1. PAINPOINT DRIVEN OPENING

Managing a certified sand and gravel mining operation presents distinct challenges that directly impact profitability and compliance. Are you contending with inconsistent material quality from your deposit, leading to product rejection and lost revenue? Is your wash plant throughput limited by frequent screen blinding or inefficient fines recovery, causing bottlenecks? Are you managing excessive water consumption and complex settling pond maintenance, escalating operational costs and environmental scrutiny? Perhaps manual sampling and grade control processes are introducing variability, risking noncompliance with certification specifications. These inefficiencies translate into measurable costs: downtime for screen changes, lost saleable product in waste streams, and high water procurement or treatment expenses. The central question for plant managers is how to enhance yield and consistency from their certified reserve while controlling operational costs and maintaining stringent compliance standards.

2. PRODUCT OVERVIEW

This content addresses a HighEfficiency, Modular Wash Plant system engineered for certified sand and gravel production. This equipment is designed to transform raw feed from a mining face into precisely graded, specification aggregates and washed sand products.

The operational workflow is streamlined:
1. Primary Scrubbing & Sizing: Raw feed is aggressively scrubbed to break down clay conglomerates and then screened to remove oversize rock.
2. Gravel Fraction Processing: Oversize material is routed to crushers and sizing screens to produce various certified gravel products.
3. Sand Classification & Dewatering: The sandbearing slurry is processed through a hydraulic classifier or sieve bend, separating coarse and fine sand fractions.
4. ​Fines Management & Water Recovery: Ultrafine silt and clay are removed via a cyclone or clarifier system, with clean process water recirculated to the feed.

Application scope includes virgin aggregate deposits, river dredging operations, and sitewon material processing for constructiongrade products. A key limitation is feed material consistency; highly variable or boulderladen deposits may require enhanced prescreening or scalping circuits not covered by a standard modular system.

3. CORE FEATURES

Patented AntiBlinding Screen System | Technical Basis: Polyurethane tensioned panels with intermittent highamplitude vibration nodes | Operational Benefit: Reduces screen clogging by up to 70%, maintaining consistent throughput of sticky materials | ROI Impact: Cuts downtime for manual cleaning by estimated 1520 hours per month

HydroCyclone Fines Recovery Cluster | Technical Basis: Bank of smalldiameter cyclones generating high Gforce for precise particle cutpoint separation | Operational Benefit: Recovers up to 95% of +75µm sand particles typically lost to waste ponds | ROI Impact: Increases saleable sand yield by 510%, directly boosting revenue per ton processed

Intelligent Water Management Module | Technical Basis: Automated sensors controlling pump rates and flocculant dosing based on turbidity feedback loops | Operational Benefit: Reduces fresh water makeup requirements by approximately 80% through closedloop recycling | ROI Impact: Lowers water procurement costs and minimizes settling pond volume/management expenses

Modular PlugandPlay Design | Technical Basis: Skidmounted, prepiped subassemblies with standardized connection points | Operational Benefit: Reduces onsite installation time by up to 40% compared to stickbuilt plants | ROI Impact: Accelerates timetoproduction, reducing capital deployment lag

Centralized Process Control (CPC) System | Technical Basis: SCADAbased interface providing realtime monitoring of feed rate, product grades, and machine health diagnostics | Operational Benefit: Enables rapid operator adjustment for consistent product specification compliance | ROI Impact: Minimizes offspec production batches, ensuring certification integrity

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Wash Plant | This HighEfficiency Modular Solution | Advantage (% Improvement) |
| : | : | : | : |
| Sand Product Yield (% of total feed) | 2025% (varies by deposit) | 2833% (with fines recovery) | Up to +40% in sand revenue stream |
| Fresh Water Consumption (m³/ton processed) | ~1.0 1.5 m³/tonne (open loop) ~0.5 m³/tonne (basic recycle) 60% reduction vs basic recycle |
| Screen Maintenance Downtime (hours/month) ~3040 hours ~1015 hours ~65% reduction |
| OnSite Installation & Commissioning Time (weeks) ~812 weeks ~46 weeks ~50% reduction |

5. TECHNICAL SPECIFICATIONS

Capacity/Rating: Configurable from 100 to 400 tonnes per hour of raw feed.
Power Requirements: Total connected load ranges from 350 kVA (Model HP100) to 850 kVA (Model HP400), dependent on configured modules.
Material Specifications: Contact surfaces in slurry lines utilize AR400 abrasionresistant steel; pump volutes are highchrome cast iron; screen panels are polyurethane.
Physical Dimensions: Primary module dimensions standardized at 12m L x 2.8m W x 4m H for transportability.
Environmental Operating Range: Designed for operation from 20°C to +45°C ambient temperature with optional heating/cooling packages for extreme climates.

6. APPLICATION SCENARIOS

Certified Concrete Sand Production Challenge A producer's existing cyclones were losing fine sand (600µm), failing ASTM C33 gradation requirements while overconsuming water Solution Implementation of the HydroCyclone Fines Recovery Cluster alongside the Intelligent Water Module Results Sand yield increased by 8%, meeting ASTM C33 spec consistently; fresh water consumption reduced by 75%; payback period achieved in under 14 months.

Alluvial Gravel Pit with High Clay Content Challenge Significant clay contamination caused constant screen blinding, reducing effective plant capacity by over 30% during wet periods Solution Deployment of the Patented AntiBlinding Screen System combined with a primary log washer module Results Throughput stabilized at nameplate capacity; monthly operating hours increased by an average of 120 hours without additional labor.

7. COMMERCIAL CONSIDERATIONS

Equipment pricing follows a tiered modular structure:
Base Tier: Core scrubbing, screening, and basic water recycling system.
Yield Optimization Tier: Base tier plus Fines Recovery Cluster and advanced control system.
Full Compliance Tier: Includes all features plus automated sampling systems and data logging for audit trails.

Optional features include mobile skidding packages, dust enclosures, custom product stacking conveyors, and remote telematics for performance monitoring.

Service packages range from basic preventative maintenance plans to comprehensive fullprocess guarantees that cover total costperton performance metrics.

Financing options include traditional equipment leasing, throughputbased rental agreements where payments correlate with production volume, and upgradeinclusive tradein programs for existing fleet modernization.

8. FAQ

Q1: Is this wash plant system compatible with our existing primary crushing circuit?
A1 Yes The modular design accepts conveyorfed material Standardized feed hopper heights ensure compatibility Industry standard belt widths are used facilitating integration into most existing site layouts

Q2 What is the expected impact on our power consumption per ton processed?
A2 Field data shows power consumption per ton decreases between due higher throughput efficiency However total connected load may increase depending on added modules A detailed sitespecific energy analysis is recommended

Q3 How does the intelligent water system handle heavy rainfall which dilutes the process water?
A3 The automated sensors detect turbidity changes adjusting flocculant dosing accordingly Excess volume can be diverted ensuring system equilibrium without compromising recycled water clarity

Q4 What commercial terms are available beyond outright purchase?
A4 We offer several models including operating leases capital leases payfortonnage rental contracts These structures can preserve capital expenditure budgets aligning equipment costs directly with production revenue

Q5 What workforce training is required for implementation?
A5 Comprehensive training covering operation maintenance safety procedures provided onsite during commissioning The centralized control system simplifies operation requiring fewer adjustments than manual systems