How to avoid the cost of stockpiling oversized materials

For 20 years Fortis has been making IBA aggregates(marketed as Fortistone®)  from the thermal treatment of a mixture of municipal (household), commercial and industrial waste. When the oversized stockpile was becoming too much they got an MB Crusher unit to help. But before we find out why, let’s take a step back.

Ash, which is obtained from the incineration process of waste, offers an opportunity to transform what was once considered problematic and useless into a valuable resource: secondary aggregates. Which are used as a sub-base in the construction of roads, footpaths, structural platforms and car parks.

Diverting waste from landfills reduces the burden on waste management while also creating a new revenue stream, Fortis has taken advantage of this win-win situation and has been processing the IBA bottom ash from an incinerator, creating secondary aggregate to be sold to the construction industry.

However, during the maturation process of the IBA, a combination of moisture and heat can cause some of the IBA to harden and clump. Unfortunately, getting oversized portions is a natural part of the process, but it represents a bit of an issue as oversized it cannot be used.

Consequently, the by-product that was 65mm plus got stockpiled until they got to the stage where the oversize was too much, in any business stockpile management processes are riddled with difficulties. A possible solution was to recirculate the oversize into the plant hoping that it could provide a degree of size reduction, but this alternative could be time-consuming and financially burdensome.
 

So how does an MB Crusher attachment fit into the process?

A jaw crusher model BF90.3 was installed to their Volvo EC220 as it crushes down the clumps to 40mm, which then is the right size to be put back into the plant to produce the secondary aggregate. Also, another advantage to running the oversize through the MB Crusher attachment is that it liberates the metal, so it can be recovered and the secondary aggregate quality improves.

Luke in an interview during Plantworx 2023 shed light on why they chose MB Crusher and how it has transformed their operations, going from a situation where the oversized materials were creating logistical challenges to a game-changer in stockpile management all by using the MB Crusher attachment.

Secondary aggregates are usually by-products of other industrial processes that have not previously been used in construction, and ash is the by-product of burning waste it comes with many beneficial applications that contribute to a more sustainable future.

Numbers on the Fortis website are impressive, in 10 years they have recycled, processed and distributed over 4 million tonnes of IBA aggregates into the construction industry.

So we asked Luke ‘’How does the construction industry react to using IBA aggregates, what is the strongest advantage?’’

"IBA Aggregate (marketed as Fortistone®) is a more cost-effective and sustainable solution than virgin aggregates, with no tax levy added to the sale of the product.  Its use in construction ensures the preservation of our natural resources and demonstrates a clear commitment to the environment and potential carbon reduction."

Fortis’ decision to invest in the MB Crusher attachment stemmed from its promising features and potential to alleviate its stockpile challenges. MB Crusher attachment is designed for volumetric reductions.

"The BF90 has reduced recirculation of oversize with subsequent reductions in processing plant wear and OPEX costs" said Luke.

MB Crusher's efficient crushing capabilities, versatility, and cost-effectiveness have allowed Fortis to streamline our stockpile management processes with incredible outcomes. The added environmental benefits further solidify the satisfaction with this innovative solution. They highly recommend the MB Crusher attachment to other companies seeking to optimize their aggregate stockpile management and drive overall.

And the operator says: …"you can hardly hear it in the cab of the excavator. It is like it's not silent because you're looking at it and you can hear it, but it's very bearable. It's very operator-friendly and doesn't shake you out all over."