Hawaiian Cement, the largest concrete producer in Hawaii, faced challenges in producing sufficient sand fractions from existing operations. Partnering with Miller Machinery, a Metso distributor, they successfully turned non-saleable inventory into manufactured sand.
Company Overview
Hawaiian Cement is a vertically integrated construction material company supplying cement, aggregate, and ready-mix concrete. It operates two central-mix plants and the Halawa Valley Operations quarry, producing aggregates for concrete mixes.
Challenges and Solutions
Due to depleted natural sand resources, Hawaiian Cement had to manufacture sand from native deposits or import it, leading to high costs. The production process generated unusable byproducts, adding to expenses.
“We have been looking for a good solution to re-process the waste material for years. With Metso’s HRC8, we were able to decrease the amount of imported sand from 50% to 25%,” said Jonathan Esperanza, General Manager, Hawaiian Cement.
Technological Innovation
After extensive research, Hawaiian Cement adopted the HRC™ Series high-pressure grinding rolls (HPGR). This technology, proven in mining and gaining traction in aggregates, consumes up to 50% less power and efficiently converts waste into manufactured sand.
Miller Machinery acquired an HRC8 crusher, mounted it on a portable chassis, and transported it to Hawaii. This innovative setup addressed the challenge of processing wet materials, where traditional crushers failed.
Operational Success
The HRC8’s unique crushing action eliminated issues like packing and excessive wear, ensuring consistent output and reduced maintenance costs. The quiet operation and minimal dust emissions had no impact on operational safety.
“HRC8 crusher is an ideal solution for this case where the feed material is wet. It has a consistent output volume, low variability in reduction ratio, and less wear compared to typical VSI crushers, leading to lower maintenance costs,” said Michael Miller, President, Miller Machinery.
This collaboration resulted in significant operational and financial success, setting a new industry standard.
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This news and cover image is sourced from www.metso.com.
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