1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y el tiempo de inactividad impredecible están erosionando sus márgenes de ganancias de arena y grava?? Managing a modern aggregate operation presents distinct challenges that directly impact your bottom line. Los puntos débiles comunes incluyen:

Alto mantenimiento & Desgaste de componentes: Constant abrasive action from sand and gravel rapidly degrades standard components, llevando a frecuentes, unplanned maintenance stops and high parts replacement costs.
Clasificación de materiales ineficiente: Inconsistent particle size separation results in offspec product, forcing reprocessing cycles that consume energy, time, and capacity.
Generación excesiva de multas: 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.
Intensidad energética: Inefficient drive systems and process design lead to unsustainable power consumption, a primary variable cost in mineral processing.

La pregunta central para los gerentes de planta es: how can you increase throughput of inspec material while systematically reducing cost per ton for maintenance, energía, and rework?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO: 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 (grueso, bien) from gravel and the removal of contaminants.

Flujo de trabajo operativo:
1. Alimentar & Pre-selección: Runofmine material is conveyed to a primary vibrating screen, removing oversized debris (+63milímetros) and bypassing natural fines.
2. Desgaste & Depuración: The screened material enters a log washer or attrition scrubber to break down claybound aggregates and remove deleterious coatings.
3. Clasificación Hidráulica: 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. Deshidratación & Almacenamiento: Classified sand is dewatered on fine material screw washers or linear motion dewatering screens, producing a dripfree product for stockpiling.
5. Gestión del agua: Effluent is sent to a settling tank or thickener for water recovery and silt management, closing the process loop.

Ámbito de aplicación & Limitaciones:
Alcance: Ideal para depósitos aluviales, riverrun gravel pits, and hard rock quarries producing concrete sand, arena de mampostería, and various gravel specifications. Designed for feed capacities from 100 a 500 TPH.
Limitaciones: 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. CARACTERÍSTICAS PRINCIPALES

Sistema de revestimiento resistente a la abrasión | Base técnica: Highchrome white iron castings (700+ BHN) in highwear zones | Beneficio operativo: Liner service life increased by up to 300% compared to standard AR steel | Impacto del retorno de la inversión: Reduces component change frequency by 60%, Reducir el costo del inventario de piezas y las horas de mano de obra..

Precision Hydraulic Classification Bank | Base técnica: Bank of polyurethane hydrocyclones with adjustable vortex finders and apex valves | Beneficio operativo: Enables realtime tuning of cut points for precise separation of coarse/fine/ultrafine fractions | Impacto del retorno de la inversión: Improves yield of inspec product by up to 8%, minimizing waste and reprocessing.

HighEfficiency Dewatering Screws | Base técnica: Longpitch flights with weir overflow control and hydrocyclone underflow feed | Beneficio operativo: Achieves final product moisture content as low as 1215%, reducing haulage weight | Impacto del retorno de la inversión: Lowers water content per ton shipped, improving transport efficiency.

Sistema centralizado de lubricación con grasa | Base técnica: Automated singlepoint system with metered delivery lines to all critical bearings | Beneficio operativo: Ensures optimal bearing lubrication without manual intervention during operation | Impacto del retorno de la inversión: Extends bearing life by an average of 40% and prevents costly seizurerelated downtime.

Unidad de frecuencia variable (VFD) Control | Base técnica: VFDs on major motors including pump drives and screw washers | Beneficio operativo: Allows softstart capability and precise speed adjustment to match feed variations | Impacto del retorno de la inversión: Reduces peak power demand by up to 30% and cuts overall energy consumption by approximately 1520%.

Diseño modular montado sobre patines | Base técnica: Premontado, prepiped modules on structural steel skids | Beneficio operativo: Reduces onsite installation time by an estimated 50% versus componentbycomponent builds | Impacto del retorno de la inversión: Accelerates timetorevenue by weeks; simplifica la futura reubicación o expansión de la planta.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Solución estándar de la industria | This CEMarked Sand Gravel Plant Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Wear Component Life (Primary Screw Flight) | Standard AR Steel (400 BHN), ~1.500 horas | HighChrome Iron Casting (700+ BHN), ~4.500 horas| +200% vida útil |
| 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% mejora del rendimiento |
| Average Moisture Content of Final Sand Product| Singlestage dewatering; típicamente 1822% humedad| Twostage dewatering with controlled retention; típicamente 1215% humedad| ~30% reduction in transported water weight |
| Instalación & Tiempo de puesta en servicio (for 200TPH plant)| Field assembly & alineación; ~68 weeks| Skidmounted modular installation; ~34 weeks| ~Implementación un 50 % más rápida |
| Consumo de energía específico (kWh/Ton procesada)| Fixedspeed motors; ~2.8 3.2 kWh/tonelada| VFDcontrolled motors with load sensing; ~2.2 2.5 kWh/tonelada| Up to ~22% lower energy use |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad nominal: Configurable desde 120 TPH a 450 TPH dry feed.
Requisitos de energía: Carga total conectada aproximadamente 350 kilovatios 900 kW dependiendo de la configuración; main supply required at 400V/50Hz (or as specified).
Especificaciones de materiales: Contact surfaces in wear zones utilize Trellex® rubber lining or NiHard castings; structural steel is S355JR grade with ISO12944 C4 corrosion protection coating.
Dimensiones físicas (Diseño típico): Footprint approximately 35m (l) x 18m (W.) x 12m (h). Modular skid dimensions vary but are designed for standard container transport.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C. All electric drives are IP66 rated; control panel is IP54 rated.

6. ESCENARIOS DE APLICACIÓN

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.

Agregado de hormigón reciclado (RCA) Tratamiento

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%. Además ,the recovered 0/4mm washed sand fraction created a new revenue stream ,with final effluent turbidity reduced significantly easing water discharge compliance .

7. CONSIDERACIONES COMERCIALES

This CEmarked solution is offered in three primary tiers:

1. Nivel esencial: Includes core processing modules—primary screen ,log washer ,banco de hidrociclones ,dewatering screws—with manual controls . Suitable for operations with existing experienced crews focused on CapEx minimization .Pricing structured around base capacity .
2.Nivel avanzado: 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.Nivel Premium: Comprises full Advanced Tier features plus modular silt management(highrate thickener)and complete plantwide dust suppression system piping .Also includes extended warranty coverage(24 meses piezas/mano de obra)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.Preguntas frecuentes

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