international schauenburg engineeringmaterials in the best possible and most efficient manner at all...
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International
Engineering
ASTECH PROJECTS LTD. Cheshire, UKwww.astechprojects.com
B&D PROCESS EQUIPMENT B.V.Rotterdam, Netherlands Mülheim an der Ruhr, Germany www.zand.nu
SCHAUENBURG MASCHINEN- UND ANLAGEN-BAU GMBHMülheim an der Ruhr, Germanywww.schauenburg-mab.com
SCHAUENBURG MAB ASIA PTE. LTD.Singaporewww.schauenburg-mab.com
SCHILLER APPARATEBAU GMBHEssen, Germanywww.schiller-apparatebau.com
SCHAUENBURG ENGINEERING
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ELECTRONICTECHNOLOGIES
PLASTICS PROCESSING
ENGINEERING
INDUSTRIAL SOLUTIONS
INNOVATIVE SOLUTIONS.
COMPREHENSIVE EXPERIENCE.
OUTSTANDING QUALITY.
As one of SCHAUENBURG INTERNATIONAL’s four
business units, Engineering is a key division of the
group. Made up of well-established companies
operating around the globe, it offers first-class
expertise in the sector. Focusing on the individual
requirements of our clients, we deliver custom-
ised solutions in a number of key industries.
Areas of special importance include process en-
gineering for tunnelling and mining operations,
environmental and power plant technology,
and the construction materials industry as well as
robotics and automation for research & de-
velopment and advanced manufacturing indus-
tries. Sound engineering, innovative solutions
that meet the requirements of real-life applica-
tions, and the stability offered by a large group
of companies make us partners that our custom-
ers can trust. In particular, they appreciate the
durability of our equipment and the reliable ser-
vice we offer throughout the world.
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SYSTEM COMPONENTS
We supply each component required for the treat-
ment process and all to the highest specifica-
tions. These range from log washers, which break
up lumpy material in an initial processing stage,
to thickeners, which separate the finest particles
from the wash water. Using years of experience,
our centrifugal pumps are designed to withstand
the toughest conditions on construction sites,
and are particularly robust, thanks to remov-
able lining manufactured from extremely wear-
resistant Linatex® natural rubber.
Some of the components used in B&D and
Schauenburg MAB equipment are presented in
more detail below.
VIBRATING DEWATERING SCREENS
These screens vibrate to dewater and classify
mineral material. They can be adapted to indivi-
dual customer requirements with different screen
coatings, e.g. made of polyurethane, natural
rubber or stainless steel. Thanks to the high
durability of our screens,
our customers can
benefit from low
operating costs
and minimal
downtime.
HYDROCYCLONES
Developed in-house, our
high-performance cyc-
lones are designed to
separate sand and silt.
These can be manu-
factured from steel with
Linatex® natural rubber lin-
ing, from a high-quality poly-
urethane compound or, where
especially high wear-resistance is required, from
ceramic. High-quality, hand-made natural rubber
underflow pockets ensure the fluid thickens well.
HYDRAULIC CLASSIFIERS AND GRADERS
When it comes to classifying and grading large
mineral deposits, for example in gravel- and
sandpits, our hydraulic
classifiers and graders
are the ideal solution.
Our T-type and Hydrosort®
range offers excellent
separation efficiency,
while minimal wear, low
energy consumption, ex-
cellent reliability and ease
of use are additional plus
points.
Wherever new tunnels are installed or connec-
tions are made, or raw materials are extracted
and new energy sources tapped into, mineral
processing plays a critical role. Unlike other pro-
cesses that frequently use chemicals detrimen-
tal to the environment and human health, our
equipment operates mainly with water. Environ-
mentally friendly technologies enable us to con-
tribute to the efficient and sustainable use of re-
sources.
EQUIPMENT TAILORED TO INDIVIDUAL NEEDS
The demands placed on end products and the
equipment used are as diverse as the raw mater-
ials we work with. Various processes – from wash-
ing, classifying and separating, through to de-
watering and thickening – are available to treat
materials in the best possible and most efficient
manner at all times. Working closely with our
customers, we develop a tailor-made treatment
process based on a modular system using stand-
ardised components. We adapt this process to
suit the properties of the mineral raw materials
and the qualities required of the end product.
Each project contract starts with detailed discus-
sions, analysis of samples in our laboratory and
a detailed assessment of the local conditions.
Armed with this information and using state-of-
the-art 3D programs, our engineers then prepare
a design in line with requirements.
CUSTOMISED EQUIPMENT AND SYSTEMS
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5 MEDIUM RECEIVING TANKCollects cleaned suspension
FLOW SHEET OF SEPARATION PLANT Coarse constituentsSandSiltFine material
1 CLASSIFYING SCREENSeparates large constitu-ents such as gravel, lumps of clay or natural stone
6 FINES EXTRACTIONSeparates finest particles through centrifuges or cham-ber filter presses
4 SECOND CYCLONE STAGESeparates silt
3 DEWATERING SCREENSeparates and carries off dewatered solids (sand and silt)
2 FIRST CYCLONE STAGESeparates sand
to TBM
from Tunnel Boring Machine (TBM)
Our separation technology was used, for example,
in the construction of the Elbe Tunnel in Ham-
burg and in the Mass Rapid Transit (MRT) system
in Kuala Lumpur. It is also deployed around the
world in laying sewage pipes and supply lines
underground.
COMPACT PLANTS IN CONTAINERISED FORMAT
SCHAUENBURG MAB offers standardised, extra-
compact equipment for use in tunnelling and
other applications which require mobile plants.
The equipment combines several treatment pro-
cesses, and is supplied in container format so
that it can be extended or
transported quickly and
easily.
Whether in the construction of transport tunnels,
laying of supply lines or sewage pipes, or the in-
stallation of pipework for electricity, telecommu-
nications or data transfer, our separation equip-
ment is at work around the globe.
SEPARATION OF DRILLING FLUID
Efficient separation equipment lies behind the
successful use of fluid-based tunnel boring ma-
chines. It separates drilling fluid from solid elem-
ents such as gravel, sand, loam and clay and
returns the cleaned fluid to the slurry circuit.
Sophisticated separation and dewatering pro-
cesses minimise waste disposal costs and
increase operating efficiency. Our equipment has
been used in a wide range of projects around
the world, from boring large tunnels to micro-
tunneling and horizontal directional drilling.
SEPARATION PLANTS
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ENVIRONMENTAL TECHNOLOGY
A responsible attitude towards our environment
has become more important than ever. Activ-
ities which affect the ecological balance must
therefore be offset or their negative impact
minimised. This includes the treatment of contam-
inated soils.
SOIL WASHING EQUIPMENT
SCHAUENBURG MAB specialises in the develop-
ment and manufacture of fixed and mobile soil
washing equipment. This is used when contam-
inated spoil or building rubble requires cleaning.
This is particularly important in civil engineering
and demolition, in environmental remediation or
in recycling building materials. This equipment
breaks up the material mechanically and then
removes the contaminated elements. The
end product is decontaminated soil, which
our customers can reuse as a recycled
building material, e.g. in road building
or track laying, or simply dispose of
without incurring expense.
PROCESSING EQUIPMENT FOR SAND TRAP RESIDUE
AND FINE SAND RECOVERY
Residue, especially minerals fouled with oil, col-
lects in the sand traps of petrol stations, wash-
ing plants, sewage works and similar facilities.
SCHAUENBURG MAB equipment separates this
residue into its constituent parts: oil, water and
mineral solids. B&D equipment is used to recover
and treat waste water from processing
substances such as sugar beet, tubers and bulbs,
as well as potatoes and
other vegetables. The
sand which is decontam-
inated and dewatered
in the treatment process
can be recycled. The
treated waste water can
be reused to wash sand.
As a result, minimal fresh
water is required.
POWER PLANT TECHNOLOGY
EQUIPMENT FOR PROCESSING SLAG FROM
DOMESTIC WASTE INCINERATION
With raw materials in increasingly short supply,
the need to recover metals and valuable non-fer-
rous metals from waste becomes ever greater. In
response to this rise in demand, SCHAUENBURG
MAB has developed a patented process for treat-
ing slag from domestic waste. This enables iron,
copper and aluminium to be recovered from
slag in particle sizes which were previously im-
possible to process. The treated products can
then enter the economic cycle as raw ma-
terials. After treatment, the residual slag meets
high environmental standards and can therefore
be salvaged and reused far more effectively.
EQUIPMENT FOR
DEWATERING HARD AND
BROWN COAL ASH
In coal-fired power sta-
tions, the hot ash from the
combustion chambers of
hard or brown coal-fired
boilers is often quenched
with water in wet scrub-
bers. The quenched ash
has a high surface wa-
ter content, which often
results in problems with
further transport or stor-
age. This can be resolved
by using dewatering equipment, which signifi-
cantly reduces the residual moisture in combus-
tion chamber ash. If the combustion chamber
ash is to be processed further into a marketable
product, it must meet special quality standards.
These relate in particular to the unburned coal
content or the residue from refuse-derived fuels.
Our patented processing technique in the Hydro-
sort® upgrades the quality of the waste materials
to the required standard. This equipment is easy
to use and low wear, and allows contaminants,
unburned carbon fractions and heavy metals to
be separated in an extremely efficient manner.
ENVIRONMENTAL AND POWER PLANT TECHNOLOGY
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PROCESSING OF SAND AND GRAVEL
Sand and gravel are valuable raw materials. To
make the best use of deposits, equipment must
be tailored to the particular situation and require-
ments. Sand and gravel producers around the
world rely on equipment from B&D. Benefits for
customers include highly accurate end prod-
ucts, minimal sand loss, low water and energy
consumption, user-friendly operation and low
maintenance costs.
In addition to our head office in Rotterdam, we
operate extensive laboratory facilities and a
fixed test bay at our Mülheim site. Various mobile
test plants are available for use on site, and our
development and project departments employ
the latest drawing and design techniques. As a
result, we are perfectly equipped to create the
complete installation, from the draft stage right
through to commissioning.
AUTOMATION
Modern equipment can no longer function with-
out automated control systems. This is why we
offer our customers full automation. Intensive
training sessions familiarise operating staff with
control systems, and we can also monitor and
control equipment online upon request.
EQUIPMENT AND SYSTEMS FOR “SAND ACCORDING
TO RECIPE”
Using our classifiers, it is possible to obtain sands of
consistently high quality – unaffected by variations
in the raw material. "Sand according to recipe"
ensures the deposit is exploited to the full and
produces a constant particle-size distribution. This
results in greater efficiency, thanks to smaller rejected
volumes in sand-lime brick or roof tile production
and other sand processing industries.
IN-LINE BLENDING
In-line blending uses a computerised process to
determine the proportion of different sand frac-
tions to mix directly into the desired sand prod-
uct. This saves the need for costly, inconvenient
storage in silos.
SYSTEMS FOR REMOVING LIGHT-SOLIDS
Our sorting equipment removes light-solids such
as wood or coal from raw materials and consist-
ently delivers the right results. This guarantees
high-quality production of materials such as con-
crete, glass and silica sands. Our components
are retrofitted in numerous existing sand plants.
PROCESSING OF ORES AND MINERALS
Raw-material mining and processing is becoming
increasingly important throughout the world due
to the growing long-term demand for resources.
As one of the leading players in wet mechanical
processing of ores and minerals, SCHAUENBURG
MAB supplies complete systems all over the
world. Examples include a processing plant for
uranium-bearing sands in Namibia and one for
copper ore in the rich soil of the Democratic
Republic of the Congo. Backed by extensive
experience in process engineering, we are a
partner our customers can trust, meeting their
rigorous quality standards and delivering
tailored processes and
reliable on-site
support.
PROCESSING OF SAND, GRAVEL AND MINERALS
ROBOTICS AND AUTOMATION
INSTALLATION, COMMISSIONING AND TESTING
Once manufactured and thoroughly tested,
our automated systems are shipped worldwide.
ASTECH manages the whole delivery and instal-
lation process. We arrange for packing, shipping
and unpacking of the equipment at your prem-
ises. Installation is performed by our experienced
staff and the customer is invited to witness Site
Acceptance Testing (SAT) on completion of in-
stallation.
LIFETIME SUPPORT
To ensure the automated system achieves opti-
mum performance long into the future, we offer
a comprehensive system support service called
REACTS®, providing peace of mind for the life-
time of the system. ASTECH offers a range of
maintenance packages that suit the operation-
al requirements of the customer. We also offer
training courses tailored to both specific systems
and customer needs.
QUALITY-DRIVEN INNOVATION
In recognition of our outstanding achievements,
ASTECH was honoured in 2009 with the Queen’s
Award for Enterprise: Innovation. The Queen’s
Awards for Enterprise are the UK’s most presti-
gious awards for business performance and are
made on the advice of the Prime Minister.
We hold ISO-9001 TickITplus-based accreditation
and have a mature, well-proven quality man-
agement system in place. We are regularly
audited by our assessment body (BSI) as well
as our cl ients
and prospects.
Our quality man-
agement system
incorporates a
PRINCE2-based
approach to
project manage-
ment.
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Whether our client’s business
is cutting-edge R&D
or state-of-the-art
manufacturing, ASTECH
PROJECTS’ customised
automation and robot-
ics solutions play a vital
role in the improvement
of product quality, cost
reduction and workflow
efficiency.
With a strategic focus on regulated markets such as
pharmaceutical, medical-device, chemical, con-
sumer goods, aerospace and automotive sectors,
we have the experience and capability to meet
the toughest quality standards and most demand-
ing user requirements.
CLIENT CONSULTATION
We work closely alongside our customers to de-
fine user requirements and project objectives.
ASTECH develops concepts solutions using the
latest 3D design technologies to help explain
our ideas and solutions. Customer workshops
are undertaken to review and optimise concept
designs. 'Proof of Concept' exercises are often
recommended to mitigate design risk and give
confidence prior to detailed design and manu-
facture of the automated solution.
DESIGN, MANUFACTURE AND TEST
The next key phase of the project life cycle is
detailed design, manufacture and testing. All of
ASTECH’s design, manufacturing, software de-
velopment and testing activities are undertaken
at our specialist facility in Cheshire, UK, and carried
out by dedicated groups specialising in laboratory
and industrial automation.
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We support our customers at every stage of com-
plex assignments, calling on extensive expertise
in project management and fabrication, and de-
velop and produce top-qual-
ity, tailored solutions. We cre-
ate structural designs, run
strength calculations
and draw up tech-
nical specifications
to domestic and
foreign standards,
such as DIN EN ISO
9001:2008, AD2000
data sheets, ASME
Code, TEMA, Pressure Equip-
ment Directive (PED), EN 13445
and MLO China.
EXPERTISE AND LATEST TECHNOLOGY
We have an extensive range of machinery avail-
able for forming and processing materials. Our
workshops, mechanical facilities and our site are
ideally designed for manufacturing and trans-
porting items of equipment of all sizes. With a
92-metre long workshop and 9-metre crane hook
clearance, components weighing
up to 30 tonnes are easily trans-
portable. Our welding equip-
ment makes use of the lat-
est techniques for welding
high-quality materials. And, backed by various
approvals and certificates, we are authorised to
conduct procedure tests on the materials and
combinations of materials we process.
FROM INDIVIDUAL COMPONENTS TO COMPLETE
SYSTEMS
With an excellent track record in all sectors of
the chemical industry, SCHILLER is a renowned
specialist that provides tailored solutions for
process equipment manufacture. Our team of
experienced designers, engineers and highly
qualified fabrication experts has extensive
knowledge of processing stainless, acid and
heat-resistant high-grade steels, nickel, cupro-
nickel and aluminium, as well as nickel alloys
such as Monel, Inconel and Hastelloy. Further-
more, we have acquired an outstanding repu-
tation for processing special materials such as
titanium, tantalum and zirconium. Employing
the latest equipment and production methods,
we develop and manufacture products such
as heat exchangers, vessels, columns, reactors,
tube systems, equipment components, internals
and special designs.
TOP-QUALITY, CUSTOMISED SOLUTIONS
Whether finding a solution for a specific problem
or managing an entire project, our international
clients trust our expert advice, professional project
management and comprehensive documentation.
PROCESS EQUIPMENT MANUFACTURE AND SPECIAL DESIGN