up to 95%
water recovery
Quarries & Aggregates
dewatering and
waste-volume reduction
energy-efficient
process management
Wash-water and sludge treatment plants for the quarrying sector
From clarification to filter-press dewatering, from chemical conditioning to process automation, Tecnoidea designs and builds complete wash-water and sludge treatment plants for the Quarries & Aggregates sector, with 45 years of experience in Italy and abroad.
Conventional sludge management
In crushing plants, production continuity often depends on how the resulting sludge is managed.
Conventional natural settling in open-air ponds creates logistical and regulatory difficulties, as well as plant downtime that can significantly affect production continuity.
All our solutions for treating aggregate wash water and sludge, from clarification to the filter press, are built on a deep knowledge of quarry dynamics and processes, where effective water management is critical to operational continuity and regulatory compliance.
The Tecnoidea solution
The wash-water and sludge treatment process for water recovery
Clarification and flocculation
After a thorough laboratory analysis of the material to be treated, we identify the most suitable flocculant and, where required, coagulant to destabilise the electrostatic charge of the suspended silts and clays, promoting the formation of larger, denser flocs that settle rapidly to the bottom of the clarifier.
Sludge settling and automated discharge
Our clarifiers can be equipped with the LEM sludge-level monitoring system, which detects changes in sludge density to identify the sludge–water interface and automates sludge discharge. This is the first step in the “Top-Down” management of the process: the sludge is discharged only when needed, avoiding unnecessary empty filter-press cycles and the associated energy consumption. The clarified water overflows at the surface, ready to be reused in the washing process.
Automated chemical dosing
Our SADF systems (automatic flocculant dosing) continuously monitor water clarity and automatically adjust flocculant dosing according to process conditions, helping reduce reagent consumption.
Filter-press dewatering
The discharged sludge is pumped to the filter press. Here, mechanical pressure separates the liquid fraction, producing spadeable cakes with a residual moisture content of around 30%.
Clarified-water recirculation
The recovered water is stored and then returned to the washing plant, reducing the need for make-up water.
Machines, plants and technologies for wash-water and sludge treatment in the Quarries & Aggregates sector
From a single machine to a complete turnkey plant, including complex revamping projects.
Every project, down to the simplest component, is engineered and sized to the operating conditions of your quarry process.
Overhead-beam filter press
The Tecnoidea overhead-beam filter press is designed for mechanical sludge dewatering in high-output applications. It separates the water from the...
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Sidebar filter press
Designed for the mechanical dewatering of sludge in standard and medium-output applications (with a capacity of up to around 3.3...
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Chiarificatore statico verticale
Il chiarificatore statico verticale è la tecnologia di riferimento privilegiata da Tecnoidea per separare i solidi sospesi dall’acqua di lavaggio....
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SADF – Sistema Automatico Dosaggio Flocculante
Il SADF è la tecnologia sviluppata da Tecnoidea per regolare in maniera automatizzata e in tempo reale il dosaggio del...
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LEM – Misuratore livello fango
LEM è il sistema di controllo progettato da Tecnoidea per rilevare la presenza di fango all’interno del chiarificatore statico verticale....
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Vasca fanghi
La vasca di stoccaggio fanghi progettata da Tecnoidea è un’unità di processo dinamica, concepita per ricevere il fango addensato in...
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Dynamic clarifier
Intro: The dynamic clarifier is Tecnoidea’s clarification solution for flow rates above 800–1,000 m³/h, and for sites where vertical development...
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Three-chamber flocculant unit
The three-chamber flocculant unit is Tecnoidea’s solution for preparing and dosing flocculant in plants with flow rates above 100 m³/h....
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Contact usWhy choose Tecnoidea Impianti’s solutions and technologies
Specialist expertise
Since 1981 we have specialised in aggregate wash-water and sludge treatment plants. We operate an in-house analysis laboratory and offer a complete range of products (clarifiers, pumps, overhead-beam filter presses, sidebar filter presses, chemical dosing plants and units), process automation systems (LEM, SADF) and complete plant solutions — the result of 45 years of specialist experience in the sector.
Process engineering
Our engineering team develops complete solutions tailored to the plant’s process requirements. From turnkey plants to complex revamping projects, we deliver solutions designed for high productivity and process efficiency.
Service and after-sales
Extensive spare-parts availability, scheduled maintenance, remote support and rapid-response service. Our service is structured to support operational continuity and reduce unplanned downtime.
45
Years of experience in aggregate wash-water and sludge treatment
890
Water and sludge management plantsdesigned and installed in the quarrying sector
4.0
Industry 4.0 plantswith integrated sensing and connectivity technologies
References
Tecnoidea Impianti's solutions for Gruppo Gatti S.p.A.
ItalySector Construction and Demolition
Material treated Natural aggregates
Gruppo Gatti S.p.A.
Closed-loop water management and digitalisation in quarry operations
Read the case study
Germany
Sector Quarries & Aggregates
Material treated Natural aggregates
HEIM Gruppe
Efficiency and Sustainability in Aggregate Processing: The Turnkey Solution for HEIM-Gruppe
Read the case study
Italy
Sector Quarries & Aggregates
Material treated Natural aggregates
Cava Nord
Water clarification and sludge treatment plant supporting closed-loop water recovery and site restoration.
Read the case study
Czech Republic
Sector Quarries & Aggregates
Material treated Limestone
Vápenka Vitosov
Water and sludge treatment plant for aggregate washing under harsh climatic conditions and continuous operation.
Read the case study
Czech Republic
Sector Quarries & Aggregates
Material treated Natural aggregates
Eurovia
Wash-water and sludge treatment plant for the Czech Republic's largest quarry.
Read the case study
Belgium
Sector Quarries & Aggregates
Material treated Limestone
Carrière de Leffe (Holcim Belgium)
Integration of a sludge-dewatering system to replace natural drying, reduce freshwater demand and support closed-loop water management in a protected...
Read the case study
France
Sector Quarries & Aggregates
Material treated Natural aggregates
Carrière de Vignats
Integration of a sludge-treatment line into an existing aggregate-washing water-treatment plant.
Read the case study
Italy
Sector Quarries & Aggregates
Material treated Natural aggregates
Beton Lana
Plant integration and upgrade within a limited footprint.
Read the case study
Germany
Sector Quarries & Aggregates
Material treated Natural aggregates
Steinwerke Anton Eireiner GmbH
New water clarification and sludge treatment plant.
Read the case study
Swiss
Sector Quarries & Aggregates
Material treated Natural aggregates
Catellani S.A.
Compact water and sludge treatment plant for confined spaces
Read the case study
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