3 Unique Crushing System There is an autogenous crushing within the particle cloud and on the rock bed for both, the Barmac and V7 Crushers.The V7 Crusher is constructed so there are multiple impacts in the new dense material zone.As the material drops down from the stone wall into an increasingly dense zone, it is re-crushed by particle interaction as well as hammers, being both shaped and scrubbed.
4 Unique Shaping to 75μm Shape of particles <1mm vital Workability PumpabilityDensityCone CrusherBarmac VSIV7 Crusher
5 A Unique Separation System DustcollectorWindpowerView showingdispersion systemDiffusion feederGrain size damperCut screenProductOver size(Return to VSI)Inner structure of air screenBlowerVSIAir screen gives partial return, top-size cut and classification.Raw material flows from VSI → diffusion feeder → air screen separation using the blower.(5) is fully returned, and (4) is partially returned by the damper.Top size (1) - (3) and part of (4) screened for oversize return.
6 Unique Flexibility in Gradation A poorly graded crusher dust becomeseven poorer after the removal of filler by washing or dedusting.Kayasand is evenly graded andgradations can be changed to makethe ideal sand as a single fine aggregatecomponent for concrete or asphalt.
7 Can V7 Kayasand can COMPLETELY replace natural sand in concrete? Summary of DifferencesThe V7 has a more efficient crusher than other autogenous VSI’sThe V7 has an airscreen with the ability to recirculate a variable size of productThe V7 can vary the gradation of the sandThe V7 can control the minus 75 micron content of the sandThe V7 produces a shaped particle size to 75 micron particlesThe V7 operates dry as well as quietly and dust freeCan V7 Kayasand can COMPLETELY replace natural sand in concrete?
9 Environmental Benefit Key ObjectivesPrimary aim to show that a manufactured sand can be made to replace natural sand and sand blendsSecondary aim to refine gradations to reduce cement usage and to find new uses for rock filler in agricultureEnvironmental BenefitIf replacement is proven viable then dredging for sand can be reduced or eliminated, and viable concrete sands can be made in most quarries.
10 Manufactured sands Manufactured sands from crusher dusts with at least 4 gradings for each quarryBasalt (B) – Duntilland Quarry, HolcimGranite (G) – Glensanda Quarry, HolcimSandstone (S) – Gilfach Quarry, CEMEXLimestone (L) – Taff’s Well Quarry, CEMEXBasaltGraniteSandstoneLimestoneMaterials:CEM I 52.5 N, Crushed limestone 4/20 mm, Sea dredged natural sand control (N), Mid range plasticizer WRDA 90, manufactured sands
11 Characterisation tests New Zealand Flow Cone (NZS )Observations from mixing(finishability, ease of placement)Particle size distribution (BS EN 933-1)Plastic DensitySlumpWater absorption (BS EN )Fine AggregateFresh ConcreteAir EntrainmentHardened ConcreteMethylene Blue Value (BS EN 933-9)Flexural strength28 daysGMBV (Grace Rapid Clay test)Compressive strength1 day7 days28 daysSand Equivalent (BS EN )
12 Manufactured sand test results New Zealand flow cone –simple indirect test indicatingshape, grading and surface textureAll manufactured sands fitwithin the standard envelopeMethylene blue test –indication of potential presence of clays,Grace’s rapid clay test directly correlatedwith these resultsMBV reduced in allmanufactured sands ifcompared to feed material0/4 mm fraction
13 Concrete, Stage 1Stage 1: without plasticizer, aiming for S2 slump, fixed w/c ratio for particular quarry sands which provides S2 slump.CementFACAWater3507531040varies
14 Concrete, Stage 2Stage 2: Varying plasticizer dosage to achieve S2 slump, fixed w/c ratio at 0.55 for all sands.CementFACAWaterPlasticizer3507531040193varies
15 V7 sand can COMPLETELY replace natural sands in concrete! Primary Objectiveto show that a manufactured sand can be made to replace natural sand and sand blends in concreteMETV7 sand can COMPLETELY replace natural sands in concrete!
17 V7-60 Economics (60 tph throughput) Operating CostsPower = 6.7kwhr per tonne throughput@ 15c/kwhr = Aus $1.00Wear parts and maint = $1.85 to $2.80 depending on materialCapital CostsTypical ~ Aus $3m turnkey installation60tph capacity = 200ktpa+10 yr amortisationTypical Opex ~ $3.20 /t throughputTypical capital rec ~ $1.50 /t throughput
18 Premium all in fine aggregate ~ $5.80/t V7-60 Economics (60 tph throughput)Sand YieldsRange = 75% to 85%Typical = 80%Depends on feed- Crushing properties- Filler contentFiller (dry premium product)15% to 30%- Granulate – drainage = $15/t- Road base = $20/t- Asphalt/block plants = $20/t- Agriculture = $20/tPremium all in fine aggregate ~ $5.80/t(Assuming filler has no value and full capital recovery)Significant upside likely from filler
19 The economics compared Kayasand V7-60Dredged SandWashed Pit SandOperating Cost per tonne sand produced$3.00-$3.801$7.00 to $12.003$8.00 to $12.005Capital Cost per tonne per annum capacity$301$45 to $752$30 to $454Environmental ImpactNilHighAvailabilityMed1 Costs will vary depending on location and feed, these costs are typical of installations Kayasand has completed detailed evaluations for.2 Allowance for resource consent, dredger, wharf facilities.3 Will vary depending on the distance off shore for dredging.4 Allowance for resource consents and capital investment – wash-plant , filter press etc.5 Wash plant operating costs vary depending on water, waste costs, efficiency etc.
21 The Japanese Experience Japan banned unnecessary dredging in 1991Kayasand now accounts for 45% of all of their manufactured sandWhile the introduction of Kayasand has been successfully implemented and the environment as well as the construction industry has benefited, regulatory change was necessary
22 Driving Change for Environmental Gain There is often resistance to change in any industry due to:Vested interests (from existing sand, gravel and dredging companies)Economic pressures and lack of priority (bigger problems so park this)Relatively slow adopters of proven but novel technologyThe environmental cost is not borne by them
23 AcknowledgementsKayasand would like to acknowledge the financial and in kind support of:The Aggregate Levy Fund for WalesKotobuki Engineering & Manufacturing Company (Kemco)CEMEXAggregate Industries (Holcim)Grace Construction Productsand Cardiff University’s Engineering Department for their input and supervision, in particular Diane Gardner and Professor Bob Lark
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