1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your sand and gravel profit margins? Managing a modern aggregate operation presents distinct challenges that directly impact your bottom line. Common pain points include:

High Maintenance & Component Wear: Constant abrasive action from sand and gravel rapidly degrades standard components, leading to frequent, unplanned maintenance stops and high parts replacement costs.
Inefficient Material Classification: Inconsistent particle size separation results in offspec product, forcing reprocessing cycles that consume energy, time, and capacity.
Excessive Fines Generation: Overly aggressive or poorly configured processing creates an excess of fine particulate (sub75µm), which represents lost saleable product and complicates water management.
Regulatory Compliance Pressure: Operations must consistently meet strict environmental and workforce safety standards (including CE Marking for the EU market), where equipment failure or noncompliance risks fines and operational shutdowns.
Energy Intensity: Inefficient drive systems and process design lead to unsustainable power consumption, a primary variable cost in mineral processing.

The central question for plant managers is: how can you increase throughput of inspec material while systematically reducing cost per ton for maintenance, energy, and rework?

2. PRODUCT OVERVIEW: CEMarked Sand Gravel Mining Quotation

This quotation details a fully compliant, stationary sand and gravel washing and classification plant, engineered for highvolume aggregate producers. The solution is designed as a modular circuit to optimize the separation of sand fractions (coarse, fine) from gravel and the removal of contaminants.

Operational Workflow:
1. Feed & PreScreening: Runofmine material is conveyed to a primary vibrating screen, removing oversized debris (+63mm) and bypassing natural fines.
2. Attrition & Scrubbing: The screened material enters a log washer or attrition scrubber to break down claybound aggregates and remove deleterious coatings.
3. Hydraulic Classification: The scrubbed slurry is distributed to a battery of hydrocyclones or a rising current classifier, using precise water flow dynamics to separate sand fractions by particle size.
4. Dewatering & Stockpiling: Classified sand is dewatered on fine material screw washers or linear motion dewatering screens, producing a dripfree product for stockpiling.
5. Water Management: Effluent is sent to a settling tank or thickener for water recovery and silt management, closing the process loop.

Application Scope & Limitations:
Scope: Ideal for alluvial deposits, riverrun gravel pits, and hard rock quarries producing concrete sand, masonry sand, and various gravel specifications. Designed for feed capacities from 100 to 500 TPH.
Limitations: Not suitable for primary crushing of blasted rock. Feed material with excessive clay content (>15%) may require additional pretreatment stages. Site requires adequate water supply and silt pond area.

3. CORE FEATURES

AbrasionResistant Liner System | Technical Basis: Highchrome white iron castings (700+ BHN) in highwear zones | Operational Benefit: Liner service life increased by up to 300% compared to standard AR steel | ROI Impact: Reduces component change frequency by 60%, lowering parts inventory cost and labor hours.

Precision Hydraulic Classification Bank | Technical Basis: Bank of polyurethane hydrocyclones with adjustable vortex finders and apex valves | Operational Benefit: Enables realtime tuning of cut points for precise separation of coarse/fine/ultrafine fractions | ROI Impact: Improves yield of inspec product by up to 8%, minimizing waste and reprocessing.

HighEfficiency Dewatering Screws | Technical Basis: Longpitch flights with weir overflow control and hydrocyclone underflow feed | Operational Benefit: Achieves final product moisture content as low as 1215%, reducing haulage weight | ROI Impact: Lowers water content per ton shipped, improving transport efficiency.

Centralized Grease Lubrication System | Technical Basis: Automated singlepoint system with metered delivery lines to all critical bearings | Operational Benefit: Ensures optimal bearing lubrication without manual intervention during operation | ROI Impact: Extends bearing life by an average of 40% and prevents costly seizurerelated downtime.

Variable Frequency Drive (VFD) Control | Technical Basis: VFDs on major motors including pump drives and screw washers | Operational Benefit: Allows softstart capability and precise speed adjustment to match feed variations | ROI Impact: Reduces peak power demand by up to 30% and cuts overall energy consumption by approximately 1520%.

Modular SkidMounted Design | Technical Basis: Preassembled, prepiped modules on structural steel skids | Operational Benefit: Reduces onsite installation time by an estimated 50% versus componentbycomponent builds | ROI Impact: Accelerates timetorevenue by weeks; simplifies future plant relocation or expansion.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | This CEMarked Sand Gravel Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Wear Component Life (Primary Screw Flight) | Standard AR Steel (400 BHN), ~1,500 hours | HighChrome Iron Casting (700+ BHN), ~4,500 hours| +200% service life |
| Fines Recovery Efficiency (<150µm) | Static sieve bends / settling ponds; ~65% recovery in spec sand| Optimized hydrocyclone bank with density control; ~85% recovery in spec sand| +20% yield improvement |
| Average Moisture Content of Final Sand Product| Singlestage dewatering; typically 1822% moisture| Twostage dewatering with controlled retention; typically 1215% moisture| ~30% reduction in transported water weight |
| Installation & Commissioning Time (for 200TPH plant)| Field assembly & alignment; ~68 weeks| Skidmounted modular installation; ~34 weeks| ~50% faster deployment |
| Specific Energy Consumption (kWh/Ton processed)| Fixedspeed motors; ~2.8 3.2 kWh/Ton| VFDcontrolled motors with load sensing; ~2.2 2.5 kWh/Ton| Up to ~22% lower energy use |

5. TECHNICAL SPECIFICATIONS

Nominal Capacity Range: Configurable from 120 TPH to 450 TPH dry feed.
Power Requirements: Total connected load approximately 350 kW 900 kW depending on configuration; main supply required at 400V/50Hz (or as specified).
Material Specifications: Contact surfaces in wear zones utilize Trellex® rubber lining or NiHard castings; structural steel is S355JR grade with ISO12944 C4 corrosion protection coating.
Physical Dimensions (Typical Layout): Footprint approximately 35m (L) x 18m (W) x 12m (H). Modular skid dimensions vary but are designed for standard container transport.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. All electric drives are IP66 rated; control panel is IP54 rated.

6. APPLICATION SCENARIOS

RiverRun Gravel Operation in Northern Europe

Challenge A producer faced inconsistent feed gradation due to seasonal variation in deposit composition, leading to frequent offspec concrete sand production exceeding allowable fines content.
Solution Implementation of this CEmarked plant featuring the tunable hydrocyclone classification bank allowed operators to adjust cut points seasonally without changing physical screens.
Results Field data shows a consistent yearround production of EN12620 compliant concrete sand with less than 95% of operating time.

Recycled Concrete Aggregate (RCA) Processing

Challenge Processing demolition concrete generated excessive fine particulates (<75µm), creating dust issues , loss of saleable material ,and water clarification problems .
Solution Integration of an attrition scrubber module within the quoted circuit effectively dislodged cement paste from aggregate , followed by the highefficiency classification system capturing usable fine sand fractions previously lost .
Results The operation increased total saleable product yield by 15%. Furthermore ,the recovered 0/4mm washed sand fraction created a new revenue stream ,with final effluent turbidity reduced significantly easing water discharge compliance .

7. COMMERCIAL CONSIDERATIONS

This CEmarked solution is offered in three primary tiers:

1. Essential Tier: Includes core processing modules—primary screen ,log washer ,hydrocyclone bank ,dewatering screws—with manual controls . Suitable for operations with existing experienced crews focused on CapEx minimization .Pricing structured around base capacity .
2.Advanced Tier: Adds automation features—centralized PLC control with HMI touchscreen ,VFDs on all major drives ,and automated grease lubrication system .Includes advanced instrumentation for pump sump leveland density monitoring .This tier offers the optimal balanceof capital investmentand operational savings .Pricing includes commissioning support .
3.Premium Tier: Comprises full Advanced Tier features plus modular silt management(highrate thickener)and complete plantwide dust suppression system piping .Also includes extended warranty coverage(24 months parts/labor)and remote telematics supportfor predictive maintenance alerts .Financing options available through our partner institutions include operating lease structuresor fixedrate equipment loans typically over 36to 60months .Service packages range from annual inspection planssto fullsite maintenance contracts providing guaranteed uptime percentages .

8.FAQ

Q What documentation accompanies the CE marking?
A Full technical file including risk assessment declarationof conformity harmonized standards appliedand detailed instructionsfor safe installationoperationmaintenanceare provided ensuring compliancewith EU Machinery Directive2006/42/EC

Q How does this plant integratewith our existing primary crushing circuit?
A The plant is designedto accept conveyorfed materialtypically after secondary crushingand screeningThe feed hopperand conveyor interface dimensionscan be adaptedto match your existing discharge heightand rateControl integration optionsare available

Q What arethe ongoing spare part requirements?
A Basedon industry wear datawe providea recommended twoyear critical spares kitincluding cyclone liners pump wear partsspecific liner sectionsThis reducesdowntime riskOur inventory managementsystem can automate replenishmentbasedon your consumption

Q Can this system handle sticky claybound materials?
A Whilethe included attrition scrubberis effectivefor moderate claysfeeds with persistentplastic claysmay requirea preliminary rinsing screenor clay cannon optionwhich can be quotedas an addon module

Q What levelof operator trainingis required?
A We providecomprehensive onsite trainingfor shift supervisorsand maintenance personnelcovering normal operationsroutine adjustments troubleshooting basic mechanical proceduresTraining manualsare specificto the deliveredplant

Q What isthe typical timeframe from orderto commissioning?
A For standard configurationslead timeis currently 20weeksFOB our facilityOnsite installationand mechanical commissioningby our technicianstypically requires 3weeksdepending on site readiness

Q Are performance guarantees offered?
A YesWe offer guaranteed throughput capacityfor defined feed material specificationsalongside guaranteed final product gradationenvelopeand maximum power consumptionfiguresThese are detailedin the commercial offer