Event
St. Louis, Missouri
25 - 27 Mar 2025
AGG1 2025
Peter Fitzpatrick Ltd futureproof and expand with CDE investment. New CDE washing solution to process over 200k tonnes per year.
Volume
130tph
Material
Crushed Rock, Manufactured Sands, Quarry Waste, Sand & Gravel
Output
Manufactured Sand
End Use
Asphalt production
Peter Fitzpatrick Ltd futureproof and expand with CDE investment. The new CDE wet processing solution will process over 200k tonnes of crushed rock fines (CRF's) per year.
Peter Fitzpatrick Ltd, a family-owned quarrying and contracting company based in County Down, Northern Ireland, has been a key player in the quarry and asphalt industry for over fifty years. From its modest beginnings in the early 20th century, the company has grown into a dynamic business serving a broad customer base across various sectors.
Recently, Peter Fitzpatrick Ltd collaborated and invested with CDE to implement a cutting-edge wash plant to address the growing issue of excess crushed rock fines (CRF) and blinding from their greywacke processing operations.
The Challenge
Peter Fitzpatrick Ltd has historically faced challenges managing the by-products of their quarrying operations. The primary issue was the accumulation of excess CRF and blinding material, which had been stockpiled with a view to future processing. As natural sand reserves becomes increasingly scarce, the need to efficiently process and repurpose these by-products became more pressing. The excess material not only took up valuable space within the quarry but also posed environmental and operational challenges.
Additionally, the company recognised an opportunity to transform this by-product into a saleable manufactured sand, which could alleviate some of the pressure on natural sand resources.
Paul Fitzpatrick, Managing Director at Peter Fitzpatrick Ltd highlighted the specific problems: “The fine dust, 4mm material, which we didn’t have enough of an output of, in terms of what we had in the quarry, was becoming an issue. It started to take up a huge footprint within the quarry and we wanted a solution for dealing with that by-product. One of the more obvious things we were looking to address was how to turn it into sand.”
CDE proposed a comprehensive solution to address the challenges faced by Peter Fitzpatrick Ltd. The 130tph solution centred around the installation of a new washing plant that included the M2500 modular washing plant, the EvoWash™ sand washing system, and the AquaCycle™ thickener. This combination of equipment was designed to process the excess CRF and blinding material, transforming it into high-quality manufactured sand and other aggregates.
The Solution
The M2500 mobile washing plant integrates feeding, screening, sand washing, and stockpiling on a single chassis. The EvoWash™ system, specifically designed to remove the unwanted fines from the material, produces a consistent and high-quality sand product. The AquaCycle™ thickener recycles up to 90% of the water used in the washing process, significantly reducing the need for fresh water and minimizing the environmental impact.
The team at Peter Fitzpatrick Ltd was invited to local sites that were already reaping the benefits of utilising CDE technology, to see the equipment in operation. Paul Fitzpatrick commented: “It was impressive to see the CDE equipment in operation at other quarries. There was always the worry that our abrasive gritstone material would prove a challenge for the M2500 and Evowash system but we were encouraged after viewing the plant operating in other gritstone quarries and sand and gravel sites, and after listening to other operators talk so positively about their relationship with CDE.”
The implementation process involved detailed discussions and collaboration between CDE's sales and technical engineers and the team at Peter Fitzpatrick Ltd. They meticulously planned the design and location of the plant, considering factors such as power generation, water servicing, and the construction of silt ponds. The plant was strategically located to minimise civil engineering requirements and optimise operational efficiency.
The new CDE washing plant has delivered impressive results for Peter Fitzpatrick Ltd. By processing the excess CRF and blinding material, the plant was able to produce a consistent and high-quality sand product. This not only addresses the issue of stockpiled material and contributes to the conservation of natural sand reserves, but has also created a valuable new revenue stream for the company.
The Results
The plant's capacity to handle up to 100,000 tonnes of dust and another 100,000 tonnes of secondary blinding material per year has significantly reduced the footprint of stockpiled material within the quarry. This has not only freed up valuable space but also improved the overall efficiency and sustainability of the quarrying operations.
Moreover, the quality of the manufactured sand has attracted new customers, further expanding the company's market reach. The integration of the new plant has also enhanced the company's ability to meet the demands of their Asphalt Plant ensuring a steady supply of high-quality materials.
The strategic planning, innovative technology, and effective implementation of the CDE solution has enabled Peter Fitzpatrick Ltd to optimise its quarrying operations and enhance the company’s product offerings. The results speak for themselves, with significant reductions in stockpiled material, improved operational efficiency, and the creation of a new revenue stream through the sale of manufactured sand.
Des Crawford, Business Development Manager at CDE commented: “As Peter Fitzpatrick Ltd continues to build on the legacy of the company’s founders, this successful project exemplifies their commitment to innovation, sustainability, and excellence in the quarrying and contracting industry. The new CDE washing plant not only addresses current challenges but also positions the company for future growth and success in an increasingly competitive market.
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