Monday, 15 June 2015 11:16

£4m plant to create aggregate from energy-from-waste furnace residues

A patented technique of making construction aggregates from the residues of energy from waste has been given a boost as construction begins on an Avonmouth plant.

avonmouth plant1Carbon8 Aggregates' £4 million new manufacturing facility near Bristol is scheduled to produce secondary aggregates later this year.

High demand from the Energy from Waste (EfW) industry means more than 75% of the plant's future capacity has already been contracted and the Carbon8 team is currently in advanced negotiations for the remaining available space.

The company uses an award-winning patented technique, known as Accelerated Carbonation Technology (ACT), to process residues from thermal processes in EfW facilities, producing lightweight secondary aggregates for the construction industry.

Carbon8 managing director, Steve Greig, said: "Construction work is on schedule and we expect aggregate production to begin in November, which will more than double our ability to serve both EfW customers and the construction industry.

"The benefits of our facility are two-fold. Firstly, it gives EfW operators an alternative to disposing of flue gas residues into landfill and secondly, the aggregate provides a sustainable and cost effective alternative to natural aggregates at a time when demand from the building industry is outstripping supply.

At least 20 new jobs will be created at the three-acre Avonmouth site in Hallen, overlooking the Severn Estuary and just over 12 miles from the centre of Bristol.

Because the manufacturing process is able to permanently capture more carbon dioxide than is generated during manufacture, it means the product – known as Carbon8 Aggregate  – is described as a truly carbon negative aggregate.

Once fully operational, the new plant will permanently capture nearly 2,000 tonnes of CO2 a year – equivalent to planting 200,000 trees.

Built to complement Carbon8's existing facility at Brandon in Suffolk, the new development has been designed to be as environmentally-friendly as possible. All the manufacturing processes are contained within the new building to minimise impact on the immediate surroundings, while efficiency measures including the harvesting of rainwater and zero emissions.

The development includes silo storage for incoming incinerator residues, storage for associated fillers and binders, a new building to house the processing equipment, and covered storage bays for the aggregate.

Initial civil engineering works are being carried out by Churngold Construction, while Worksop-based Wrights Engineering, which built the Brandon facility, is responsible for the design, manufacture, installation and commissioning of the process equipment.

Among its many uses, C8A can be used in the manufacture of lightweight concrete masonry blocks, and other pre-cast concrete applications, such as architectural and ornamental products; as well as in ready-mix concrete and lightweight screed systems, reducing both weight and carbon footprint.

Carbon8 Aggregates
Churngold Construction
Wrights Engineering