Kleemann plants prove themselves in tough recycling conditions

ADEC Global is a family-owned company based in Barcelona that processes waste materials from the construction industry and steelworks. Since it was founded in 2010, the company has established itself as a major player in the recycling sector. The company depends on Kleemann expertise for processing highly abrasive slag.

ADEC Global started out by recycling construction waste. Then the opportunity arose to recycle material from steelworks. Today, the company processes an annual volume of about 500,000 tonnes of material, 50 percent of which is black slag contaminated with steel. “We convert waste materials that used to end up in landfills into valuable products”, explains Maria Vazquez, Operations Manager at ADEC Global. At the heart of the processing operation are the impact crusher MOBIREX MR 110 EVO2 and coarse screening plant MOBISCREEN MSS 802 EVO – both of which process slag into aggregates for asphalt. They ensure high quality in road construction and reduce the risk of skidding in wet conditions. The separated iron components are also returned to foundries – achieving 100% recycling!

The MR 110 EVO2 and the MSS 802 EVO are not the only Kleemann plants in the company’s fleet: ADEC Global has a total of eleven Kleemann plants. In addition to recycling, ADEC also offers quarrying services, including the production of various aggregates for the concrete and cement industry using a MOBIREX MR 130 PRO.

Extremely challenging material

“Together with Kleemann and EMSA, our local contacts for Kleemann plants, we have developed an ideal process to tackle this demanding task”, explains Fernando Hernandez, Managing Director and Founding Partner at ADEC Global. “Wear parts were a real challenge: How could the impact bars withstand the abrasive material and achieve a long service life without breaking? How could we make the process safer?” In the end, a solution was found in close collaboration with Kleemann that is economically viable despite the challenging material.

Oscar Hernandez responsible for machinery and logistics in the company. He is especially impressed with the robust design of the plants and parts: “There are very few machines out there that can withstand this extremely abrasive material. The slag contains iron deposits that are broken down during the crushing process. Even then, the Kleemann impact crusher remains steadfast. I don’t know of any other plant that can handle that!”

Impact crusher – the backbone of the machine fleet

“Without this high-performance impact crusher, the entire process wouldn’t work”, summarises Fernando Hernandez. The plant has been in operation at ADEC Global since 2018 and has already logged 10,000 hours of work. It processes feed material measuring up to 200 mm and produces 200 tonnes per hour under optimal conditions. A magnetic separator separates the metal from the slag as the final step. Sophisticated solutions such as the overload system, which reacts immediately to material jamming and protects the crusher, contribute to the smooth and efficient operation of the entire crushing process.

Development of the process hand in hand

The fact that this demanding material can now be processed efficiently and cost-effectively is also due to the excellent teamwork between the employees of ADEC Global responsible for the process and the Kleemann application experts. It was only through this collaboration that a cost-effective solution for achieving high product quality with this difficult material could be found.Maria Vazquez sums it up: “Of course, what counts at the end of the day is a good final product. Cubicity is key for asphalt production. What we’re showing here is that recycling can go hand in hand with high quality standards and outstanding cost-effectiveness.”