1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Les coûts opérationnels croissants et les temps d'arrêt imprévisibles érodent vos marges bénéficiaires sur le sable et le gravier.? Managing a modern aggregate operation presents distinct challenges that directly impact your bottom line. Les points douloureux courants incluent:

Entretien élevé & Usure des composants: Constant abrasive action from sand and gravel rapidly degrades standard components, conduisant à de fréquents, unplanned maintenance stops and high parts replacement costs.
Classification des matériaux inefficace: Inconsistent particle size separation results in offspec product, forcing reprocessing cycles that consume energy, time, et capacité.
Génération d’amendes excessives: 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.
Intensité énergétique: Inefficient drive systems and process design lead to unsustainable power consumption, a primary variable cost in mineral processing.

La question centrale pour les directeurs d'usine est: how can you increase throughput of inspec material while systematically reducing cost per ton for maintenance, énergie, and rework?

2. APERÇU DU PRODUIT: 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 (grossier, bien) from gravel and the removal of contaminants.

Flux de travail opérationnel:
1. Alimentation & Présélection: Runofmine material is conveyed to a primary vibrating screen, removing oversized debris (+63mm) and bypassing natural fines.
2. Usure & Lavage: The screened material enters a log washer or attrition scrubber to break down claybound aggregates and remove deleterious coatings.
3. Classification hydraulique: 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. Assèchement & Stockage: Classified sand is dewatered on fine material screw washers or linear motion dewatering screens, producing a dripfree product for stockpiling.
5. Gestion de l'eau: Effluent is sent to a settling tank or thickener for water recovery and silt management, closing the process loop.

Champ d'application & Limites:
Portée: Idéal pour les alluvions, riverrun gravel pits, and hard rock quarries producing concrete sand, sable à maçonnerie, and various gravel specifications. Designed for feed capacities from 100 à 500 TPH.
Limites: 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. CARACTÉRISTIQUES PRINCIPALES

Système de revêtement résistant à l'abrasion | Base technique: Highchrome white iron castings (700+ BHN) in highwear zones | Avantage opérationnel: Liner service life increased by up to 300% compared to standard AR steel | Impact sur le retour sur investissement: Reduces component change frequency by 60%, réduire le coût des stocks de pièces et les heures de travail.

Precision Hydraulic Classification Bank | Base technique: Bank of polyurethane hydrocyclones with adjustable vortex finders and apex valves | Avantage opérationnel: Enables realtime tuning of cut points for precise separation of coarse/fine/ultrafine fractions | Impact sur le retour sur investissement: Improves yield of inspec product by up to 8%, minimizing waste and reprocessing.

HighEfficiency Dewatering Screws | Base technique: Longpitch flights with weir overflow control and hydrocyclone underflow feed | Avantage opérationnel: Achieves final product moisture content as low as 1215%, reducing haulage weight | Impact sur le retour sur investissement: Lowers water content per ton shipped, improving transport efficiency.

Système de lubrification centralisé à la graisse | Base technique: Automated singlepoint system with metered delivery lines to all critical bearings | Avantage opérationnel: Assure une lubrification optimale des roulements sans intervention manuelle pendant le fonctionnement | Impact sur le retour sur investissement: Extends bearing life by an average of 40% and prevents costly seizurerelated downtime.

Entraînement à fréquence variable (VFD) Contrôle | Base technique: VFDs on major motors including pump drives and screw washers | Avantage opérationnel: Allows softstart capability and precise speed adjustment to match feed variations | Impact sur le retour sur investissement: Reduces peak power demand by up to 30% and cuts overall energy consumption by approximately 1520%.

Conception modulaire montée sur patins | Base technique: Préassemblé, prepiped modules on structural steel skids | Avantage opérationnel: Reduces onsite installation time by an estimated 50% versus componentbycomponent builds | Impact sur le retour sur investissement: Accelerates timetorevenue by weeks; simplifie le déménagement ou l'agrandissement futur de l'usine.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Solution standard de l'industrie | This CEMarked Sand Gravel Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Wear Component Life (Primary Screw Flight) | Standard AR Steel (400 BHN), ~1 500 heures | HighChrome Iron Casting (700+ BHN), ~4 500 heures| +200% durée de vie |
| 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% amélioration du rendement |
| Average Moisture Content of Final Sand Product| Singlestage dewatering; typiquement 1822% humidité| Twostage dewatering with controlled retention; typiquement 1215% humidité| ~30% reduction in transported water weight |
| Installation & Temps de mise en service (for 200TPH plant)| Field assembly & alignement; ~68 weeks| Skidmounted modular installation; ~34 weeks| Déploiement ~50 % plus rapide |
| Consommation d'énergie spécifique (kWh/Ton processed)| Fixedspeed motors; ~2.8 3.2 kWh/tonne| VFDcontrolled motors with load sensing; ~2.2 2.5 kWh/tonne| Up to ~22% lower energy use |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité nominale: Configurable à partir de 120 TPH à 450 TPH dry feed.
Exigences d'alimentation: Charge totale connectée environ 350 kW 900 kW selon configuration; main supply required at 400V/50Hz (or as specified).
Spécifications matérielles: Contact surfaces in wear zones utilize Trellex® rubber lining or NiHard castings; structural steel is S355JR grade with ISO12944 C4 corrosion protection coating.
Dimensions physiques (Disposition typique): Footprint approximately 35m (L) x 18m (W) x 12m (H). Modular skid dimensions vary but are designed for standard container transport.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C. All electric drives are IP66 rated; control panel is IP54 rated.

6. SCÉNARIOS D'APPLICATION

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.

Granulat de béton recyclé (RCA) Traitement

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

7. CONSIDÉRATIONS COMMERCIALES

This CEmarked solution is offered in three primary tiers:

1. Niveau essentiel: Includes core processing modules—primary screen ,log washer ,banque d'hydrocyclones ,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.Niveau 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 mois pièces/main d'oeuvre)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 Des garanties de performance sont-elles offertes?
A YesWe offer guaranteed throughput capacityfor defined feed material specificationsalongside guaranteed final product gradationenvelopeand maximum power consumptionfiguresThese are detailedin the commercial offer