Harsco Metals: Slag Processing

By efficiently screening and removing metal rebars and oversized contaminants, Harsco minimizes conveyor belt damage, reduces downtime, and repurposes slag into valuable materials for construction and road applications.
Case study

Harsco Metals: Slag Processing with ALLU

Laverton, Melbourne, Australia

Material Slag with embedded metal rebars and oversized contaminants

Industry Construction, Waste material handling

Application Slag processing and material screening

Function Screening slag, separating contaminants

Model ALLU DN 2-12, ALLU DH 3-17 with X75 drums

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.

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.

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BonnyView and ALLU the perfect partners

See how BonnyView Quarries in NSW improves efficiency and reduces costs with ALLU DH4-23 XHD25 screening buckets for soil stabilization and material processing.
Case study

BonnyView and ALLU the perfect partners

NSW, Australia

Material Topsoil, blacktop, dirt, excavated and waste soil, clay, peat, bark

Industry Construction, Mining, Quarrying

Application Mining, quarrying, material processing

Function Screening, crushing, mixing, separating and loading materials

Model DH4-23 XHD25

BonnyView and  ALLU the perfect partners

When mine and quarrying veteran Len Hardy decided he needed two “big” new buckets for his of Bonnyview Quarries business in NSW, he knew exactly what brand he wanted and where to turn to when he wanted to buy them.

Having used a number of smaller ALLU buckets on his excavators over the years, Len had his eyes on a pair of ALLU DH4-23 XHD25 screening buckets to take on the bigger jobs and provide additional versatility to his operation, which supplies customers right across NSW.

Built by Finnish private limited company ALLU Finland Oy, the ALLU screen crushers are highly versatile and the ideal tool for creating material such as road base and building materials.

According to Len, they are the perfect fit for his business.

“They are the best constructed buckets for the applications we use them for. They are really well engineered and provide a very reliable performance,” he said.

“The two new buckets we acquired are performing really well and we couldn’t be happier.”

Len is just as high in his praise for local ALLU support distributors in Australia, with whom he has had a lengthy relationship.

“RDW group are a very, very, good company to deal with. They are great suppliers and will always come up with what you want,” he recently told Australian Mining Review.

RDW group has been the Australian importer and distributor for ALLU for around four years. distributing the product through a nation wide network, servicing major infrastructure projects including water and gas , however, the versatile ALLU system is quickly making inroads with civil and composting contractors.

Sales Area Manager in Rockbreakers Queensland, Craig Einam, said ALLU bucket applications and  installations continue to grow and develop each year.

The versatility  of the buckets to be fitted to 5T – 80T excavators and larger style loaders makes them particular popular with quarry operators like Len, while the smaller buckets are also effective on skid steer loaders.

About the ALLU Screener Crusher

With the ALLU Screener Crushers you can screen, crush, pulverise, aerate, blend, mix, separate, feed and load materials all in one stage.

The versatile accessory can process many types of material such as topsoil, black top and dirt, excavated and waste soil, contaminated soil, clay, peat, bark, compost, biowaste, demolition waste, construction waste, milled asphalt, glass, coal, oil shale, limestone and several other materials.

The versatility of the highly efficient ALLU screening buckets can also mean big savings for their users as they no longer need to bring both a wheel loader/excavator and a crusher on site. Instead, this is a bucket which screens, crushes, pulverises, aerates, blends, mixes, separates, feeds and loads materials.

ALLU has the widest range of screening buckets and screener light crushers on the market. The units fit for almost any base machine size starting from the most compact ALLU DL Series to the massive ALLU M Series that will fit up to 160 tonnes excavator.

The DH4-23 XHD25 screening buckets are part of the impressive ALLU Transformers range which are purpose built for efficient material processing by reducing the number of process steps needed and transforming waste into useable material.

With the ALLU Screener Crushers you can screen, crush, pulverise, aerate, blend, mix, separate, feed and load materials all in one stage.

Mining applications

Efficient material flow is a key issue in any mining operation, power plant, bulk harbour and bulk material or storage area.

ALLU Transformer Screener Buckets mounted on an excavator improve efficiency in material processing due to work speed and reach which results in almost double the processing capacity compared to a slow-moving wheel loader as a carrier.

With ALLU’s Screener technology, existing loaders and excavators can be converted into effective processing, sorting and screening equipment due to the ALLU Transformers ability to deliver a one-step screening and loading solution capable of handling all materials from wet soils to coal and softer rock materials.

This helps improve efficiencies through less chute blockages and also reduces the need for buffer storage areas and transportation of material heaps that are clogged due to moisture or contamination.

When looking at a project with a holistic approach given multiple equipment mobilisations, fuel costs and cost to process in low margin return Ore reclaiming projects etc.

ALLU Case studies have shown between $1.50-$2.50 per tonne savings in running costs in comparison to multiple unit processing configurations.

The ALLU Transformer M series of buckets for mining applications suit 50 to 160 tonne excavators and 30-90 tonne wheel loaders. To meet the specific needs of each application – a range of blade and drum sizes are available to provide fragment sizes of 50, 75, 100 and 150mm.

Dealer Network Servicing the country.

All the ALLU distributors are well known across Australia as suppliers of an extensive range of leading European and Australian manufactured excavator and skid steer attachments, such as those from ALLU.

They have a strong focus on ensuring the  customers are using the right attachment for the task – ensuring it is not only safer, but also helps reduces downtime, lower operating and lifetime ownership costs and – most importantly – helps them reduce the cost per tonne of material moved.

When a full turn-key solution, integration or varied application for equipment is required,  the network have it covered,  engineering and project management resources have proven record of delivering innovative, high-quality and cost-effective solutions to optimise your operations.

Australian ALLU dealer network:

QLD Rockbreakers in QLD and NT:

rdw.com.au/qld-rock-breakers

Walkers Hammers in VIC:

walkershammers.com.au

Total Rockbreaking Solutions in WA:

totalrockbreaking.com.au

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Case study

Making construction recycling easy

France

Material Construction waste

Industry Construction, Waste material handling

Application Construction and Demolition

Function Construction and Demolition

Model ALLU D-Series

Problem

Having to transport waste from a construction site to a waste center. This increases costs due to transportation and material purchases.

Solution

ALLU Screening Bucket is an ideal choice whenever you need to screen, crush, mix, separate, sort, pulverize, or load these materials to the desired fragment size. Reducing the waste to smaller or more uniform fragment sizes makes it easier and faster to reuse them. The debris that is generated in construction and demolition sites is bulky and heavy to handle, traditionally increasing your transportation costs and double handling operational costs. ALLU takes these issues away, increasing your operational efficiency. The ALLU recycling bucket sorts materials from actual waste. Doing this lowers the transportation and landfill costs, increasing your efficiency and productivity at the work site along with your sustainability credentials. Helping you to increase your sustainability ALLU enables you to recycle construction and demolition debris in an environmental way. Turning waste material into profit by producing aggregates and reusable materials such as bricks, concrete, metals, wood, cardboard, and bitumen. Bringing your waste to life!

Benefit

Increased the sustainability of the business, reducing costs and time yet increasing the business profits and efficiency.

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