps and facilitating subsequent filtration.

From the homogeniser, workers send the sludge to the filter press. The filter press applies strong pressure to extract water from the solids, forming a dry sludge cake ready for disposal. Meanwhile, the separated water collects in a clarified water tank. Operators can then reuse or discharge this water in accordance with regulations.

Finally, the plant includes a de-oiler that removes any residual traces of oil and grease from the clarified water, further improving its quality. Completing the process, a flocculant preparation and dosing system aids the coagulation of solids, ultimately increasing overall treatment efficiency.

Type 3: Chemical-Physical Treatment in IPS plant

The chemical-physical treatment plant purifies wastewater through integrated processes that ensure effective management of pollutants. First, the process starts with collecting water in a constantly monitored tank. A submersible pump transfers the water to the de-oiling unit. There, a lamellar pack oil separator separates oils and greases, improving water quality for subsequent stages.

Next, in the absorption phase, powdered activated carbon removes additional impurities from the water. Then, coagulation and neutralisation occur by adding a chemical agent that promotes the aggregation of suspended particles, facilitating their removal. pH control remains crucial for coagulant effectiveness, while flocculation forms larger particles. An agitator evenly distributes the flocculant in the tank.

During settling, solids sink in a decanter, allowing the clarified liquid to separate from particles as the water moves slowly. Finally, sludge thickening and filtration complete the treatment process. The treatment plant concentrates the settled sludge in a thickener, increasing its consistency to facilitate disposal. Afterward, a filter press separates residual water from the sludge, creating a more manageable solid material.

Additionally, a section dedicated to preparing and storing chemical reagents supports each treatment stage, enabling a sustainable process and optimizing water resource use. Ultimately, this integrated system reduces the environmental impact of treated wastewater.

Type 4: Extractor Screw and Water Treatment

The sludge treatment plant is specifically designed to handle sludge containing sand and gravel, ensuring effective separation and recovery of different fractions. Initially, the process starts with the receiving hopper, where the sludge is introduced. This hopper is equipped with an extraction screw that conveys sand and stones forward. As the auger moves the solids, water and sludge flow out of the weir, thus allowing efficient handling of incoming material.

Next, a cycloning and sorting unit comes into action, separating the gravel, sand, sludge, and water. This separation system utilizes centrifugal force, ensuring optimal handling of the different fractions. Subsequently, the gravel and stones are stored in special boxes, ready for reuse or disposal. Finally, the separated water and sludge are directed to the treatment plant. There, further chemical and physical processes purify and manage the remaining sludge. Ultimately, this plant ensures effective and sustainable wastewater treatment, contributing to the reduction of environmental impact and the recovery of resources.

Result achieved in IPS plant

In conclusion, the waste treatment plant serves as an innovative model of sustainable management. It effectively recovers resources like sand and gravel while significantly reducing environmental impact. Furthermore, by dividing operations into two groups, the plant treats excavation and road sweeping waste separately. This division optimizes the recovery of useful components.

Additionally, the use of screens and advanced machinery reduces material volume and recovers valuable fractions, transforming waste into reusable resources. This integrated facility complies with environmental regulations and promotes conscious management of waste and wastewater. Ultimately, this approach contributes to a circular and sustainable economy.

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