Harsco Metals: Slag Processing

Harsco Metals and ALLU – A Partnership for Operational Excellence

Harsco Environmental is a global leader in providing sustainable solutions for the steel and metals industries. At its Laverton branch in Melbourne, Australia, the team specializes in slag processing, repurposing industrial byproducts into valuable products like aggregates for the road and civil industries. However, recurring operational challenges threatened efficiency and productivity, prompting the need for an innovative solution.

The Challenge: Conveyor Belt Tearing

At Harsco’s Laverton branch, the conveyor belts were frequently damaged during slag processing. The issue arose from the fact that the slag collected from the caster pit contained metal rebars and other oversized contaminants that were not effectively screened out using the existing equipment. These materials were not properly filtered using a skeletal bucket, leading to sharp items damaging the downstream conveyor belts during transfer to the crushing line. This caused increased downtime due to frequent maintenance, high operational costs from repairs and inefficiencies, as well as safety risks and disruptions in the overall slag processing operations.

Impact:

• Increased downtime due to frequent maintenance.
• High operational costs from repairs and inefficiencies.
• Safety risks and disruptions in slag processing.

The Solution: ALLU Transformer Bucket

Recognizing the need for a more efficient and robust screening solution, Harsco Metals’ maintenance team contacted Walkers Hammers, the ALLU dealer in Melbourne, Victoria.

• Site Study and Demo:
  On 12th April 2024, Sami Rahman, ALLU area sales manager conducted a site study and recommended the ALLU DN 2-12  Transformer bucket with specialized X75 drums. Carlo Costanzo, Walkers Hammers’ service technician, prepared the equipment by fitting a head bracket for a CAT excavator.
• Key Stakeholders at the Demo:
  The demo was attended by General Manager Andrew Hayes, site supervisor Nazz, and Dan from the maintenance team. The ALLU bucket demonstrated its ability to screen slag efficiently, removing metal rebars and oversized contaminants while protecting downstream equipment.
• Extended Testing:
  Impressed by the demo, Harsco Metals rented the ALLU DN 2-12 bucket for two weeks to test it with their operators across multiple shifts. This ensured operator familiarity and confidence in the equipment’s performance.

The Result: Quick Decision and Seamless Delivery

At the conclusion of the rental period, Walkers Hammers presented a sales offer tailored to Harsco’s needs.

Bucket Selection:
Considering the continuous-duty operation and need for a robust solution, the ALLU DH 3-17 with X75 drums was proposed.

• Features:
  • Two hydraulic motors for enhanced torque.
  • Heavy-duty frame for durability in demanding conditions.
  • X drums with Changeable blades  to easily replace when they wear out

Approval and Delivery:
Harsco’s management swiftly approved the purchase, thanks to the proven performance during trials and Walkers Hammers’ prompt service. The equipment was ordered and delivered in July 2024, ensuring minimal disruption to operations.

Conclusion: A Partnership for Productivity

The collaboration between Harsco Metals and Walkers Hammers highlights the value of effective problem-solving and reliable dealer support. The ALLU DH 3-17 bucket not only resolved a critical challenge but also set new standards for efficiency, productivity, and sustainability in the metals recycling industry.

With ALLU’s robust solution and the dealer network’s readiness, Harsco Metals reinforced its commitment to operational excellence and sustainable processing—setting a benchmark for efficiency in the metals recycling industry.

Timeline:

• April 2024: Problem identified and demo conducted.
• April–May 2024: Two-week rental period for extended testing.
• July 2024: Delivery and implementation of the ALLU DH 3-17 bucket.

Related products

Screening Bucket – D-Series

Carriers 6 – 45 t

Versatile DN-, DS- and DH-Series Screening Buckets serve in a wide range of applications ensuring high-quality material processing on-site.

Explore

Other case studies