< Back to ListingHOME > NEWS > CEMEX UK - Angerstein Wharf gets back into production with the help of DUO

CEMEX UK - Angerstein Wharf gets back into production with the help of DUO
11th September 2007

CEMEX UK - Angerstein Wharf gets back into production with the help of DUO

Angerstein Wharf is a marine aggregates facility situated on the south bank of the Thames close to the Millennium Dome in Greenwich. Owned and operated by CEMEX UK the site has recently been redeveloped as part of their current national investment programme.

This recent £2 million replant at Angerstein Wharf was required to reinstate the plant following a devastating fire in October 2004 which destroyed a substantial part of the plant resulting in the complete cessation of production on the site.

Following subsequent demolition and clearance of the site CEMEX UK continued to supply their customers by sourcing product externally. This situation changed for the better when in August 2005 DUO (Europe) plc supplied and installed a 200tph Powerscreen mobile sand and gravel plant; providing the capabilities for CEMEX to produce 70,000 tonnes per month. This plant proved to be so commercially and operationally successful for CEMEX that a turnkey contract was awarded to DUO (Europe) plc for the supply and installation of the replacement fixed plant.

The new plant, based on a simple modular arrangement incorporates twin processing lines with a nominal output capacity of 400tph; although less complicated than its predecessor it achieves similar end results with fewer operating elements.

Commencing late 2006 new site services were installed along with new concrete foundation pads allowing DUO (Europe) plc to start the plant build the following January. Throughout the build the Powerscreen mobile plant was maintained in running order to ensure continuity of supplies.

The raw material processed at Angerstein Wharf is obtained from licensed dredging areas in the Thames estuary and Eastern Channel by two dredging vessels operated by CEMEX UK. Unloaded from self-discharge dredgers at a rate of approximately 2,000tph material is then deposited in a reception hopper located at the end of the Angerstein mooring jetty. Material is then transported by an inclined conveyor that discharges on to an existing high-level tripper conveyor system creating a 50,000t capacity stockpile of as-dredged material.

From the stockpiles a 50/50 blend is collected by wheeled loader and fed into a 50t capacity feed hopper. Fitted with 100mm grid bars and a variable-speed feed belt this unit feeds on to a 31 metre long inclined 400tph conveyor. Equipped with an Eriez permanent magnet, this conveyor deposits the – 100mm material into a reception chute arrangement that also allows for a future feed direct from the wharf and a crushed material input.

Material is then fed on to a 20m long inclined conveyor; rated at 650tph this conveyor feeds into a two-way discharge chute and boiling box arrangement allowing either of the processing lines to be utilized. 
Material is sent forward to two double-deck 20ft x 6ft Cedarapids horizontal rinsing screens where any oversize +80mm material is scalped off and distributed to an adjacent ground storage bay via a 13.4m long wide stocking conveyor,

The – 6mm underflow (sand) content is then flumed to two Powerscreen Finesmaster 200 sand plants.  The dewatered sand is blended from both these machines and discharged on to a 26m catenary conveyor; rated at 280tph this feeds on to 24m long radial stockpile conveyor. An added feature is a moisture-reduction system which has been installed beneath the sharp sand stockpile to increase the rate of drying.  

The tiny fraction of waste silt (2.5-3%) produced is flumed to an existing treatment plant, incorporating a 10tph Wemco belt press. The -80mm +6mm fraction from each rinsing screen is then despatched independently via a pair of 24m long inclined conveyors. Rated at 260tph, these conveyors feed two further 20ft x 6ft Cedarapids horizontal screens.

Material from the top decks feeds on to a 30m long stocking conveyor to produce a 20mm final product stockpile. Any material passing the bottom decks is discharged on to a 24m long radial stockpile conveyor producing a 10mm final product stockpile.

Any oversize -80mm +20mm material is fed onto a reversible 16m long horizontal conveyor.  Rated at 180tph this conveyor either feeds a 12m long wide stocking conveyor for maintenance purposes or normally a 32m long crusher feed inclined conveyoRated at 180tph and equipped with an Eriez permanent magnet and metal detector, this conveyor discharges the oversize into a 15t capacity crusher surge bin.  A Siemens Multi Ranger level sensor determines when to start/stop a Rotex vibrating tray feeder which is used to surge feed a Pegson 1000 Automax cone crusher.  Crushed material is then fed on to a 26m long inclined belt conveyor. Rated at 180tph this conveyor feeds into a reception chute where it is blended with the as - dredged feed material.

The DUO Equipment division through their UK dealership supplied the Powerscreen Finesmaster sand plants, all Cedarapids screens and the Pegson cone crusher.
Working alongside, the DUO Manufacturing division (LJH) designed and manufactured all the fixed conveyors including the installation of fully galvanized heavy-gauge steelwork with guarding throughout.
The supply and installation of polyurethane modular systems for the Cedarapid Screens was completed by SCS of Rugby. SCS also installed rubber wear resistant linings to protect the Cedarapid screen frames, drive tubes, support chassis and feed and discharge trays and rubber wear resistant chute linings.
The company has also received a 2 year contract to supply and maintain the screening surfaces & rubber wear resistant screen & chute linings.

Plant operation is via a touch-screen, with full start/stop, alarm, history recording and fault diagnostic capabilities supplied by AXON Power and Control. A fully linked trip wire system also allows complete shut down of the entire plant instantaneously should any wire be activated. The plant design also allows operation either in full twin-line specification or with one of the two processing lines shut down.

Much thought to fine detail has been included within the site including remote greasing on all bearings and site cleanliness in the form of multiple wash down points.
In its current configuration when operating at full capacity, Angerstein Wharf is capable of delivering around 1.4 million tonnes of clean sand and gravel per annum. The new plant design is a step forward for CEMEX UK which will allow them to adjust to any future market demands over the next 25-30 years with only minor modifications to the plant.

Approximately 80% of current production is supplied internally to CEMEX ready-mixed concrete plants within the city, with the company’s newly commissioned Liebherr Betomix concrete batching plant, located on a site adjacent to Angerstein Wharf, taking around 80,000t per year. Further on-site facilities include a 450 tonnes/h barge-loading system which is used to supply washed sharp sand to a CEMEX ready-mixed concrete plant in Fulham.