Around 7:20pm on 30th March at the Port of Bilbao, the first finished product of the new Biscay Eco Aggregates (BEA) plant made its way off the first processing line and up the final conveyor, heading towards the storage bays. This moment represented a key milestone for Don Valley Engineering as the target set by the client, to have the facility producing product by 31st, had been achieved with a day to spare. All that remained was to complete the second line and hand over the plant.
By 7th May commissioning was complete. On time, on budget and ready to start producing up to 125,000 tonnes of Eco Aggregate annually.
Don Valley Engineering Ltd (DVE) are delighted to announce the successful completion of their first major overseas engineering project.
Formed by a joint venture of Don Valley’s existing client O.C.O Technology Ltd and Petronor S.A, Biscay Eco Aggregates’ mission was to create continental Europe’s first mineralisation plant utilising O.C.O’s pioneering Accelerated Carbonation Technology to transform thermal residues into sustainable aggregates while capturing CO₂ during the production process.
Based on the success of Don Valley’s continued collaboration with O.C.O and their UK based facilities, BEA awarded DVE with the Mechanical & Electrical engineering package for the main process and bulk handling equipment.
Despite DVE’s prior knowledge of the process and the equipment required, working in a post Brexit Europe brought a whole new set of challenges. From securing the correct visas and work permits to overcoming language barriers while managing European sub-contractors, a number of steep learning curves were successfully navigated during the 20-month operation.
Supported by Don Valley Group companies Don Valley Materials Handling & Don Valley Engineering Construction Ltd, all elements of the project including design, manufacture, international logistics, export & import, site management, health & safety, construction and commissioning assistance were seamlessly brought together by the project management team.
Operations Manager Dan Hobson recalls the first visit to the project site with the BEA team in July 2024.
“It was an empty plot sandwiched between two existing, unrelated processing facilities, right out in the port next to the sea wall. Piles of aggregate were strategically placed over the area, pre-loading the ground ready for civil works, but that’s all that was there.
It’s always amazing to see projects transform from the ground up, ending in what we see now. Being on site to witness the first material being produced gives an enormous sense of pride and achievement, one I know is shared by the whole Don Valley team”.
The plant drew on the strengths and experience of the Don Valley Group and its trusted subcontractors and comprised:
- Material storage in several 125m³ silos and purpose designed bunkers.
- Various conveying methods including belts, screws & pneumatic.
- Process recipe control and batch weighing.
- 950m² footprint portal frame process building.
- Full plant automation control and software development.
- Low voltage distribution, motor control, local control and remote I/O panel build.
- Mechanical & electrical installation and commissioning support.
- Site health & safety management of 30+ operatives of different disciplines and nationalities.
The journey from conception to commissioning culminated in an invitation for Don Valley to attend the grand inauguration event on the 21st May. The event saw CEOs of the parent companies, members of the Basque government and esteemed guests from industry gather to celebrate the achievement and to promote the benefits of this groundbreaking technology to wider Europe and the world.
On returning from the event, Don Valley Engineering Managing Director Lee Ashurst was full of praise for his team.
“Being able to attend such a high-profile event with the audience it generated and watching all those people admiring the facility, its nice to stand back and think “we did that”. I’ve seen the challenges first hand and witnessed the hard work to overcome them. It really showcases the abilities of our company and the direction we are heading”.
O.C.O Technology CEO Steve Greig was also kind enough to offer comment on the contribution of Don Valley to the overall success of the project:
“Following multiple successful collaborations with our UK business, Don Valley was the obvious choice as the M&E contractor for our new venture and it proved to be the right decision. The quality we have come to expect from DVE was evident throughout and my thanks go to all involved.”
