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

1. ABERTURA ACIONADA POR PAINPOINT

Managing a sand and gravel operation means contending with persistent challenges that directly erode profitability. Material de alimentação inconsistente, stringent environmental regulations, and the relentless demand for higherquality aggregates create significant pressure. Você está enfrentando:
Product Specification Failures: Inconsistent silt content or improper particle size distribution leading to rejected loads, reclamações de clientes, e reprocessamento dispendioso.
Excesso de água & Consumo de energia: Inefficient washing cycles and outdated pump systems that inflate operational costs and complicate water recycling efforts.
Alto tempo de inatividade para manutenção: Falhas frequentes em rolamentos, substituições de pano de tela, and pump blockages in abrasive environments, causing unscheduled production halts.
Riscos de conformidade ambiental: Inability to effectively manage siltladen process water, risking permit violations and site closure.
Operação Intensiva em Mão de Obra: 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. VISÃO GERAL DO PRODUTO

A CEmarked sand gravel washing plant is an integrated material processing system designed to liberate, classify, dewater, and clarify aggregates to meet precise commercial specifications. The CE marking signifies compliance with EU health, segurança, e directivas ambientais, ensuring a baseline of operational safety and environmental consideration.

Fluxo de Trabalho Operacional:
1. Alimentar & Esfregar: Raw feed is introduced into a log washer or scrubbing barrel to break down claybound aggregates and dissolve contaminants.
2. Classificação de tamanho: Material is screened via vibrating decks or hydrosizers to separate coarse gravel from sand fractions (por exemplo, grosseiro, concreto, plaster sand).
3. Remoção de Multas & Lavando: Sand fractions are routed through cyclones or screw classifiers to remove silt and ultrafine particles while being cleansed of soluble salts.
4. Desidratação & Estoque: Washed sand is dewatered on fine material screens or in a dewatering tower to achieve a handleable, stackable product with optimal moisture content.
5. Gestão da Água: Siltladen process water is sent to a clarifier or thickener for solids settlement, allowing clean water to be recirculated.

Escopo de aplicação & Limitações:
Escopo: Ideal para depósitos aluviais, crushed rock quarries producing concrete/plaster sands, and construction/demolition waste recycling. Effective on materials with up to 30% silt/clay content.
Limitações: Not suitable for dry processing applications. Feed size is typically limited by the scrubber inlet (muitas vezes <150milímetros). Highly cemented or conglomerate materials may require primary crushing upstream.

3. RECURSOS PRINCIPAIS

Patented Cyclone Cluster | Base Técnica: HighG force centrifugal separation | Benefício Operacional: Consistent removal of ultrafines (down to 63µm) regardless of feed rate fluctuation | Impacto do ROI: Guarantees product silt content compliance (<3%), eliminating load rejections.

Modular BridgeBox Construction | Base Técnica: Pré-projetado, bolted structural framework | Benefício Operacional: Reduced site installation time by up to 40% versus weldedsite builds | Impacto do ROI: Lower capital installation costs and faster commissioning for revenue generation.

Unidade de frequência variável (VFD) Pump Control | Base Técnica: Precise electric motor speed control for slurry pumps | Benefício Operacional: Operators match pump output exactly to feed rate; reduces cavitation and wear | Impacto do ROI: Os dados de campo mostram 2230% reduction in energy consumption versus fixedspeed pumps.

Sistema de revestimento resistente à abrasão | Base Técnica: Interchangeable urethane/ceramic liners in highwear zones (lavagens, ciclones) | Benefício Operacional: Liner life extended 3x over standard steel plates; quickchange design | Impacto do ROI: Lowers spare parts inventory cost and reduces downtime for liner replacement by over 50%.

Integrated Process Water Clarifier | Base Técnica: Lamella plate settling technology with flocculant dosing system | Benefício Operacional: Recupera >95% de água de processo; produces stackable filter cake for easy disposal | Impacto do ROI: Drastically reduces freshwater intake costs and ensures continuous operation under strict environmental permits.

Sistema centralizado de lubrificação com graxa | Base Técnica: Automated delivery of lubricant to all critical bearings | Benefício Operacional: Ensures bearings in hardtoreach locations are serviced without operator intervention | Impacto do ROI: Os testes da indústria demonstram uma 60% reduction in bearingrelated failures in abrasive wash plant environments.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Solução padrão da indústria | CEMarked Sand Gravel Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Consumo Específico de Água (m³/tonelada) | 1.5 2.0 m³/tonne recirculated + água de maquiagem

|
| Consistência do Produto (Silt Content Variation) |
| Instalação & Tempo de comissionamento |
| Custo total de propriedade (5Período do ano) |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Modelos de 50 toneladas por hora (TPH) para 400+ Taxa de transferência de TPH.
Requisitos de energia: Carga total conectada de 75 kW (for compact units) para 450 kW (for full wash plants with clarifiers), typically requiring a 400V / 50Alimentação Hz.
Especificações de materiais: Estrutura primária: Aço S355JR. Componentes de alto desgaste: AR400 steel plate or NiHard cast iron. Forros: Customformulated polyurethane or ceramic composite.
Dimensões Físicas (Exemplo 150 Planta TPH): Aprox.. comprimento: 25eu; largura: 8eu; altura: 7eu (excluindo funil de alimentação). Peso: ~45 tonnes.
Faixa operacional ambiental: Designed for ambient temperatures from 20°C to +45°C with appropriate lubrication specs. Dust encapsulation standard on conveyors; noise emissions below 85 dB(UM) nas estações da operadora.

6. CENÁRIOS DE APLICAÇÃO

Concrete Aggregate Producer Challenge Solution Results

Recycled Aggregates Facility Challenge Solution Results

7. CONSIDERAÇÕES COMERCIAIS

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

Níveis de preços:

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

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

Pacotes de serviços:
1year comprehensive warranty including parts/labor
5year structural warranty
Annual inspection service contract

Opções de financiamento:
Equipment leasing plans
Project financing solutions

8 Perguntas frequentes

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

P Vocês oferecem treinamento ao operador?
A Comprehensive training is included covering startup/shutdown procedures routine maintenance troubleshooting classification adjustment ensuring your team achieves optimal performance quickly