H1: CEMarked Sand & Gravel Washing and Classification Plants: Engineered for Uninterrupted Production and Specification Compliance

1. PEMBUKAAN PAINPOINT DRIVEN

Managing a sand and gravel operation means contending with persistent challenges that directly erode profitability. Bahan suapan yang tidak konsisten, Peraturan alam sekitar yang ketat, and the relentless demand for higherquality aggregates create significant pressure. Adakah anda menghadapi:
Product Specification Failures: Inconsistent silt content or improper particle size distribution leading to rejected loads, aduan pelanggan, dan pemprosesan semula yang mahal.
Air Berlebihan & Penggunaan tenaga: Inefficient washing cycles and outdated pump systems that inflate operational costs and complicate water recycling efforts.
Masa Henti Penyelenggaraan Tinggi: Kegagalan galas yang kerap, penggantian kain skrin, and pump blockages in abrasive environments, causing unscheduled production halts.
Risiko Pematuhan Alam Sekitar: Inability to effectively manage siltladen process water, risking permit violations and site closure.
Operasi Intensif Buruh: Reliance on manual adjustment and monitoring to maintain product grade, leading to variability and increased labor costs.

A CEmarked sand gravel washing plant is not just equipment; it is a controlled processing system designed to systematically address these issues.

2. GAMBARAN KESELURUHAN PRODUK

A CEmarked sand gravel washing plant is an integrated material processing system designed to liberate, mengelaskan, dewater, and clarify aggregates to meet precise commercial specifications. The CE marking signifies compliance with EU health, keselamatan, dan arahan alam sekitar, ensuring a baseline of operational safety and environmental consideration.

Aliran Kerja Operasi:
1. Suapan & Menggosok: Raw feed is introduced into a log washer or scrubbing barrel to break down claybound aggregates and dissolve contaminants.
2. Klasifikasi saiz: Material is screened via vibrating decks or hydrosizers to separate coarse gravel from sand fractions (mis., kasar, konkrit, pasir plaster).
3. Pembuangan Denda & Mencuci: Sand fractions are routed through cyclones or screw classifiers to remove silt and ultrafine particles while being cleansed of soluble salts.
4. Penyahairan & Stok: Washed sand is dewatered on fine material screens or in a dewatering tower to achieve a handleable, stackable product with optimal moisture content.
5. Pengurusan Air: Siltladen process water is sent to a clarifier or thickener for solids settlement, allowing clean water to be recirculated.

Skop Permohonan & Batasan:
Skop: Sesuai untuk mendapan aluvium, crushed rock quarries producing concrete/plaster sands, and construction/demolition waste recycling. Effective on materials with up to 30% silt/clay content.
Batasan: Not suitable for dry processing applications. Feed size is typically limited by the scrubber inlet (selalunya <150mm). Highly cemented or conglomerate materials may require primary crushing upstream.

3. CIRI TERAS

Patented Cyclone Cluster | Asas Teknikal: HighG force centrifugal separation | Faedah Operasi: Consistent removal of ultrafines (down to 63µm) regardless of feed rate fluctuation | Kesan ROI: Guarantees product silt content compliance (<3%), eliminating load rejections.

Modular BridgeBox Construction | Asas Teknikal: Pra-kejuruteraan, bolted structural framework | Faedah Operasi: Reduced site installation time by up to 40% versus weldedsite builds | Kesan ROI: Lower capital installation costs and faster commissioning for revenue generation.

Pemacu Frekuensi Pembolehubah (VFD) Pump Control | Asas Teknikal: Precise electric motor speed control for slurry pumps | Faedah Operasi: Operators match pump output exactly to feed rate; reduces cavitation and wear | Kesan ROI: Data lapangan menunjukkan 2230% reduction in energy consumption versus fixedspeed pumps.

Sistem Pelapik Tahan Lelasan | Asas Teknikal: Interchangeable urethane/ceramic liners in highwear zones (pencuci pakaian, taufan) | Faedah Operasi: Liner life extended 3x over standard steel plates; quickchange design | Kesan ROI: Lowers spare parts inventory cost and reduces downtime for liner replacement by over 50%.

Integrated Process Water Clarifier | Asas Teknikal: Lamella plate settling technology with flocculant dosing system | Faedah Operasi: Pulih >95% daripada air proses; produces stackable filter cake for easy disposal | Kesan ROI: Drastically reduces freshwater intake costs and ensures continuous operation under strict environmental permits.

Sistem Pelinciran Grease Berpusat | Asas Teknikal: Automated delivery of lubricant to all critical bearings | Faedah Operasi: Ensures bearings in hardtoreach locations are serviced without operator intervention | Kesan ROI: Ujian industri menunjukkan a 60% reduction in bearingrelated failures in abrasive wash plant environments.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penyelesaian Standard Industri | CEMarked Sand Gravel Plant Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Penggunaan Air Tertentu (m³/tan) | 1.5 2.0 m³/tonne recirculated + air solek

|
| Konsistensi Produk (Silt Content Variation) |
| Pemasangan & Masa Pentauliahan |
| Jumlah Kos Pemilikan (5Tempoh Tahun) |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Model dari 50 tan sejam (Tph) ke 400+ Daya pengeluaran TPH.
Keperluan kuasa: Jumlah beban bersambung daripada 75 kw (for compact units) ke 450 kw (for full wash plants with clarifiers), typically requiring a 400V / 50Hz supply.
Spesifikasi Bahan: Struktur utama: Keluli S355JR. Komponen pakaian tinggi: AR400 steel plate or NiHard cast iron. Pelapik: Customformulated polyurethane or ceramic composite.
Dimensi Fizikal (Contoh 150 Tumbuhan tph): Lebih kurang. panjang: 25m; lebar: 8m; ketinggian: 7m (tidak termasuk corong suapan). Berat: ~45 tan.
Julat Operasi Persekitaran: Designed for ambient temperatures from 20°C to +45°C with appropriate lubrication specs. Dust encapsulation standard on conveyors; noise emissions below 85 db(A) di stesen operator.

6. SENARIO APLIKASI

Concrete Aggregate Producer Challenge Solution Results

Recycled Aggregates Facility Challenge Solution Results

7. PERTIMBANGAN KOMERSIL

CEmarked sand gravel plants are offered in scalable configurations aligned with production needs:

Peringkat Harga:

Basic Washing Unit: Includes scrubber screen combination unit
Standard Classification Plant: Incorporates log washer
Full Wash & Water Recycling Plant: Complete system with clarifier

Ciri Pilihan: Mobile wheelmounted chassis
Remote monitoring PLC package with data logging
Automatic flocculant dosing system
Additional dewatering screens for specialized sands

Pakej Perkhidmatan:
1year comprehensive warranty including parts/labor
5year structural warranty
Annual inspection service contract

Pilihan Pembiayaan:
Equipment leasing plans
Project financing solutions

8 Soalan Lazim

Q What upstream equipment is required?
A A CE marked plant requires pre sized feed material Typically this means pairing it with a primary crusher screen combination unit

Q How does the CE marking impact my site operations?
A The marking provides documented assurance that the equipment meets essential EU safety EMC machinery directives It simplifies insurance approvals demonstrates due diligence supports permit applications

Q What is the typical payback period?
A Based on client data replacing an inefficient legacy system payback periods range from months depending on local aggregate pricing reduced waste lower water costs

Q Can the plant be modified after installation?
A Yes The modular design allows for capacity upgrades addition of extra classification decks integration of new water treatment technologies as your business evolves

Q Adakah anda menyediakan latihan pengendali?
A Comprehensive training is included covering startup/shutdown procedures routine maintenance troubleshooting classification adjustment ensuring your team achieves optimal performance quickly