BBT’s secondary-crushing plant at Fujairah.
SBM plant ensures quality aggregates
01 November 2007
Demand-driven and economic solutions from SBM Mineral Processing continue to ensure that major projects in the region are provided with quality aggregates, according to the Austria-based manufacturer of crushers and screens.
Among the many clients that SBM has served is Bahrain Bulk Trade (BBT), one of Bahrain’s prominent producers and exporters of aggregates, which decided to install a plant for processing dolomitic limestone in Fujairah, UAE, to keep pace with the surging demand for premium quality aggregates.
The contract for supplying and commissioning this plant with a capacity of 5 million tonnes per year (tpy) was awarded to SBM early in 2004, and commissioning of the plant took place in mid-2005.
To be able to serve the markets in the UAE, Bahrain, Qatar, and Kuwait, BBT specified the design parameters for the plant which would be required to process blasted dolomitic limestone with an edge length up to 1,200 mm to produce aggregates in three sizes of 0 to 5, 5 to 10 and 10 to 20 mm. The output expected was 1,000 tonnes per hour (tph) with product holding of approximately 19,000 tonnes per aggregate size.
Initial pre-planning discussions with BBT for the plant took place as early as 2003 to ensure that the plant would meet market and product-specific demands, and comply with BS (British Standard), says a spokesman for SBM, adding that the parameters specified by BBT were all incorporated in the SBM design.
The plant has now been in production for almost two years to the customer’s total satisfaction.
According to the spokesman, a number of characteristics/circumstances were taken into consideration on planning and implementing the plant. These include:
• The requirement for extremely robust electronics and controls to be able to withstand high ambient temperatures of up to 55 deg C;
• Planning and delivery of extremely wide loading belts, thus ensuring optimum usage of the terrain characteristics for open air storage on large depots;
• High truck loading capacity of three 800 tph units;
• Machine and plant component housings, and use of de-dusting units to comply with extremely strict regulations concerning dust emission;
• All conveyor belts have covers to provide wide-ranging protection against climatic conditions;
• Large depot volumes for temporary holding of approximately 40,000 tonnes and stockpiles for products of approximately 19,000 tonnes per aggregate size, ensuring high availability of large quantities;
• Fully-automated controls via SPS ensuring high availability, low staffing requirements and thus eliminating human error;
• Visualisation of the production process, and production monitoring through conveyor belt weighers, allowing quick adjustment to different volumes of finished product;
• Use of a flip-flop screening machine to enable extraction of the finest components (up to 75 microns) from crushed sand of 0 to 5 mm size to comply with the concrete standard of maximum seven per cent;
• Optimised short maintenance intervals, offering high availability with two-shift operation of 10 hours per shift
As SBM adhered precisely to the specified parameters, the Austrian company has secured a further substantial contract for planning and supplying a large-scale plant for processing gabbro with a throughput of 1,000 tph. This system was commissioned early last year also in Fujairah.
SBM offers a wide range of reliable and highly productive mobile screens for a variety of applications: including crawler-mounted, wheel-based or containerised mobile plants; flat-deck screens as circular vibrating screen; flip-flop screens; external conveyor belt feeding or with integral conveyor belt and/or apron feeder; integral stacker conveyor; washing screens with dewatering screen; revolving screens with double or single trammel; axle assemblies and tractor equipment depending on screen type and plant size; and on-board drive with sufficiently rated diesel three-phase generator
The company combines engineering knowledge with experience from the operating industry to produce mobile plants that are used for wet and dry processing in the natural stone, sand and gravel and recycling industries.
“SBM’s priorities are to ensure demand-driven and economic solutions and a high level of efficiency for the operator,” the spokesman concludes.
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