The hybrid plant, which integrates both wet and dry processes, is already delivering dramatic improvements to waste recovery rates in the Brisbane metropolitan area and capturing high-value construction materials that would have otherwise been destined for landfill.
Washing experts CDE, who designed and engineered the wet processing solution that integrates with the Turmec-supplied dry processing system, say the groundbreaking plant will make important contributions to SEQ over the coming years.
CDE Australasia general manager Daniel Webber commented: "South East Queensland is in the early stages of a very significant investment period. Over the next two decades, we're going to see a real uptick in construction to support the development of major infrastructure and large-scale capital projects. The SEQ City Deal is creating a more connected, prosperous and sustainable South East Queensland region and this plant will be one of the primary supply lines to help deliver on those aims in an economic and environmentally sustainable way."
The $1.8 billion SEQ City Deal is a long-term collaboration between the three levels of government – the Australian Government, Queensland Government and the Council of Mayors SEQ – to deliver 29 commitments aimed at generating long-term benefits for the SEQ region. Currently home to 3.8 million people, the region's population is expected to rise by over 40% by 2041, making it one of the most desirable and fastest-growing in Australia.
Alongside major capital investments to support population growth, such as a new Brisbane Metro station at Woolloongabba, other key areas of investment in the SEQ City Deal include resource recovery infrastructure.
"Rino Recycling is ahead of the curve in this respect. This plant is really leading the charge towards a circular economy and flying the flag for C&D waste as a viable alternative to virgin quarried materials," Weber added.
Rino Recycling general manager Daniel Blaser said: "We truly believe this plant to be one of SEQ's crown jewels for sustainable construction. It's a beacon of sustainability, not only for this region but for any fast-developing region that recognises economic growth doesn't have to come at the cost of the environment."
Designed to minimise the need for operator intervention, the interconnected system melds CDE's expertise in materials washing with Turmec's experience in dry recyclables to accept a wide range of highly variable waste streams, including commercial skip and bin waste, C&D waste, hydro excavation waste, concrete, and excavated fills.
Linked by a network of conveyors, waste materials transition seamlessly between the wet and dry systems without manual input. First, feed material is processed via Turmec's tried-and-tested dry mixed recyclables plant to separate fines and removes contaminants before passing through CDE's advanced wet processing plant to produce a range of washed and graded recycled sand and aggregate products.
"This really is uncharted territory," Webber said.
"It's the first time two systems of this kind have been brought together in this way, under one roof. It's living proof that wet and dry waste recycling can coincide, and it highlights the power of collaboration because the results are undeniable."
The fully-automated facility has a maximum processing capacity of 475 tonnes of C&D waste per hour – equivalent to 1.5 million tonnes per year – and while the plant has only been operational for a number of months it is expected to reach full capacity in the next 12-18 months, according to Rino's Daniel Blaser.
"We're currently operating at around 50% of our total capacity, but this is steadily increasing to the point we anticipate reaching full capacity by the end of 2025. A major component of the work we're doing is about educating the industry about the potential of recycled construction materials. We're making a very strong case in favour of recycled sand and aggregate. More and more are adapting and as that increases so too will our capacity to meet that growing demand. We see a greener, cleaner future just over the horizon and are steadfast in our commitment to see it realised."
Webber said the plant has the capacity to turn the tide on waste.
"As a proportion of C&D waste generated, the plant has the capacity to really turn the tide to give resource recovery rates a healthy boost and help accelerate progress towards a circular economy," Webber said.
C&D waste accounts for 38% of all waste generated in Australia and in the year 2020-21 the sector produced 29 million tonnes of waste, according to figures from the Department of Climate Change, Energy, the Environment and Water.
The plant is also helping drive down carbon emissions.
Webber said: "Historically in this region trucks had to travel considerably long distances to access resource recovery facilities. It essentially made waste recycling a cost-prohibitive exercise. This solution and its proximity to Brisbane's Central Business District – the beating heart of many major infrastructure projects – will help reduce the sector's carbon footprint by tackling the waste burden, repurposing materials, and limiting the need to extract new raw materials."
CDE's industry-leading water management and recycling means up to 95% of the water passing through the wash plant is recycled and immediately recirculated for reuse in the system. This is made possible by a closed-circuit configuration of CDE's AquaCycle thickener, holding tanks for recycled water and sludge, and a filter press.
Operating in unison alongside the core processing plant is the addition of CDE's HYDRO:TIP, which handles non-destructive digging (NDD) muds with ease and efficiency. With the HYDRO:TIP, Rino Recycling can process waste mud cost-effectively while recovering recycled materials. Clean water from the vacuum waste is also recovered. This top-up water coupled with that recovered by CDE's water treatment process means the plant is totally water self-sufficient.
"Achieving water neutrality is no small feat, but the benefits both economically and environmentally are huge," Weber said.
"From water permits and environmental assessments to water scarcity and increasing pressure from population growth, insufficient water supply can really drive up operating expenditure. The value of construction materials increase significantly when washed, so a water neutral plant reduces costs and helps produce products that command a premium."
The plant is currently producing a wide variety of high-quality products that rival quarried materials, including washed fine sand and clean, washed aggregates in a range of sizes: 5mm, 10mm, 20mm, and 40/70mm.
CDE's new Australian headquarters, located in Stapylton, just 30 minutes from the Rino Recycling facility, is helping to increase return on investment and plant optimisation.
Pete Neely, CDE's regional CustomCare manager, said: "Throughout install and commissioning, CDE had a local team of install professionals, project managers, technical and electrical experts overseeing the job. That service level continues post-commissioning. Our CustomCare team is providing responsive on-the-ground support and our proximity to the facility means spare parts are available locally with short lead times, all of which is helping reduce downtime, lower shipping costs, and lower operating costs while boosting productivity."
