INDUSTRIAL RECYCLING

IPAS designs and builds solutions for industrial recycling, worldwide.

Sectors of experience are:

1. COAL SLUDGE RECOVERY
2. BOTTOM ASH TREATMENT
3. SOIL WASHING / REMEDIATION / SANITATION
4. GLASS RECYCLING
5. WATER PURIFICATION & TREATMENT OF ORGANICS IN THE FOOD INDUSTRY
6. SLUDGE & WATER TREATMENT IN THE CONCRETE INDUSTRY & BRICKWORKS

1.COAL SLUDGE RECOVERY

In the environment of working and closed coalmines most often exist PONDS, that can be very big. They are used to store in a temporary or permanent way the SLUDGE from the coal washing process. Very often these ponds are still rich in fine coal to very fine fractions of usable coal. IPAS is a top specialist in recovery of coal from these ponds, as IPAS masters the wet process technology. IPAS has designed and build several POND WASHING INSTALLATIONS to recover coal from sludge mass. IPAS installations run profitable for coal ponds from 40 % coal content. The recovery and sanitation of coal ponds is, of course also a necessity when the mining activity stops.

References:

IPAS references in coalmine sludge recovery. The projects are situated in run of mine environment or in sanitation contexts or pit recovery operations.
Fechner (1988 / Germany / Total Separation Concept -TSC-); Sewater (1989 / Belgium / TSC); Solichar (1989 / Belgium / TSC); Haisy (1990 / USA / TSC); Hansen Coal Gmbh (1990 / Germany / TSC); Issabel (1990 / USA / TSC); Kempense Steenkoolmijnen (1990 / Belgium / TSC); IPAS Polska (2010 – 2013 / Poland / contaminated Coal Tips and Sludge Ponds – studies).

2.BOTTOM ASH TREATMENT

IPAS designed and build a world premier installation in the year 2000 to clean and separate the bottom ash from the INDAVER waste incinerators in Antwerp, Belgium. This installation runs ever since without any technical defects and still is a reference in the sector of Waste Management.

In the ash treatment unit, ashes from the household incineration facilities are washed, sieved and purified. The end product is a valuable secondary material that can be used for several applications. Ferrous and non-ferrous metals are carefully removed in various cut, sieve and wash units. Some of those recuperated metals will be re-used in industry. Inert ashes remaining after incineration are converted into granulates. These can be used as secondary materials in the construction industry, in accordance with the relevant environmental regulations.

ashtreatment

3.SOIL WASHING / REMEDIATION / SANITATION

In IPAS developed installations for SOIL WASHING. Highly contaminated soils are cleaned in high volumes and until a 100 % recyclability of the materials.

Top reference:
Grondreinigingscentrum Limburg / Carmans NV (2007 to 2015, Belgium / TSC). This installation runs 90 t / hour of highly contaminated soil. IPAS is currently preparing a similar installation to process 250 t/hour.
Moreover the whole plant runs on renewable energy.
As final step, IPAS is developing an added on installation to valorise the last 20 % fraction of the contaminated sludge: 17 % of fine materials will be turned in to a new product, capturing and stabilizing the contaminants and 3 % organics will go to energetic valorisation.
So this plant will soon reach a 100 % recycling of contaminated soils.

Other references:
NMB (1991 / the Netherlands / TSC for road construction); Gyproc nv (1991 / Poland / combustion plant in Gypsum industry); Basse Sambre (1991 / Belgium / TSC sand recovery); SET nv (1991 / Belgium / TSC); Hogeschool Delft (1996 / the Netherlands / TSC); Watco RSW nv (1999 / Belgium / TSC); Rens (2000 / Belgium / TSC);

4.GLASS RECYCLING

The collection of used glass (bottles, jars, …) from households is a common practise in Europe. Glass represents an important inert fraction in the Municipal Waste stream. IPAS has developed a fully automatic recycling line that processes up to 25 tons per hour.

Different steps in the glass recycling process:

  • Separation of the course fraction to prepare colour separation on complete bottles
  • Separation of granulates
  • Separation of non-ferrous fraction
  • Separation of stones and porcelain.

Glass-Recycling

References:
GRV (1992 / Belgium / TSC); VLAR (1994 / Belgium / Engineering); GRL (1997 : Belgium / TSC); GRL (2009 / Belgium / CHP installation)

5.FOOD INDUSTRY

In the food industry IPAS has built several projects based on DAF technologies (Dissolved air flotation). This is a water treatment process that clarifies wastewaters by the removal of suspended matter such as oil or solids. The removal is achieved by dissolving air in the wastewater under pressure and then releasing the air at atmospheric pressure in a flotation tank or basin. The released air forms tiny bubbles which adhere to the suspended matter causing the suspended matter to float to the surface of the water where it then is removed by skimming.

References:
Clarebout nv ( 1991 / Belgium / PWT);Organic Waste System (1992 / Belgium / TSC); Noliko Vegetables (1992 / Belgium / PWT); Van Reusel Snacks (1993 / Belgium / BAK reactor); Vanlommel Slachthuis nv (1994 / Belgium / PWT research meat industry); Krikro (1994 / Belgium / PWT – potato industry); Decoster bvba (1996 / Belgium / PWT potato industry); Van Reusel Snacks (1996 / Belgium / consultancy on process); Van Reusel Snacks (1998 / Belgium / process optimisation); Van Reusel Snacks (2000 / Belgium / PWT); Equinox (2000 / Belgium / consulting); Bravi nv (2002 / Belgium : PWT potato industry);

6.CONCRETE INDUSTRY & BRICKWORKS

IPAS developed and implemented in the concrete sector a very performant system for recuperation of process water. The payback time for these investments was everywhere less than 6 months, because of the reuse of water streams and the fact that no longer contaminated water needs to be discharged in to the environment or in the public wastewater systems or that no longer sludge needs to be put in the landfills.

References:
De Nieuwe Zandgroeven (1992 L/ Belgium / TSC); ECHO (1994 / Belgium / PWT – development of new concept); Varenberg nv (1994 / Belgium / PWT – research gravel recovery); Winters (1994 / Belgium / PWT – research gravel recovery); Goudezeune (1996 & 1997 & 1998 &1999 / Belgium / PWT 4 installations); Ropa bvba (1996 / Belgium / PWT meat industry); Vos Vleeswaren (1996 / Belgium / PWT meat industry); Heylen (1997 / Belgium / PWT – ceramics); Betonson (Kampen) (1997 / Belgium / PWT); Trilco (1997 / Belgium / PWT); Vasco (1997 / Belgium / PWT process optimization in heating system); Ergon (1998 / Belgium / PWT); Kerkstoel (1998 / Belgium / PWT); Carrières du Hainaut (1998 / Belgium / PWT stone quarry); Damman nv (1999 / Belgium / TSC – brick works); Martens Beton nv (1999 / Belgium / PWT); Carrières du Boulonnais (1999 / France / PWT research – stone quarry); Agref (2000 / Belgium / PWT); Ebema (2000 / Belgium / PWT); Marlux (2000 / Belgium / PWT); Sander-Pebüso (2000 / Belgium / PWT); Tripan (2000 / Belgium / PWT); Carrières du Hainaut (1998 / Belgium / PWT stone quarry); Boskalis (2001 / the Netherlands / TSC research sieve sand); De Vijfhoek (2001 / the Netherlands / TSC research sieve sand); SVK (2001 / Belgium / PWT); De Meteoor (2001 / the Netherlands / PWT research); Heembeton (2001 / the Netherlands / PWT); Klaps Beton (2001 / Belgium / PWT); Seveton nv (2001 / Belgium / PWT research); EWI nv (2001 / Belgium / PWT); Mostone (2001 / Poland / PWT research stone quarry); Marlux (2001 / Belgium / chemicals); Seveton (2002 / Belgium / PWT – adjustment); BDI Ambés (2002 / France / PWT); BDI Grigny (2002 / France / PWT); Den Boer Beton (2002 / Belgium / PWT adjustment); MBI (2002 / Belgium / PWT); Heembeton (2002 / the Netherlands / chemicals); BMI (2003 / France / PWT); Lithobeton (2003 / Belgium / PWT); C&G (2003 / UK / PWT); C&G (2004 / UK / PWT); BDI Pujaut (2004 / France / PWT); Den Boer Beton (2005 / the Netherlands / PWT)