تحسين الرمال & إنتاج الحصى: معالجة التحديات التشغيلية الأساسية

Are you managing inconsistent feed material that disrupts your entire wash plant’s efficiency? Struggling with the high cost and downtime associated with frequent screen panel replacements? Concerned about lost fines reporting to waste, directly impacting your recoverable yield and profitability? لمديري المصانع والمقاولين الهندسيين, these are not minor inconveniences—they are significant barriers to operational reliability and margin protection. How do you achieve consistent specification product while controlling maintenance costs and maximizing material recovery from every ton processed? The solution lies in the critical separation stage: a highperformance sand classifying tank.

نظرة عامة على المنتج: Precision Hydraulic Classification for Aggregate Processing

أ sand classifying tank is a hydraulic classification system designed to separate sand particles by size and density using controlled upward current water flow. It is a core component in sand washing and beneficiation plants, replacing or enhancing less efficient methods like cyclones or screw washers for fine material separation.

سير العمل التشغيلي:
1. Slurry Inlet: A sandandwater slurry from a wash screen or hydrosizer enters the feed box.
2. Controlled Settling: The slurry flows across a series of chambers or cells. In each cell, precisely controlled upward flow of water creates a hydraulic "teeter" or fluidized bed.
3. SizeBased Separation: Particles finer than the cut point are carried upward by the water current and overflow the weir as product. Heavier, coarser particles settle against the current and are discharged from the bottom of each cell.
4. Product Diversion: Valves on each discharge allow for blending or diverting different sand products (على سبيل المثال, الرمال الخرسانية, رمل البناء) to separate stockpiles.
5. إدارة المياه: Overflow water, carrying silt and clays, is sent to a water treatment circuit for clarification and reuse.

نطاق التطبيق & القيود:
نِطَاق: Ideal for washing and precise sizing of natural sand or crushed fines in the range of approximately 150 شبكة (100 ميكرون) ل 3/16" (4.75مم). Essential for producing multiple inspec sand products from a single feed source.
القيود: Not a dewatering device; products require further dewatering via cyclones, شاشات, or dewatering screens. Requires a consistent supply of process water and is not suitable for dry classification.

الميزات الأساسية: Engineered for Control, كفاءة, and Yield

ملكنا sand classifying tank design is based on decades of field application engineering. Each feature addresses a specific pain point in aggregate processing.

Manifold Water Distribution System | الأساس الفني: Laminar Flow Hydraulics | المنفعة التشغيلية: Provides uniform, nonturbulent upward current across the entire cell area for precise size separation. | تأثير عائد الاستثمار: Improves product consistency by up to 15%, reducing offspec loadouts and maximizing premium product yield.

WearResistant Polyurethane Cell Liners | الأساس الفني: Abrasionresistant elastomer chemistry | المنفعة التشغيلية: Outlasts steel liners by 35x in highwear zones, eliminating frequent welding repairs. | تأثير عائد الاستثمار: Reduces liner replacement downtime by over 50% annually and lowers consumable parts inventory costs.

DiaphragmType Divertor Valves | الأساس الفني: Pneumaticactuated fullport valve design | المنفعة التشغيلية: Provides reliable, nonclogging control of sand discharges even with variable feed density. Operators can change product blends in seconds. | تأثير عائد الاستثمار: Increases plant flexibility to meet changing order demands without process stoppages, optimizing sales opportunities.

Integrated Density & مجسات المستوى | الأساس الفني: Nonnuclear pressure transducer technology | المنفعة التشغيلية: Delivers realtime data on bed level and density within each cell for process control automation. Your operators can maintain optimal teeter conditions consistently.| تأثير عائد الاستثمار: Automates critical control points, stabilizing performance across shift changes and reducing operator burden.

Modular Cell Design | الأساس الفني: Bolttogether sectional construction| المنفعة التشغيلية: Simplifies transportation, تثبيت, and future plant modifications. Individual cells can be serviced without dismantling the entire tank.| تأثير عائد الاستثمار: يخفض وقت التثبيت بنسبة تصل إلى 30% and minimizes future expansion costs through easy addon capability.

المزايا التنافسية: DataDriven Performance

| مقياس الأداء | معيار الصناعة (Conventional Tank) | Our Sand Classifying Tank Solution | ميزة (% تحسين) |
| : | : | : | : |
| Screen Panel Life on Dewatering Screen | 46 أسابيع (due to inconsistent feed gradation) | 812 أسابيع (stable, wellclassified feed) | +100% Life Extension |
| Fines Loss to Settling Pond| 812% of minus 200mesh material | 35% of minus 200mesh material | حتى 60% Reduction in Loss |
| Time to Adjust Product Blend| Manual valve adjustments; 1520 دقائق| Automated valve control; <2 دقائق| ~90% Faster Changeover |
| Annual Liner Maintenance Downtime| 4060 hours for cutting/welding steel| <10 hours for polyurethane inspection/replacement| ~80% Less Downtime |
| استهلاك المياه لكل طن| Varies significantly with manual control| Optimized & consistent flow via automated controls| حتى 20% تخفيض |

المواصفات الفنية

نطاق السعة: الموديلات المتوفرة من 50 الهيدروكربونات النفطية لأكثر من 500 TPH sand feed capacity.
متطلبات الطاقة: System operates on plant air (80100 psi) for valves; optional control panel requires standard 480V/3Ph/60Hz service.
مواصفات المواد: Tank structure fabricated from ASTM A36 carbon steel with abrasionresistant polyurethane liners (AR400 steel optional). Valves feature natural rubber diaphragms with cast iron bodies.
الأبعاد المادية (Example Model SCT200): طول: 24 قدم / عرض: 8 قدم / ارتفاع:10 قدم / الوزن التشغيلي:12，000 lbs.
نطاق التشغيل البيئي: Designed for outdoor installation; operating fluid temperature range of 35°F (37درجة مئوية) to +120°F (+49درجة مئوية).

سيناريوهات التطبيق

Concrete Sand Production from Variable Feed

تحدي: A Midwest producer's deposit variability caused their existing cyclones to frequently produce outofspec fineness modulus (FM) رمل， leading to high reject rates。
حل: Installation of a customconfigured fourcell sand classifying tank after the scrubber screen， with automated controls tied to continuous weighing monitors。
نتائج: Achieved FM consistency within ±0。1 specification， reduced offspec product by 98%，and increased saleable concrete sand yield by 22% from the same raw feed。

Frac Sand Silica Recovery Upgrade

تحدي: An existing operation was losing highvalue 70 mesh silica grains to waste due to inefficient classification， directly impacting reserve economics。
حل: Integration of a bank of finematerial sand classifying tanks designed for sharp cuts at 100 شبكة， replacing older spiral classifiers。
نتائج: Field data shows silica recovery in target size fractions improved from 82%to 94%，payback achieved in under nine months through increased product volume。

الاعتبارات التجارية

مستويات تسعير المعدات:
النموذج الأساسي (Manual Valves， Standard Controls): For budgetconscious upgrades。
Premium Model (Automated Valves， PLC with HMI): Recommended for new plants or major automation projects。
الأنظمة الهندسية المخصصة： For complex applications like frac sand or industrial sands。

الميزات الاختيارية: Ceramic tile lining（for ultrahigh abrasion）， overflow launders with flocculant injection ports， complete skidmounted packages。

حزم الخدمة: Choose from annual inspection programs， liner replacement kits，or comprehensive remote monitoring & diagnostics subscriptions。

خيارات التمويل： Capital equipment financing leases available through partners， typically offering flexible terms from 36to 60 شهور。 Rentaltoown structures can also be arranged for projectbased work。

Frequently Asked Questions（FAQ）

1。 Is this equipment compatible with my existing wash plant？
نعم。 Sand classifying tanks are designed as modular units。 Our engineering team will review your plant layout，feed source,and desired products to specify connection points， pump requirements,and structural supports。

2。 What is the typical installation timeline？
For a standard system， onsite installation typically requires57 days with your prepared foundation。 Skidmounted systems can reduce this time significantly。

3。 How does this impact my overall water consumption？
Properly tuned,a modern classifying tank reduces water consumption per ton by creating more efficient separation。 However it requires consistent water pressure；our design optimizes flow rates which often allowsfor downsizingor optimizingwater recirculation pumps。

4。 What are the key operator skill requirements？
The system simplifies operation through automation。 Basic training focuses on understandingthe control interfaceand routine inspection points rather than manual process adjustment。

5。 What is the expected lifespanof the main structure？
With proper maintenance,the carbon steel structure typically exceeds20 yearsin service.The wear components（liners,diaphragms）are consumable itemswith predictable replacement intervals documentedin themanual。

6。 هل يمكنك تقديم ضمانات الأداء？
Yes.We provide written guaranteesfor material throughput capacityand classification efficiency basedon your providedfeed sample analysisand agreeduponproduct specifications。

7。 What does aftermarket part availability look like？
We stock critical wear parts（valve diaphragms,polyurethane liners）in regional warehouseswith guaranteed48hour shippingfor emergency orders under our service plans