Hanson Aggregates – Perch Hill Plant
- Owner: Hanson Aggregates
- Project: Fractionated Aggregates Plant
- Location: Bridgeport, Texas
- Scope: Engineering, Procurement, Construction and Commissioning
Project Background
Hanson Aggregates’ Central Division has engaged the Salt Lake City Office of Roberts & Schaefer Company (R&S) to provide detailed design, procurement, construction, and commissioning of a 7 MTPY fractionated aggregate operation in Bridgeport, Texas.
The new Perch Hill plant, which includes primary crushing, processing, and shipping operations, has been a collaborative TEAM effort by Hanson and R&S. The best available technology in process equipment, layout, chute work, and automation has been utilized, including ”virtual walkthrough reviews” using 3D modeling, to attain the highest possible availability, efficiency, product quality and customer service.
The ultimate goal for the new plant is a utilization factor above 90% for the secondary plant, 80% for the primary plant, and minimization of previously high waste factors.
Replacing the existing Hanson facility in the area, this plant will also promote faster loading, improved reliability, and lower operating costs.
The plant includes the following major equipment:
- McLanahan Primary Sizer, Scrubbers, and Log Washers to handle intermittent clay problems, while reducing fines generation.
- Sandvik Secondary and Tertiary Cone Crushing.
- Texas Crusher Systems, Inc. VSIs for Quaternary Crushing.
- McLanahan Sand Classifiers.
- LPT Dewatering Screens, Separators and Thickener for high efficiency recoveries.
- Tabor Sizing Screens throughout.
Additional highlights of the new plant include:
- High Capacity Rail Loading capable of shipping 200 cars in a single shift.
- High Capacity Truck Shipping will enable truckers to be automatically recognized, loaded and ticketed by the system, without typical interaction with plant personnel.
This speeds the configuration, positioning, and accurate receipt of rock (gate–to–gate times), while leaving one–on–one customer service to be more appropriately focused on those customers needing assistance.
Orders and shipping setup will be available through every channel of communications, including Internet configuration by the customer. Complete Process Control and Automation, with open data access by plant management and operators.
This new super–plant is designed to minimize wear in all locations, and maximize the flow of material on all processing equipment...a major element of increased efficiency.