Crushing faulty fired clay, brings great savings

In Austria an RM60 processes batches of around 700t of brick material at once, to produce 0/3mm brick sand, thus saving on the purchase of expensive additives, plus 3/6mm material which is sold as a lucrative by-product.
In England, an electrically-powered RM60, has been flat out at a glazed ceramic wall and floor tile factory for 8 and a half years. It has been working 12 hours a day, 5 days a week, crushing about 500t a week of highly abrasive flawed and broken tiles.
Maintenance is done at weekends, to ensure another production week without disturbances. The waste tiles, as well as waste pottery supplied free by nearby manufacturers, are crushed in the compact but powerful impact crusher, adjusted with 4 full chrome hammers, the gap closed to about 10 mm.
The value grain produced is 20mm to dust as required. This grain is screened off, and all oversize material is immediately run back, to be recrushed in a closed cycle. In a second step, the value grain is carried to a rotary hammer mill and crushed to dust, which can be reused in the manufacturing process.
The earning power of this recycling process is quite impressive. If you consider that the costs for a tonne of tiles out of original raw material totals about £70 ($140), and the running costs for hammers and wear plates per tonne only account for £1.20 ($2.40), and the proportion of recycled material in new tiles is 40%.
Also in England, in order to increase output and improve the quality of their recycled production waste, Stowell Concrete Ltd, Bristol, decided in 2002 to retire its jaw crusher and buy an RM60.
“Along with a VS60 pre-screen and a CS2500 screen, it is being used to recycle up to 300t a month of broken blocks and waste from the block making plant,” says Vince Stowell. “In addition this system provides the chance to recycle customers’ waste building materials for reuse in concrete block manufacturing, a service we have just recently started. The crushed material is basically screened into 0/10, giving us high-value material that saves us enormous costs.
Stowell is saving about £9 ($18) a day by reusing production waste in this way.
 More information: 02 8795 0288, sales@globalcrushers.com, www.rubblemaster.com