Peter Fitzpatrick futureproof and expand with CDE investment

New CDE wash plant solution processing over 200,000 tonnes of quarry by-products per year

Peter Fitzpatrick Ltd, a family-owned quarrying and contracting company based in Co. Down, Northern Ireland, have been a key player in the quarry and asphalt industry for more than 50 years. From their 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.

Peter Fitzpatrick Ltd have 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 become 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 recognized an opportunity to transform this by-product into a saleable manufactured sand, which could alleviate some of the pressure on natural sand resources.

Highlighting the specific problems, Paul Fitzpatrick, managing director of Peter Fitzpatrick Ltd, said: ‘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 130 tonnes/h 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 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 utilizing CDE technology, to see the equipment in operation.

Paul Fitzpatrick commented: ‘It was impressive to see the CDE equipment. There is always a worry that the plant we are visiting is not the same as our plant, but seeing the material being processed gives you a lot of confidence. We had a conversation with Brendan Campbell, of Campbell Contracts, and were encouraged by what he had to say about their plant, the installation, and his positive relationship with CDE.’

The implementation process involved detailed discussions and collaboration between CDE’s sales team 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 minimize civil engineering requirements and optimize 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.

Commenting on the positive impact of the plant, Paul Fitzpatrick said: ‘We now have a consistent sand product that we can provide to customers. We now have a product rather than the quarry dust coming from our crushing plant and being stockpiled with no prospect of getting to customers. We believe we have a product that has promising sales value or can be used internally.’

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.

Des Crawford, business development manager at CDE, commented: ‘As Peter Fitzpatrick Ltd continue 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.

‘It is always rewarding to work with a company that shares our values of creating our best world, one tonne at a time, and we look forward to a long and fruitful relationship with the team at Peter Fitzpatrick Ltd.’