Water from the washing conveyors is collected into a retaining trough to be pumped into the holding silo.
Recently, when Aggcorp took on the Matec Machinery Technology line, a maker of filter presses, the company immediately thought of Feikert Sand & Gravel Inc.
Aggcorp’s President Sean McIvor and representative Rob Armbruster have been calling on Lynn Feikert of Feikert Sand & Gravel Inc. since the company began operations in 2008.
Over the course of those five years of providing Feikert Sand & Gravel with crushing and screening equipment, both McIvor and Armbruster became well acquainted with Feikert Sand & Gravel’s operations and the challenges the company faces in producing top quality aggregate materials for a demanding market.
One challenge common in quarry operations is the need to build and maintain retaining ponds to contain sludge collected during the material washing process. The holding ponds require frequent and ongoing maintenance while taking up valuable space.
Matec’s system is capable of extracting up to 90 percent of moisture from aggregate byproduct materials in a filtering process that result in an end product that lends itself to reuse. Used most often in aggregate and sand washing operations, the system also has applications in steel mills and other material processing facilities where water is used to clean or cool materials.
On learning about the Matec filter press and its capabilities, Feikert Sand & Gravel owner and manager Lynn Feikert clearly saw the benefits of the filter press and made arrangements with Aggcorp to have a system installed at the facility.
At Feikert Sand & Gravel, the Matec filter press dehydrates sludge that is a runoff product from their washing system by squeezing the water out to produce dry cakes of pressed sludge which can be readily collected and recycled. In the system, water collected from the washing process which contains sludge is pumped into a holding silo in preparation for processing.
From the holding silo, the water moves to an agitator where it is combined with a flocculant material that adheres to the sludge particles suspended in the water, creating large clusters. The flocculant product has a high molecular weight that, on adhering to the sludge particles, causes the clusters to settle for further processing. The process is monitored by an automatic dosing system that pulls samples at scheduled intervals, measures the time it takes for the material to settle and automatically adjusts the pump speed and volume of the flocculant product being used.
The material is then pumped into the filter press, which consists of a series of horizontally stacked filter plates. Water is extracted when the filter plates are compressed under high pressure. After cycling, the filter plates automatically open, allowing the dehydrated cake material to drop from the filter press to be collected and recycled.
Feikert is pleased with the system, claiming that during operation, the press cycles every 15 minutes while processing 2,000 gal. (7,571 L) of water per minute and producing 120 tons (109 t) of reusable materials per day. The great benefit of the filter plant is that materials that were once set aside, consuming valuable space and resources, can now be recycled, according to Feikert.
Feikert added he is equally enthusiastic about working with Aggcorp, saying that both Sean McIvor and Rob Armbruster bring a good deal of knowledge to the table and are dedicated and focused on getting the job done right. For the installation of the filter press, two Matec technicians came in from Italy to assist Aggcorp’s crew of five installers on the job. The entire system was assembled and operational in two weeks. Currently, the entire system is open to the elements, however, Feikert plans to winterize it by enclosing the operation within a building structure.
Matec Machinery Technology’s headquarters and manufacturing facility are located in in Massa, Italy. The company specializes in the design and production of waste water filtration and purification plants used in many industries, with a focus on aggregates, gravel, sand, stone, ceramics, glass.
Aggcorp provides equipment-based solutions in aggregate, mining, topsoil and recycling industries. The company is the authorized Powerscreen dealer in Ohio and has recently taken on the Matec lines as well as Terex environmental equipment, and Telestack mobile conveyor line.
Feikert Sand & Gravel Inc. is a family-owned business located at 7188 County Road 189 in Millersburg, Ohio, and was started by Lynn’s Grandfather, Henry Feikert in 1935. Currently the company is owned and managed by Lynn, his brother Tim, and their two cousins, James and Larry Feikert. Several fourth generation family members also are active in the day to day operations of the company.
The company produces redi-mix concrete, limestone, and sand and gravel at its 500 acre operation. Rated ODOT Group 0 in sand, the company supplies concrete plants in Elyria and Norwalk, Ohio, and in Wheeling, W.Va. The company also provides excavating, hauling and snow removal services locally in Wayne and Holmes County.