November 20, 2013 was a day of adventure for a select group of aggregate industry professionals when they took part in the second session of a two-part product forum hosted by Terex Washing Systems and Carolina Sunrock’s Butner Quarry. There, they had an opportunity to tour Sunrock’s MATEC Filter Press system, a recent addition to the quarry’s fines removal and materials washing process.
Because of Sunrock-Butner’s high output of trap rock materials, especially the washed sand and aggregate products, the need for high levels of sand recovery and for recycling the tremendous amounts of materials wash water that the plant requires, led them to acquire a Phoenix/Kisa twin dewatering bucket system. This unit works in conjunction with the Matec Filter Press to produce high quality, washed sand and aggregates.
Our two busloads of attendees were met by the two owners of Matec, Managing Director and CEO , Matteo Goich, and CTO Massimo Bertolucci. Together, they provided us with a detailed description of how this automated fines removal system actually works.
We began at the thickening silo. From there we visited the automated flocculent system and we concluded beneath the 190-plate filter press. There, the retained solids from the filter press are dropped into an awaiting haul truck and are taken to a designated site for use in quarry reclamation efforts.
Goich said that this size filter press, designed for the aggregates market, is capable of three cycles per hour of compacted fines. That means that roughly speaking; the filter press is capable of producing 100 tons per hour of pressed material, working at a flow rate of 5,400 gallons per minute.
Goich explained that after the wash water does its work in the dewatering bucket system, it is pumped into the buffer tank where flocculants are automatically introduced into the wash water to begin the process of precipitating the solids from the liquid. From there, the water is pumped via a 2-stage pump at 420psi, to the thickening silo then on to the filter press. After the water has been processed through the filter press, it is returned to the clean water tank where it is re-used in the washing process once again.
“This system is one of about 75 currently in use in the United States,” said Goich. “This unit went into service in mid-2013. It has done a wonderful job.”
“We have more than 1000 in service around the world. We began making these twelve years ago. They were originally designed for the winemaking industry, and because of their large scale, the transition into the coal and aggregates industry was an easy one. The needs are very similar, and on a grand scale. These systems work extremely well for removing large quantities of fines from a wash system.”
Goich said that the care and maintenance of this system is very simple. “When it is needed, we are able to change a filter in the filter press in about five minutes,” he said. “Regular maintenance is just as simple.” For more information on the Matec Filter Press, contact Matteo Goich or Salem Alameri – Matec America – (270) 841-9180 or online at www.matecamerica.com – firstname.lastname@example.org