CRH / Dufferin Aggregates – Paris Twin Screen Wash Plant

CRH / Dufferin Aggregates – Paris Twin Screen Wash Plant

Client: CRH / Dufferin Aggregates Canada

Location: Paris, Ontario, Canada

Industry: Aggregates and Construction Materials

Project Type: Custom Design & Build Wash Plant

Project Duration: 11 months (from design inception to commissioning)

Stacker Throughput: 1000 TPH

CRH / Dufferin Aggregates

Project Overview

Assinck Limited was tasked with designing and building a custom wash plant capable of processing aggregate materials at a rate of 1000 tons per hour (TPH) for CRH/Dufferin Aggregates. The goal was to create a plant with the flexibility to maximize material reserves while producing seven different aggregate products simultaneously to meet diverse client requirements. This project involved a comprehensive, customized solution to satisfy complex client demands while ensuring product quality and operational efficiency.

The Challenge

The primary challenge was meeting the client’s request to produce both natural and manufactured aggregates at the same time. Additionally, CRH/Dufferin Aggregates required the ability to offer highly specific blends of coarse aggregate products to serve various industry needs. Balancing flexibility, throughput, and quality control posed significant design and operational challenges.

The Solution

Assinck provided an innovative solution in the form of a twin 8’ x 20’ wash plant. This plant was outfitted with a Syntron feeding station designed to handle variable feed materials, ensuring smooth and efficient processing. The wash plant incorporated several blending gates on the discharge chutes to meet stringent quality control demands.

To further enhance flexibility, Assinck designed and built a blending station that enabled the client to fine-tune custom blends of coarse aggregate for industry-specific requirements. This customization allowed the client to produce a wide range of gradations, giving them the ability to meet changing market demands and future industry trends.

Customization and Innovation

This project was highly customized from the outset, allowing CRH/Dufferin Aggregates to achieve maximum flexibility in their aggregate production. Key features of the plant include:

  • Twin 8’ x 20’ Wash Plant: Designed for optimal throughput and flexibility.
  • Syntron Feeding Station: Capable of handling variable feed materials efficiently.
  • Blending Gates & Discharge Chutes: Precise control over product gradation to meet stringent quality specifications.
  • Custom Blending Station: Additional capability to produce tailored aggregate blends for specific client needs.
  • Electric Solenoid Valve Controls: These valves, integrated into the blending gates, allow operators to make real-time adjustments at the touch of a button.

These custom features ensure that CRH/Dufferin Aggregates can efficiently adapt to evolving industry needs while maximizing operational efficiency.

Timeline

The project was completed within a timeline of 11 months, from the initial design phase to the final commissioning of the wash plant.

Results

The new wash plant has delivered outstanding results for CRH/Dufferin Aggregates, offering:

  • 1000 TPH throughput: Consistent performance to meet production targets.
  • Maximum Flexibility: The plant can simultaneously produce seven different aggregate products.
  • Customizable Product Blends: Operators can tailor products to meet diverse client requirements.
  • Operational Efficiency: The plant runs with minimal staffing, requiring only two operators to run at full capacity.
  • Meeting Quality Control Demands: Through innovative blending systems and discharge gates, the plant ensures top-notch product quality.

Operational Impact

The new plant has significantly improved operational efficiency at CRH/Dufferin Aggregates. The plant is managed by just two operations personnel, reducing labor requirements while maintaining high levels of production and flexibility.

Innovation and Futureproofing

One of the standout innovations of this project was the integration of electric solenoid valves on the blending gates, which allowed for easy, on-the-fly adjustments with a simple press of a button. This innovation not only streamlines plant operations but also positions CRH/Dufferin Aggregates for future adaptability, as the plant can meet any future changes or challenges in the aggregates industry.

Outcome

The Paris twin screen wash plant has been operational since its commissioning, consistently meeting the client’s production targets. The plant has provided CRH/Dufferin Aggregates with a robust, flexible solution that aligns with their long-term goals and enables them to meet their clients’ diverse and evolving needs.