1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo suas margens de areia e cascalho? Your wash plant is the heart of your operation, yet common inefficiencies directly impact profitability. Consider these persistent challenges:
Inefficient Fines Removal: Inconsistent clay and silt rejection leads to offspec product, increased pond maintenance, and potential loss of premium material to waste.
Água alta & Consumo de energia: Traditional scrubbing and washing methods require excessive water recirculation and horsepower, creating unsustainable utility costs and environmental footprint.
Frequent Component Wear: Abrasive feed material accelerates wear on shafts, rolamentos, e forros, resulting in unplanned maintenance stops and high parts replacement budgets.
Flexibilidade de alimentação limitada: Can your system handle variable feedstock—from cemented aggregates to sticky claybound gravel—without choking or losing efficiency?
Espaço & Setup Constraints: Are you sacrificing processing capacity because your current equipment layout is inefficient or your site footprint is limited?

A questão central para os gerentes de fábrica é esta: how can you increase tons per hour of inspec material while systematically reducing cost per ton in water, energia, e manutenção?

2. VISÃO GERAL DO PRODUTO

O Log Washer is a core mineral processing machine designed for the tough duty of breaking down, esfregando, and cleaning heavily cemented aggregates or gravel contaminated with soluble clays, soft rock, and other deleterious materials. It is not a simple rinsing tool but an aggressive attrition machine.

Fluxo de Trabalho Operacional:
1. Alimentar & Retention: Contaminated feed (por exemplo, claybound gravel) is introduced into the inclined tub. The dual shaft design ensures positive material movement while providing extended retention time.
2. Aggressive Attrition: Counterrotating shafts fitted with NiHard paddles create intense scrubbing action. Material particles are violently abraded against each other, effectively disintegrating clay agglomerates and breaking down soft cementations.
3. Separação & Descarga: The scrubbed material is carried up the incline by the paddle action. Cleaned aggregate discharges at the elevated end, while liberated fines and dirty process water are flushed out through overflow weirs at the lower end.

Escopo de aplicação & Limitações:
Escopo: Ideal for durable aggregates requiring intense scrubbing (pedra britada, cascalho), difficulttohandle materials with plastic clays, and feed with soft rock or shale contaminants.
Limitações: Not suitable for friable or degradable materials that will break down into excess fines. Requires a steady feed rate; performance diminishes with significantly undercapacity loading.

3. RECURSOS PRINCIPAIS

HeavyDuty Tub Design | Base Técnica: Continuous weldment from abrasionresistant steel plate | Benefício Operacional: Withstands constant abrasive wear without fatigue cracking, garantindo integridade estrutural a longo prazo | Impacto do ROI: Eliminates midlife tub replacement costs; dados de campo mostram 4060% longer service life versus standard plate construction

NiHard Paddle & Shaft System | Base Técnica: Cast NiHard paddles on a forged alloy steel shaft with replaceable bolton log washers | Benefício Operacional: Maximizes abrasion resistance where wear is highest; simplifies maintenance by allowing individual paddle replacement | Impacto do ROI: Reduces downtime for shaft/paddle service by up to 70%; lowers longterm inventory cost for wear parts

Dual Shaft Gear Drive | Base Técnica: Synchronized helical gear drive housed in an oilbath chamber | Benefício Operacional: Provides positive timing of counterrotating shafts for consistent material movement; eliminates chain drive stretch and breakage risks | Impacto do ROI: Reduces driverelated downtime to near zero; gearbox efficiency yields up to 15% lower power consumption compared to equivalent chaindriven units

Adjustable Overflow Weirs | Base Técnica: Manually adjustable weir plates along the discharge end | Benefício Operacional: Operators can finetune retention time and slurry density in realtime based on feed variation | Impacto do ROI: Optimizes product grade control, reducing offspec yield by an average of 812% as reported by plant managers

Modular Bearing Cartridges | Base Técnica: Selado, prealigned roller bearing cartridges mounted externally to the tub | Benefício Operacional: Isolates critical bearings from water ingress and contamination; allows for cartridge replacement without major shaft disassembly | Impacto do ROI: Prolonga a vida útil do rolamento em 3x; reduces critical path repair time from hours to minutes

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (ChainDriven Log Washer) | Our Log Washer Solution (GearDriven) | Vantagem (% Melhoria) |
| : | : | : | : |
| Drive System Efficiency | Chain & Sprocket (~85% efficient) | Enclosed Helical Gear Drive (~98% efficient) | ~15% Lower Power Draw |
| Tempo médio entre falhas (Dirigir) | 4,000 6,000 horas (chain stretch/breakage) | 20,000+ horas (gearbox service interval) | >300% Aumentar |
| Abrasion Wear Life (Paddles) | Standard AR Steel Castings (~1,200 hrs avg.)| NiHard Castings with optimized profile (~2,200 hrs avg.)| ~80% de aumento |
| Tempo de inatividade de manutenção (Bearing Service)| 68 horas (disassembly required) | <2 horas (cartridge swap) | ~70% Reduction |
| Feed Size Flexibility Max Recommended| 4" (100milímetros) due to chain stress limitations| 6" (150milímetros) due to hightorque gear drive| 50% Larger Capacity

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade da gama de modelos: 50 400 TPH (Toneladas por hora), depending on material density and contamination level.
Requisitos de energia: 75 400 HP dual motor configuration across model range. Electrical supply must match motor nameplate specifications (por exemplo, 460V/60Hz/3F).
Especificações de materiais: Tub constructed from ¾” AR400 abrasionresistant steel. Paddles are Grade III NiHard cast iron. Os eixos são de liga de aço forjado.
Dimensões Físicas (Model LW200): Overall Length: 28’. Overall Width: 9’. Altura de descarga: 12’. Peso aproximado: 48,000 libras.
Faixa operacional ambiental: Designed for continuous outdoor operation in temperatures from 20°C to +50°C (4°F a +122°F). Sealed components protect against dust and moisture ingress.

6. CENÁRIOS DE APLICAÇÃO

Aggregate Producer – Sticky Clay Contamination

Desafio: A Midwest gravel pit faced significant clay contamination that coated aggregate, failing washed concrete sand specifications and clogging dewatering screens daily.
Solution Implementation of a hightorque Log Washer ahead of the classification deck.
Results The intense attrition stripped >95% of clay coatings. A produção da planta aumentou em 22%, pond maintenance frequency decreased by twothirds.

Construção & Reciclagem de Demolição

Desafio: Processing recycled concrete with residual mortar required effective liberation without overcrushing the valuable aggregate.
Solution Integration of a Log Washer after primary crushing to scrub recycled concrete feed.
Results Achieved consistent cleanliness meeting DOT specs for base material.Reduced manual sorting labor by an estimated $45k annually.

Sand Processing Plant Upgrade

Challenge An existing operation using only screens could not remove soluble clays leading to poor sand quality rejected by ready mix customers.
Solution A compact Log Washer was installed in the circuit postscreening.
Results Produced a premium mason sand meeting ASTM C144 specifications opening new markets Plant revenue increased by approximately $180k in the first year.

7 CONSIDERAÇÕES COMERCIAIS

Os níveis de preços de equipamentos são estruturados em torno da capacidade de produção:
Tier I Standard Duty Units Up To TPH range ideal for satellite pits or lower volume operations includes base gear drive NiHard paddles
Tier II Heavy Duty Units TPH range most common configuration includes all Core Features modular bearings adjustable weirs
Tier III Custom High Capacity Units TPH designed for major greenfield plants includes custom tub lengths specialized paddle configurations

Optional Features Premium urethane lined tub sections for less abrasive applications variable frequency drives VFDs for precise speed control automated grease lubrication systems remote monitoring sensors

Service Packages Three tiers available Bronze Annual inspection parts discount Silver Includes annual inspection priority parts shipping Gold Comprehensive planned maintenance program including annual bearing service

Financing Options Available through partner institutions include capital lease operating lease or loan structures typical terms months can be structured to match seasonal cash flow patterns

8 Perguntas frequentes

Q What upstream equipment is required before a log washer
A A log washer requires a regulated feed typically from a surge bin or conveyor belt It should follow primary crushing but precede final sizing screens For best results ensure feed size does not exceed manufacturer recommendations

Q How does this impact my overall water management system
A While effective log washers consume water they significantly reduce solids loading to your settling ponds Industry testing demonstrates our design s efficient slurry removal can reduce pond dredging cycles by compared to less efficient scrubbing methods

Q Can this unit replace my existing scrubber or trommel screen
A It depends on your material For heavy clays it often serves as a superior primary scrubbing unit For simple rinsing it may be over engineered A site audit can determine optimal circuit placement

Q What is the typical installation timeframe
A For a standard unit foundation preparation electrical hookup mechanical assembly typically requires working days assuming all site utilities are prepared Installation supervision services are available

Q As peças sobressalentes estão prontamente disponíveis
A Yes Critical wear parts paddles shafts bearing cartridges are stocked regionally Average emergency parts shipment lead time is business days within continental US

Q What financing options apply if Im upgrading an existing plant
A Upgrades often qualify for different financial structures including technology improvement loans We can provide documentation outlining projected efficiency gains savings which may assist in securing financing

Q Is operator training provided
A Yes Comprehensive training covering startup shutdown routine monitoring adjustment procedures troubleshooting basics is included with purchase Additional on site training sessions are available under our service packages