H1: CEMarked Sand & Gravel Washing and Classification Plants: Engineered for Uninterrupted Production and Specification Compliance

1. فتحة مدفوعة بنقطة الألم

Managing a sand and gravel operation means contending with persistent challenges that directly erode profitability. مادة تغذية غير متجانسة, اللوائح البيئية الصارمة, and the relentless demand for higherquality aggregates create significant pressure. هل تواجه:
Product Specification Failures: Inconsistent silt content or improper particle size distribution leading to rejected loads, شكاوى العملاء, وإعادة المعالجة المكلفة.
الماء الزائد & استهلاك الطاقة: Inefficient washing cycles and outdated pump systems that inflate operational costs and complicate water recycling efforts.
ارتفاع فترات توقف الصيانة: فشل تحمل متكرر, screen cloth replacements, and pump blockages in abrasive environments, causing unscheduled production halts.
مخاطر الامتثال البيئي: Inability to effectively manage siltladen process water, risking permit violations and site closure.
عملية كثيفة العمالة: Reliance on manual adjustment and monitoring to maintain product grade, leading to variability and increased labor costs.

A CEmarked sand gravel washing plant is not just equipment; it is a controlled processing system designed to systematically address these issues.

2. نظرة عامة على المنتج

A CEmarked sand gravel washing plant is an integrated material processing system designed to liberate, تصنيف, dewater, and clarify aggregates to meet precise commercial specifications. The CE marking signifies compliance with EU health, أمان, والتوجيهات البيئية, ensuring a baseline of operational safety and environmental consideration.

سير العمل التشغيلي:
1. يٌطعم & الفرك: Raw feed is introduced into a log washer or scrubbing barrel to break down claybound aggregates and dissolve contaminants.
2. تصنيف الحجم: Material is screened via vibrating decks or hydrosizers to separate coarse gravel from sand fractions (على سبيل المثال, خشن, أسمنت, plaster sand).
3. إزالة الغرامات & غسل: Sand fractions are routed through cyclones or screw classifiers to remove silt and ultrafine particles while being cleansed of soluble salts.
4. نزح المياه & التخزين: Washed sand is dewatered on fine material screens or in a dewatering tower to achieve a handleable, stackable product with optimal moisture content.
5. إدارة المياه: Siltladen process water is sent to a clarifier or thickener for solids settlement, allowing clean water to be recirculated.

نطاق التطبيق & القيود:
نِطَاق: مثالية للرواسب الغرينية, crushed rock quarries producing concrete/plaster sands, and construction/demolition waste recycling. Effective on materials with up to 30% silt/clay content.
القيود: Not suitable for dry processing applications. Feed size is typically limited by the scrubber inlet (غالباً <150مم). Highly cemented or conglomerate materials may require primary crushing upstream.

3. الميزات الأساسية

Patented Cyclone Cluster | الأساس الفني: HighG force centrifugal separation | المنفعة التشغيلية: Consistent removal of ultrafines (down to 63µm) regardless of feed rate fluctuation | تأثير عائد الاستثمار: Guarantees product silt content compliance (<3%), eliminating load rejections.

Modular BridgeBox Construction | الأساس الفني: تم تصميمه مسبقًا, bolted structural framework | المنفعة التشغيلية: Reduced site installation time by up to 40% versus weldedsite builds | تأثير عائد الاستثمار: Lower capital installation costs and faster commissioning for revenue generation.

محرك التردد المتغير (VFD) Pump Control | الأساس الفني: Precise electric motor speed control for slurry pumps | المنفعة التشغيلية: Operators match pump output exactly to feed rate; reduces cavitation and wear | تأثير عائد الاستثمار: تظهر البيانات الميدانية 2230% reduction in energy consumption versus fixedspeed pumps.

نظام بطانة مقاوم للتآكل | الأساس الفني: Interchangeable urethane/ceramic liners in highwear zones (مغاسل, الأعاصير) | المنفعة التشغيلية: Liner life extended 3x over standard steel plates; quickchange design | تأثير عائد الاستثمار: Lowers spare parts inventory cost and reduces downtime for liner replacement by over 50%.

Integrated Process Water Clarifier | الأساس الفني: Lamella plate settling technology with flocculant dosing system | المنفعة التشغيلية: يتعافى >95% من المياه العملية; تنتج كعكة مرشح قابلة للتكديس لسهولة التخلص منها | تأثير عائد الاستثمار: Drastically reduces freshwater intake costs and ensures continuous operation under strict environmental permits.

نظام تشحيم الشحوم المركزي | الأساس الفني: Automated delivery of lubricant to all critical bearings | المنفعة التشغيلية: Ensures bearings in hardtoreach locations are serviced without operator intervention | تأثير عائد الاستثمار: يوضح اختبار الصناعة أ 60% reduction in bearingrelated failures in abrasive wash plant environments.

4. المزايا التنافسية

| مقياس الأداء | الحل القياسي للصناعة | CEMarked Sand Gravel Plant Solution | ميزة (% تحسين) |
| : | : | : | : |
| استهلاك محدد للمياه (متر مكعب / طن) | 1.5 2.0 m³/tonne recirculated + ماء المكياج

|
| اتساق المنتج (Silt Content Variation) |
| تثبيت & وقت التشغيل |
| التكلفة الإجمالية للملكية (5Year Period) |

5. المواصفات الفنية

نطاق السعة: نماذج من 50 طن في الساعة (الهيدروكربونات النفطية في الساعة) ل 400+ إنتاجية الهيدروكربونات النفطية.
متطلبات الطاقة: إجمالي الحمل المتصل من 75 كيلوواط (for compact units) ل 450 كيلوواط (for full wash plants with clarifiers), typically requiring a 400V / 50إمدادات هرتز.
مواصفات المواد: الهيكل الأساسي: الفولاذ S355JR. مكونات عالية التآكل: AR400 steel plate or NiHard cast iron. بطانات: Customformulated polyurethane or ceramic composite.
الأبعاد المادية (مثال 150 مصنع الهيدروكربونات النفطية): تقريبا. طول: 25م; عرض: 8م; ارتفاع: 7م (باستثناء قادوس التغذية). وزن: ~45 tonnes.
نطاق التشغيل البيئي: Designed for ambient temperatures from 20°C to +45°C with appropriate lubrication specs. Dust encapsulation standard on conveyors; noise emissions below 85 ديسيبل(أ) في محطات المشغل.

6. سيناريوهات التطبيق

Concrete Aggregate Producer Challenge Solution Results

Recycled Aggregates Facility Challenge Solution Results

7. الاعتبارات التجارية

CEmarked sand gravel plants are offered in scalable configurations aligned with production needs:

طبقات التسعير:

Basic Washing Unit: Includes scrubber screen combination unit
Standard Classification Plant: Incorporates log washer
Full Wash & Water Recycling Plant: Complete system with clarifier

الميزات الاختيارية: Mobile wheelmounted chassis
Remote monitoring PLC package with data logging
Automatic flocculant dosing system
Additional dewatering screens for specialized sands

حزم الخدمة:
1year comprehensive warranty including parts/labor
5year structural warranty
Annual inspection service contract

خيارات التمويل:
Equipment leasing plans
Project financing solutions

8 التعليمات

Q What upstream equipment is required?
A A CE marked plant requires pre sized feed material Typically this means pairing it with a primary crusher screen combination unit

Q How does the CE marking impact my site operations?
A The marking provides documented assurance that the equipment meets essential EU safety EMC machinery directives It simplifies insurance approvals demonstrates due diligence supports permit applications

Q What is the typical payback period?
A Based on client data replacing an inefficient legacy system payback periods range from months depending on local aggregate pricing reduced waste lower water costs

Q Can the plant be modified after installation?
A Yes The modular design allows for capacity upgrades addition of extra classification decks integration of new water treatment technologies as your business evolves

س هل تقدمون تدريبًا للمشغلين؟?
A Comprehensive training is included covering startup/shutdown procedures routine maintenance troubleshooting classification adjustment ensuring your team achieves optimal performance quickly