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.? Common industry challenges include:
Usure élevée & Coûts d'entretien: Abrasive materials rapidly degrade crusher liners, écrans, et composants de pompe, leading to frequent part replacement and unplanned stoppages.
Classification des matériaux inefficace: Une séparation granulométrique incohérente entraîne un produit hors spécifications, retraitement coûteux, and lost revenue from premium aggregate grades.
Génération d’amendes excessives: Overcrushing in primary and secondary stages creates an oversupply of lowvalue fines, diminishing the yield of highvalue concrete and asphalt sand.
Consommation d'énergie élevée & Travail: Inefficient plant layout and manually intensive processes, like feeder regulation and belt monitoring, drive up power costs and require constant operator intervention.
Water Management Complexity: Ineffective slurry handling and dewatering systems lead to water recycling issues, sediment pond overflows, and potential environmental compliance risks.

Is your operation equipped to transform these cost centers into controlled, predictable processes? The right core processing equipment is not an expense but a direct lever for profitability.

2. APERÇU DU PRODUIT: SAND CLASSIFICATION AND DEWATERING SYSTEM

This sand classification and dewatering system is engineered for the precise washing, dimensionnement, and moisture reduction of sand products in sand gravel mining operations. It is a closedloop solution designed to maximize product value and minimize water consumption.

Flux de travail opérationnel:
1. Alimentation & Distribution: Slurry from a wash screen or attritioner is evenly distributed into the system’s feed box.
2. Classification hydraulique: Material enters a rising current cyclone or hydraulic classifier, separating sand particles by size and specific gravity.
3. Deck Dewatering: Classified sand is discharged onto a highfrequency dewatering screen, where vibration forces remove surface moisture.
4. Stockage & Recyclage de l'eau: Onspec dewatered sand is conveyed to stockpile, while effluent water is channeled to a clarifier for recycling.

Champ d'application & Limites:
Portée: Ideal for producing concrete sand, sable à maçonnerie, sables spéciaux, and glass sand from natural deposits or crushed rock. Effective for operations processing 50 à 500 tons per hour of sand feed.
Limites: Not a substitute for primary washing or scrubbing of heavily claybound material. Feed slurry consistency must be controlled for optimal classification. Requires a consistent water supply and complementary settling pond or clarifier system.

3. CARACTÉRISTIQUES PRINCIPALES

Precision Hydraulic Classifier | Base technique: Controlled rising current water velocity | Avantage opérationnel: Achieves accurate cut points for consistent product gradation meeting ASTM C33 or other specifications | Impact sur le retour sur investissement: Réduit le rejet du produit jusqu'à 15% and increases premium product yield

HighFrequency Dewatering Screen | Base technique: Linear vibratory motion with steep discharge angle | Avantage opérationnel: Reduces moisture content in finished sand to 812%, minimizing hauling costs and preventing stockpile freezing | Impact sur le retour sur investissement: Lowers drying fuel costs if thermal drying is required; improves customer satisfaction with dripfree loads

Polyurethane Wear Components | Base technique: Abrasionresistant cast polyurethane liners, nozzles, and screen panels | Avantage opérationnel: Provides 35x longer service life than standard rubber or steel in highwash environments | Impact sur le retour sur investissement: Cuts component replacement costs by over 60% annually and reduces changeout downtime

Variable Speed Drive System | Base technique: Integrated VFDs on feed pumps and screen vibrators | Avantage opérationnel: Allows operators to finetune classification cut point and dewatering intensity based on feed material changes in realtime | Impact sur le retour sur investissement: Optimizes efficiency across varying deposit strata without manual component swaps

Modular Construction | Base technique: Bolttogether subassemblies with prefitted piping | Avantage opérationnel: Permet un assemblage rapide sur site avec un minimum de soudure; simplifie la future reconfiguration ou la relocalisation de l'usine | Impact sur le retour sur investissement: Réduit le temps d'installation jusqu'à 40%, réduire les coûts des sous-traitants et accélérer les délais de production

Integrated Flocculant Dosing Ports | Base technique: Preplumbed injection manifolds at key slurry points | Avantage opérationnel: Facilitates optimal chemical mixing for enhanced fines capture in closedwater circuits | Impact sur le retour sur investissement: Improves water clarity for recycling, reduces pond cleaning frequency by an estimated 30%

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Conventional Cyclone & Écran) | This Sand Classification System | Avantage (% Amélioration) |
| : | : | : | : |
| Product Moisture Content (Concrete Sand) | 1520% typical discharge moisture| Cohérent 912% discharge moisture| Jusqu'à 40% reduction in free water weight |
| Efficacité de récupération des amendes (200 engrener)~7080% recovery rate~Consistent >92% recovery rate~Up to ~22% more saleable material retained |
| Wear Life on Primary Liners~Rubber liners lasting ~4 months~Polyurethane liners lasting ~14 months~250% longer service life |
| Power Consumption per Ton~Fixed speed drives at constant load~Variable speed drives optimizing load~Field data shows 1018% kWh/tonne inférieur |
| Footprint Requirement (à capacité égale)~Multiple units with separate supports~Single integrated structure with shared supports~Approximately 25% less floor space |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Modèles disponibles chez 50 TPH à 400 TPH of dry solids feed (slurrydependent).
Exigences d'alimentation: Total connected power ranges from 45 kW (pour les petits modèles) à 150 kW (for largest models), utilizing standard industrial voltages (460V/3Ph/60Hz).
Spécifications matérielles: Contact surfaces utilize ASTM A36 structural steel with abrasionresistant AR400 steel at highimpact points. Classification chambers feature cast polyurethane. Screen decks are polyurethane modular panels.
Dimensions physiques (Model SC200): Longueur totale: ~9 min; Largeur: ~4m; Hauteur (to top of feed box): ~5 m; Poids d'expédition approximatif: ~14,000 kg.
Plage de fonctionnement environnementale: Designed for ambient temperatures from 29°C to +45°C (20°F à +113°F). Electrical components rated for NEMA 4X (hosedown, corrosion resistant) environnements.

6. SCÉNARIOS D'APPLICATION

Usine de production de sable à béton

Challenge A Midwest producer struggled with inconsistent gradation yielding only ~65% ASTM C33compliant concrete sand from their deposit; the remainder was downgraded as fill material at significant revenue loss.
Solution Implementation of a Model SC150 Sand Classification System with precision hydraulic classifiers replaced their outdated rake classifier system.
Results Within one month of commissioning:
Production of spec concrete sand increased to over 92%.
Fines loss was reduced by twothirds.
Annualized revenue increase exceeded $280k based on increased premium product volume.

DredgeFed Mining Operation

Challenge A river dredging operation faced high pumping costs due to transporting excess water long distances from the dredge pond to the processing plant.
Solution Installation of a compact Sand Classification System directly on the dredge discharge allowed for primary dewatering at the pit face.
Results The system delivered:
A reduction in slurry volume pumped by over 35%, significantly lowering fuel consumption per ton produced.
Direct loading of dewatered sand onto haul trucks at the pit site versus pumping it miles away.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification des équipements
Tier pricing is based on capacity (TPH). Entrylevel systems (250 TPH) sont cités sur les spécifications du projet.

Fonctionnalités facultatives
Advanced features include remote monitoring PLC packages with gradation trend tracking , systèmes automatisés de dosage de floculant , stainless steel construction for corrosive environments ,et enceintes d'insonorisation .

Forfaits de services
Threetier service plans are available:
1.Basic Warranty covering parts .
2.Platinum Plan extending warranty coverage .
3.Platinum Plus Plan adding annual inspections .

Options de financement
Flexible commercial terms include capital lease , location simple ,and loan structures through partner financial institutions . Renttoown programs may be available .

8. FAQ

Quel équipement en amont est nécessaire?
The system requires a consistent slurry feed typically provided by a wash screen log washer or attrition scrubber . Feed pumps can be included as part of the package .

How does this system integrate with our existing clarifier or settling pond?
It is designed as a complementary component . By removing most solids it significantly reduces the load on your clarifier improving its efficiency . Standard discharge flanges connect directly .

Quel est le délai d'installation typique?
For modular units installation typically requires days not weeks assuming prepared foundations are ready . Our project managers provide detailed site preparation guidelines .

Des garanties de performance sont-elles offertes?
Yes performance guarantees based on achieving specified product gradation bands are included in commercial contracts subject .

What spare parts inventory should we maintain?
We provide recommended critical spares list which typically includes polyurethane wear parts specific screen panel modules .

Can this handle very coarse material like pea gravel?
No this system is optimized specifically for sandsized particles . For coarse aggregate rinsing separate solutions are recommended .

What ongoing operator training do you provide?
Comprehensive training during commissioning covers operation maintenance troubleshooting procedures . Training manuals digital resources are provided