1. فتحة مدفوعة بنقطة الألم

تؤدي التكاليف التشغيلية المتصاعدة ووقت التوقف عن العمل غير المتوقع إلى تآكل هوامش ربح الرمال والحصى لديك? Common industry challenges include:
ملابس عالية & تكاليف الصيانة: Abrasive materials rapidly degrade crusher liners, شاشات, ومكونات المضخة, leading to frequent part replacement and unplanned stoppages.
تصنيف المواد غير فعال: Inconsistent particle size separation results in offspec product, إعادة المعالجة المكلفة, and lost revenue from premium aggregate grades.
توليد الغرامات المفرطة: Overcrushing in primary and secondary stages creates an oversupply of lowvalue fines, diminishing the yield of highvalue concrete and asphalt sand.
استهلاك عالي للطاقة & تَعَب: Inefficient plant layout and manually intensive processes, like feeder regulation and belt monitoring, drive up power costs and require constant operator intervention.
Water Management Complexity: Ineffective slurry handling and dewatering systems lead to water recycling issues, sediment pond overflows, and potential environmental compliance risks.

Is your operation equipped to transform these cost centers into controlled, predictable processes? The right core processing equipment is not an expense but a direct lever for profitability.

2. نظرة عامة على المنتج: SAND CLASSIFICATION AND DEWATERING SYSTEM

This sand classification and dewatering system is engineered for the precise washing, التحجيم, and moisture reduction of sand products in sand gravel mining operations. It is a closedloop solution designed to maximize product value and minimize water consumption.

سير العمل التشغيلي:
1. يٌطعم & توزيع: Slurry from a wash screen or attritioner is evenly distributed into the system’s feed box.
2. التصنيف الهيدروليكي: Material enters a rising current cyclone or hydraulic classifier, separating sand particles by size and specific gravity.
3. Deck Dewatering: Classified sand is discharged onto a highfrequency dewatering screen, where vibration forces remove surface moisture.
4. التخزين & إعادة تدوير المياه: Onspec dewatered sand is conveyed to stockpile, while effluent water is channeled to a clarifier for recycling.

نطاق التطبيق & القيود:
نِطَاق: Ideal for producing concrete sand, رمل البناء, specialty sands, and glass sand from natural deposits or crushed rock. Effective for operations processing 50 ل 500 tons per hour of sand feed.
القيود: Not a substitute for primary washing or scrubbing of heavily claybound material. Feed slurry consistency must be controlled for optimal classification. Requires a consistent water supply and complementary settling pond or clarifier system.

3. الميزات الأساسية

Precision Hydraulic Classifier | الأساس الفني: Controlled rising current water velocity | المنفعة التشغيلية: Achieves accurate cut points for consistent product gradation meeting ASTM C33 or other specifications | تأثير عائد الاستثمار: يقلل من رفض المنتج بنسبة تصل إلى 15% and increases premium product yield

HighFrequency Dewatering Screen | الأساس الفني: Linear vibratory motion with steep discharge angle | المنفعة التشغيلية: Reduces moisture content in finished sand to 812%, minimizing hauling costs and preventing stockpile freezing | تأثير عائد الاستثمار: Lowers drying fuel costs if thermal drying is required; improves customer satisfaction with dripfree loads

مكونات ارتداء البولي يوريثين | الأساس الفني: Abrasionresistant cast polyurethane liners, nozzles, and screen panels | المنفعة التشغيلية: Provides 35x longer service life than standard rubber or steel in highwash environments | تأثير عائد الاستثمار: Cuts component replacement costs by over 60% annually and reduces changeout downtime

Variable Speed Drive System | الأساس الفني: Integrated VFDs on feed pumps and screen vibrators | المنفعة التشغيلية: Allows operators to finetune classification cut point and dewatering intensity based on feed material changes in realtime | تأثير عائد الاستثمار: Optimizes efficiency across varying deposit strata without manual component swaps

Modular Construction | الأساس الفني: Bolttogether subassemblies with prefitted piping | المنفعة التشغيلية: يتيح التجميع السريع في الموقع مع الحد الأدنى من اللحام; يبسط عملية إعادة تشكيل المصنع أو نقله في المستقبل | تأثير عائد الاستثمار: يقلل من وقت التثبيت بنسبة تصل إلى 40%, خفض تكاليف المقاول وتسريع الوقت اللازم للإنتاج

Integrated Flocculant Dosing Ports | الأساس الفني: Preplumbed injection manifolds at key slurry points | المنفعة التشغيلية: Facilitates optimal chemical mixing for enhanced fines capture in closedwater circuits | تأثير عائد الاستثمار: Improves water clarity for recycling, reduces pond cleaning frequency by an estimated 30%

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة (Conventional Cyclone & شاشة) | This Sand Classification System | ميزة (% تحسين) |
| : | : | : | : |
| محتوى رطوبة المنتج (الرمال الخرسانية) | 1520% typical discharge moisture| ثابت 912% discharge moisture| حتى 40% reduction in free water weight |
| كفاءة استرداد الغرامات (200 شبكة)~7080% recovery rate~Consistent >92% recovery rate~Up to ~22% more saleable material retained |
| Wear Life on Primary Liners~Rubber liners lasting ~4 months~Polyurethane liners lasting ~14 months~250% longer service life |
| Power Consumption per Ton~Fixed speed drives at constant load~Variable speed drives optimizing load~Field data shows 1018% انخفاض كيلووات ساعة / طن |
| Footprint Requirement (for equal capacity)~Multiple units with separate supports~Single integrated structure with shared supports~Approximately 25% less floor space |

5. المواصفات الفنية

نطاق السعة: الموديلات المتوفرة من 50 الهيدروكربونات النفطية إلى 400 TPH of dry solids feed (slurrydependent).
متطلبات الطاقة: Total connected power ranges from 45 كيلوواط (للنماذج الأصغر) ل 150 كيلوواط (for largest models), utilizing standard industrial voltages (460V/3Ph/60Hz).
مواصفات المواد: Contact surfaces utilize ASTM A36 structural steel with abrasionresistant AR400 steel at highimpact points. Classification chambers feature cast polyurethane. Screen decks are polyurethane modular panels.
الأبعاد المادية (Model SC200): الطول الكلي: ~9 م; عرض: ~ 4 م; ارتفاع (to top of feed box): ~5m; وزن الشحن التقريبي: ~14,000 kg.
نطاق التشغيل البيئي: Designed for ambient temperatures from 29°C to +45°C (20درجة فهرنهايت إلى +113 درجة فهرنهايت). Electrical components rated for NEMA 4X (hosedown, corrosion resistant) البيئات.

6. سيناريوهات التطبيق

مصنع إنتاج الرمل الخرساني

Challenge A Midwest producer struggled with inconsistent gradation yielding only ~65% ASTM C33compliant concrete sand from their deposit; the remainder was downgraded as fill material at significant revenue loss.
Solution Implementation of a Model SC150 Sand Classification System with precision hydraulic classifiers replaced their outdated rake classifier system.
Results Within one month of commissioning:
Production of spec concrete sand increased to over 92%.
Fines loss was reduced by twothirds.
Annualized revenue increase exceeded $280k based on increased premium product volume.

DredgeFed Mining Operation

Challenge A river dredging operation faced high pumping costs due to transporting excess water long distances from the dredge pond to the processing plant.
Solution Installation of a compact Sand Classification System directly on the dredge discharge allowed for primary dewatering at the pit face.
Results The system delivered:
A reduction in slurry volume pumped by over 35%, significantly lowering fuel consumption per ton produced.
Direct loading of dewatered sand onto haul trucks at the pit site versus pumping it miles away.

7. الاعتبارات التجارية

مستويات تسعير المعدات
Tier pricing is based on capacity (الهيدروكربونات النفطية في الساعة). Entrylevel systems (250 الهيدروكربونات النفطية في الساعة) ونقلت عن مواصفات المشروع.

الميزات الاختيارية
Advanced features include remote monitoring PLC packages with gradation trend tracking , automated flocculant dosing systems , stainless steel construction for corrosive environments ,ومرفقات توهين الصوت .

حزم الخدمة
Threetier service plans are available:
1.Basic Warranty covering parts .
2.Platinum Plan extending warranty coverage .
3.Platinum Plus Plan adding annual inspections .

خيارات التمويل
Flexible commercial terms include capital lease , الإيجار التشغيلي ,and loan structures through partner financial institutions . Renttoown programs may be available .

8. التعليمات

ما هي المعدات الأولية المطلوبة?
The system requires a consistent slurry feed typically provided by a wash screen log washer or attrition scrubber . Feed pumps can be included as part of the package .

How does this system integrate with our existing clarifier or settling pond?
It is designed as a complementary component . By removing most solids it significantly reduces the load on your clarifier improving its efficiency . Standard discharge flanges connect directly .

ما هو الإطار الزمني للتثبيت النموذجي?
For modular units installation typically requires days not weeks assuming prepared foundations are ready . Our project managers provide detailed site preparation guidelines .

هل يتم تقديم ضمانات الأداء؟?
Yes performance guarantees based on achieving specified product gradation bands are included in commercial contracts subject .

What spare parts inventory should we maintain?
We provide recommended critical spares list which typically includes polyurethane wear parts specific screen panel modules .

Can this handle very coarse material like pea gravel?
No this system is optimized specifically for sandsized particles . For coarse aggregate rinsing separate solutions are recommended .

What ongoing operator training do you provide?
Comprehensive training during commissioning covers operation maintenance troubleshooting procedures . Training manuals digital resources are provided