H1: HighCapacity Sand and Gravel Classifying Tanks | Precision Separation for Maximum Yield

1. PEMBUKAAN PAINPOINT DRIVEN

Are inconsistent product specs and lost fines eroding your profit margins? In sand and gravel production, inefficient material classification directly impacts your bottom line. Common operational challenges include:
Product Contamination: Inadequate separation of sand fractions leading to offspec material, causing load rejections and diminishing your brand’s reliability.
Yield Loss: Hingga 15% of valuable fine sand can be lost to settling ponds or waste piles due to imprecise classification, representing significant revenue left unrecovered.
Air Tinggi & Penggunaan tenaga: Inefficient, highvolume water usage increases pumping costs and complicates water management, while oversized pumps drive unnecessary energy expenses.
Frequent Downtime: Congestion and sand buildup in classifiers require regular shutdowns for manual cleaning and adjustment, reducing available operating hours.

How do you increase the precision of your sand products while simultaneously reducing water usage and recovering more saleable material? The solution lies in moving beyond basic settling pits to engineered hydraulic classification.

2. GAMBARAN KESELURUHAN PRODUK

The Advanced Hydraulic Classifying Tank is a controlledcurrent separation system designed for the highvolume, efficient sorting of sand and fine aggregates by particle size and specific gravity. It replaces or augments traditional methods like screw classifiers or simple settling basins.

Aliran Kerja Operasi:
1. Slurry Introduction: A sandwater slurry is evenly distributed across the full width of the tank inlet box.
2. Controlled Settling: As material flows horizontally through the tank, particles settle into multiple collection hoppers based on their settling rate—finer particles travel further, coarser particles settle first.
3. Product Extraction: Precisely adjusted valves on each hopper allow for the continuous extraction of up to four distinct, specgrade sand products (mis., coarse concrete sand, fine masonry sand).
4. Overflow Management: Ultrafine silt and clay particles remain suspended, reporting to the effluent overflow for further processing or discharge.

Skop Permohonan & Batasan:
Sesuai Untuk: Washing plants producing multiple spec sands; sites with variable feed material; operations focused on fines recovery; projects requiring precise cut points between 100 mesh and 1/4".
Batasan: Not a dewatering device—extracted sands require further dewatering (mis., on a dewatering screen). Primary crushing and scrubbing must be completed upstream.

3. CIRI TERAS

Manifold Feed Distributor | Asas Teknikal: Laminar flow engineering | Faedah Operasi: Ensures even slurry distribution across the entire tank width, preventing shortcircuiting and ensuring consistent classification across all hoppers. | Kesan ROI: Eliminates product banding, ensuring every ton meets specification and reducing reprocessing.

Modular Hopper Design | Asas Teknikal: Discrete settlement zones with independent discharge gates | Faedah Operasi: Operators can adjust gate openings to control the cut point and volume of each product fraction in realtime based on feed changes. | Kesan ROI: Maximizes yield by allowing precise tuning for changing market demands or feed stockpile variations.

CorrosionResistant Liners | Asas Teknikal: Abrasionresistant steel or polyurethane lining at highwear points | Faedah Operasi: Dramatically extends service life in critical wear zones compared to unlined carbon steel, reducing maintenance frequency. | Kesan ROI: Lowers longterm operating costs by extending time between liner replacements by up to 3x.

LowProfile, HighCapacity Design | Asas Teknikal: Optimized tank geometry for gravity flow | Faedah Operasi: Requires less static head pressure than deep cone classifiers, allowing integration with existing pump systems and reducing overall plant height requirements. | Kesan ROI: Lowers initial installation costs and simplifies retrofit into existing plant layouts.

Fines Recovery Baffle System | Asas Teknikal: Hydraulic current control baffles | Faedah Operasi: Promotes retention of difficulttocapture 70200 mesh fines within the product hoppers before they report to overflow. | Kesan ROI: Directly increases recoverable product yield by capturing valuable fines previously lost.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Screw Classifier/Basin) | Our Classifying Tank Solution | Kelebihan |
| : | : | : | : |
| denda (100200 mesh) Kadar Pemulihan | Biasanya 5070% loss to overflow | Consistent recovery >85% into product stream| +3040% yield improvement |
| Penggunaan Air setiap Tan Diproses| 100150 gelen/tan (recirculating) | 7090 gelen/tan (recirculating) |30% water volume required |
| Product Specification Consistency| Variable due to feed surges & pelarasan manual| Consistent grade with automated gate control| Reduces offspec material by ~25% |
| Masa Henti Penyelenggaraan (tahunan)| 4060 hours for wear part replacement/cleanout| <20 hours with lined components & accessible gates| ~60% reduction in downtime |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Model dari 50 TPH berakhir 500 TPH sand feed capacity.
Keperluan kuasa: System typically relies on existing plant slurry pumps; no dedicated drive motors required.
Spesifikasi Bahan: Struktur utama: ASTM A36 carbon steel. Highwear areas lined with AR400 steel (12mm) or replaceable polyurethane panels (25mm).
Dimensi Fizikal (Model CFT200): Panjang: 24 ft; Lebar: 12 ft; Ketinggian: 8 ft; Berat (dry): ~18,000 lbs.
Julat Operasi Persekitaran: Designed for outdoor installation; operates effectively in ambient temperatures from 20°F to +120°F (29°C to +49°C). Slurry temperature tolerance from 32°F to 95°F (0°C to 35°C).

6. SENARIO APLIKASI

Concrete Sand Producer Facing Market Expansion Challenge

Cabaran: A regional producer needed to separate its single "pasir konkrit" product into two distinct grades—a coarse ASTM C33 concrete sand and a finer masonry/blend sand—to access new contracts without major plant overhaul.
Penyelesaian: Installation of a Model CFT150 Classifying Tank downstream of their existing wash screen.
Keputusan: The operation now simultaneously produces two inspec products at a combined rate of 150 Tph. Data lapangan menunjukkan a 22% increase in total sales revenue from the same deposit due to premium pricing on the masonry sand fraction.

Alluvial Gravel Pit with High Fines Loss Challenge

Cabaran: Significant volumes of profitable fine concrete sand (70100 mesh) were being lost to settling ponds due to an overloaded screw classifier system, resulting in wasted resource and high pond dredging costs.
Penyelesaian: Retrofitting a classifying tank as a primary classifier ahead of the existing screws, which were repurposed as dewatering units.
Keputusan: Recovered an additional 25 TPH of saleable fine sand previously lost. This increased overall plant yield by approximately 12%, paying back the equipment investment in under one season while drastically reducing pond maintenance.

7. PERTIMBANGAN KOMERSIL

Peringkat Harga: Solutions are configured based on capacity and material specifications.
Kewajipan Standard: For consistent feeds under 150 TPH dengan lelasan sederhana.
Tugas Berat: Untuk operasi hightonnage (>150 Tph) or highly abrasive feeds featuring upgraded liners and gate assemblies.
Modular/Portable: Skidmounted units for lease/fleet operations requiring relocation.

Ciri Pilihan & Naik taraf: Automated gate actuators with PLC control interface; advanced urethane lining packages; camera monitoring systems for remote hopper level checks; custom manifold designs for unique feed conditions.

Pakej Perkhidmatan: Extended warranty plans are available covering structural components against defects beyond standard terms.

Pilihan Pembiayaan:

Equipment Lease: Fixed monthly payments over terms ranging from three years up through seven years.

RentaltoOwn: A portion of monthly rental fees apply toward eventual purchase.

Traditional Financing: Secured loan options through our commercial lending partners.

All financing is subject to credit approval.