H1: HighCapacity Sand and Gravel Classifying Tanks | Precision Separation for Maximum Yield

1. فتحة مدفوعة بنقطة الألم

Are inconsistent product specs and lost fines eroding your profit margins? In sand and gravel production, inefficient material classification directly impacts your bottom line. وتشمل التحديات التشغيلية المشتركة:
Product Contamination: Inadequate separation of sand fractions leading to offspec material, causing load rejections and diminishing your brand’s reliability.
Yield Loss: حتى 15% of valuable fine sand can be lost to settling ponds or waste piles due to imprecise classification, representing significant revenue left unrecovered.
مياه عالية & استهلاك الطاقة: Inefficient, highvolume water usage increases pumping costs and complicates water management, while oversized pumps drive unnecessary energy expenses.
Frequent Downtime: Congestion and sand buildup in classifiers require regular shutdowns for manual cleaning and adjustment, reducing available operating hours.

How do you increase the precision of your sand products while simultaneously reducing water usage and recovering more saleable material? The solution lies in moving beyond basic settling pits to engineered hydraulic classification.

2. نظرة عامة على المنتج

The Advanced Hydraulic Classifying Tank is a controlledcurrent separation system designed for the highvolume, efficient sorting of sand and fine aggregates by particle size and specific gravity. It replaces or augments traditional methods like screw classifiers or simple settling basins.

سير العمل التشغيلي:
1. Slurry Introduction: A sandwater slurry is evenly distributed across the full width of the tank inlet box.
2. Controlled Settling: As material flows horizontally through the tank, particles settle into multiple collection hoppers based on their settling rate—finer particles travel further, coarser particles settle first.
3. Product Extraction: Precisely adjusted valves on each hopper allow for the continuous extraction of up to four distinct, specgrade sand products (على سبيل المثال, coarse concrete sand, fine masonry sand).
4. Overflow Management: Ultrafine silt and clay particles remain suspended, reporting to the effluent overflow for further processing or discharge.

نطاق التطبيق & القيود:
مثالية ل: Washing plants producing multiple spec sands; sites with variable feed material; operations focused on fines recovery; projects requiring precise cut points between 100 mesh and 1/4".
القيود: Not a dewatering device—extracted sands require further dewatering (على سبيل المثال, on a dewatering screen). Primary crushing and scrubbing must be completed upstream.

3. الميزات الأساسية

Manifold Feed Distributor | الأساس الفني: Laminar flow engineering | المنفعة التشغيلية: Ensures even slurry distribution across the entire tank width, preventing shortcircuiting and ensuring consistent classification across all hoppers. | تأثير عائد الاستثمار: Eliminates product banding, ensuring every ton meets specification and reducing reprocessing.

Modular Hopper Design | الأساس الفني: Discrete settlement zones with independent discharge gates | المنفعة التشغيلية: Operators can adjust gate openings to control the cut point and volume of each product fraction in realtime based on feed changes. | تأثير عائد الاستثمار: Maximizes yield by allowing precise tuning for changing market demands or feed stockpile variations.

CorrosionResistant Liners | الأساس الفني: Abrasionresistant steel or polyurethane lining at highwear points | المنفعة التشغيلية: Dramatically extends service life in critical wear zones compared to unlined carbon steel, reducing maintenance frequency. | تأثير عائد الاستثمار: Lowers longterm operating costs by extending time between liner replacements by up to 3x.

LowProfile, HighCapacity Design | الأساس الفني: Optimized tank geometry for gravity flow | المنفعة التشغيلية: Requires less static head pressure than deep cone classifiers, allowing integration with existing pump systems and reducing overall plant height requirements. | تأثير عائد الاستثمار: Lowers initial installation costs and simplifies retrofit into existing plant layouts.

Fines Recovery Baffle System | الأساس الفني: Hydraulic current control baffles | المنفعة التشغيلية: Promotes retention of difficulttocapture 70200 mesh fines within the product hoppers before they report to overflow. | تأثير عائد الاستثمار: Directly increases recoverable product yield by capturing valuable fines previously lost.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة (Screw Classifier/Basin) | Our Classifying Tank Solution | ميزة |
| : | : | : | : |
| الغرامات (100200 شبكة) معدل الاسترداد | عادة 5070% loss to overflow | Consistent recovery >85% into product stream| +3040% yield improvement |
| استهلاك المياه لكل طن معالج| 100150 جالون/طن (recirculating) | 7090 جالون/طن (recirculating) |30% water volume required |
| Product Specification Consistency| Variable due to feed surges & التعديل اليدوي| Consistent grade with automated gate control| Reduces offspec material by ~25% |
| توقف الصيانة (سنوي)| 4060 hours for wear part replacement/cleanout| <20 hours with lined components & accessible gates| ~60% reduction in downtime |

5. المواصفات الفنية

نطاق السعة: نماذج من 50 الهيدروكربونات النفطية لأكثر من 500 TPH sand feed capacity.
متطلبات الطاقة: System typically relies on existing plant slurry pumps; no dedicated drive motors required.
مواصفات المواد: الهيكل الأساسي: ASTM A36 carbon steel. Highwear areas lined with AR400 steel (12مم) or replaceable polyurethane panels (25مم).
الأبعاد المادية (Model CFT200): طول: 24 قدم; عرض: 12 قدم; ارتفاع: 8 قدم; وزن (dry): ~18,000 lbs.
نطاق التشغيل البيئي: Designed for outdoor installation; operates effectively in ambient temperatures from 20°F to +120°F (29درجة مئوية إلى +49 درجة مئوية). Slurry temperature tolerance from 32°F to 95°F (0°C to 35°C).

6. سيناريوهات التطبيق

Concrete Sand Producer Facing Market Expansion Challenge

تحدي: A regional producer needed to separate its single "الرمال الخرسانية" product into two distinct grades—a coarse ASTM C33 concrete sand and a finer masonry/blend sand—to access new contracts without major plant overhaul.
حل: Installation of a Model CFT150 Classifying Tank downstream of their existing wash screen.
نتائج: The operation now simultaneously produces two inspec products at a combined rate of 150 الهيدروكربونات النفطية في الساعة. تظهر البيانات الميدانية أ 22% increase in total sales revenue from the same deposit due to premium pricing on the masonry sand fraction.

Alluvial Gravel Pit with High Fines Loss Challenge

تحدي: Significant volumes of profitable fine concrete sand (70100 شبكة) were being lost to settling ponds due to an overloaded screw classifier system, resulting in wasted resource and high pond dredging costs.
حل: Retrofitting a classifying tank as a primary classifier ahead of the existing screws, which were repurposed as dewatering units.
نتائج: Recovered an additional 25 TPH of saleable fine sand previously lost. This increased overall plant yield by approximately 12%, paying back the equipment investment in under one season while drastically reducing pond maintenance.

7. الاعتبارات التجارية

طبقات التسعير: Solutions are configured based on capacity and material specifications.
واجب قياسي: For consistent feeds under 150 TPH مع كشط معتدل.
واجب ثقيل: لعمليات الحمولة العالية (>150 الهيدروكربونات النفطية في الساعة) or highly abrasive feeds featuring upgraded liners and gate assemblies.
Modular/Portable: Skidmounted units for lease/fleet operations requiring relocation.

الميزات الاختيارية & ترقيات: Automated gate actuators with PLC control interface; advanced urethane lining packages; camera monitoring systems for remote hopper level checks; custom manifold designs for unique feed conditions.

حزم الخدمة: Extended warranty plans are available covering structural components against defects beyond standard terms.

خيارات التمويل:

Equipment Lease: Fixed monthly payments over terms ranging from three years up through seven years.

RentaltoOwn: A portion of monthly rental fees apply toward eventual purchase.

Traditional Financing: Secured loan options through our commercial lending partners.

All financing is subject to credit approval.