1. PAINPOINT DRIVEN OPENING

Managing a sand and gravel operation means contending with persistent, costly inefficiencies. Are you facing these common challenges?
Unplanned Downtime: Frequent mechanical failures in material handling and processing equipment halt your entire production line, costing thousands per hour in lost revenue and idle labor.
Inconsistent Feed & Product Quality: Fluctuations in feed size and moisture content from the pit lead to process instability, resulting in offspec product, increased waste, and rejected loads.
High Maintenance & Wear Costs: The abrasive nature of aggregate rapidly degrades components like pump impellers, screen decks, and classifier wear shoes, driving up your parts inventory and maintenance labor expenses.
Inefficient Water & Fines Management: Inadequate separation of fines consumes excessive process water, complicates settling pond management, and represents a direct loss of saleable material.
LaborIntensive Oversight: Reliance on manual adjustments and monitoring for crushers, screens, and classifiers leads to operator fatigue, inconsistent settings, and delayed response to process upsets.

The central question for procurement specialists and plant managers is this: how can you specify equipment that directly mitigates these issues to improve your cost per ton?

2. PRODUCT OVERVIEW: HIGHCAPACITY HYDROCYCLONE CLASSIFIER

For sand and gravel mining dealers seeking precise control over material classification, a highcapacity hydrocyclone system is a critical component. This equipment separates particles by size in a slurry using centrifugal force, specifically designed for the rigorous demands of aggregate processing.

Operational Workflow:
1. Slurry Inlet: The sandwater slurry is pumped under pressure tangentially into the cyclone’s upper chamber.
2. Centrifugal Separation: Rapid rotation creates a vortex; coarser, heavier sand particles are forced to the walls and descend.
3. Dual Discharge: Classified sand discharges as a thickened underflow from the apex (bottom), while fine particles (silt/clay) and water exit via the overflow pipe (top).
4. Process Integration: The underflow reports to dewatering screens or stockpiles; the overflow is directed to settling ponds or recirculation systems.

Application Scope: Ideal for washing, classifying, and dewatering crushed stone, sand, and gravel. Effective for removing fines (typically 200 mesh) to meet ASTM C33 or other specifications.

Key Limitations: Requires a consistent feed pump pressure for optimal performance. Not a drying solution; output is a damp solid. Primary separation is based on particle size and specific gravity; shape can be a minor factor.

3. CORE FEATURES

Modular Ceramic Liner System | Technical Basis: Interlocking alumina ceramic tiles with polyurethane backing | Operational Benefit: Provides extreme abrasion resistance in all highwear zones (apex, inlet head, cone sections). Tiles can be replaced individually without removing entire cyclone sections. | ROI Impact: Reduces liner replacement costs by up to 60% compared to standard polyurethane units and extends service intervals by over 300%.

Variable Apex & Vortex Finder Control | Technical Basis: Mechanically adjustable discharge orifices and overflow inserts | Operational Benefit: Allows operators to finetune cut point (separation size) and underflow density in realtime to adapt to changing feed material without stopping production. | ROI Impact: Minimizes product giveaway by maintaining specification compliance; field data shows a 515% increase in yield of inspec product.

Laminated Polyurethane Construction | Technical Basis: Hightensilestrength polyurethane molded under pressure with integrated steel reinforcement bands | Operational Benefit: Offers exceptional durability against abrasion while providing significant weight reduction versus allrubber or metal designs for easier handling. | ROI Impact: Lowers lifetime maintenance costs through extended body life and reduces injury risk during component changeouts.

Optimized Geometric Design | Technical Basis: CFDmodeled inlet head design & cone angles for aggregate slurries | Operational Benefit: Maximizes separation efficiency (sharpness of cut) while minimizing internal turbulence that causes premature wear. | ROI Impact: Improves hydraulic capacity per unit; one unit can often handle the duty of two older models.

Cluster Manifold Design | Technical Basis: Lowprofile feed manifold distributing slurry evenly to multiple cyclones from a single pump source | Operational Benefit: Simplifies piping reduces pump requirements ensures balanced operation across all cyclones for consistent product. | ROI Impact: Lowers initial installation costs reduces energy consumption through optimized pump sizing.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | HighCapacity Hydrocyclone Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life in Abrasive Sand Service| Standard Polyurethane (69 months) | Modular Ceramic Liners (24+ months) | +300% service life |
| Separation Efficiency (Sharpness of Cut)| Baseline design with fixed geometry| CFDoptimized geometry with adjustable controls| 1520% sharper cut point |
| Maintenance Downtime per Liner Change| Full section replacement (48 hours)| Individual tile replacement (12 hours)| ~75% reduction in downtime |
| Energy Efficiency per Ton Classified| Older cyclone design requiring higher feed pressure| Optimized inlet design reducing required pump head| 1015% lower pumping energy cost |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Models available from 50 GPM to 1，200 GPM slurry processing per unit.
Classification Cut Point: Typically adjustable between 100 mesh (150µm)和200 mesh (75µm)， depending on feed conditions.
Construction Materials: Highabrasion laminated polyurethane body， modular alumina ceramic liners， stainless steel adjustment mechanisms， optional wearresistant iron alloy apex assemblies.
Physical Dimensions & Weight: Varies by model； e.g.,， a 500 GPM unit approx.: Height： ~72"， Diameter： ~30"， Weight： ~450 lbs.
Operating Parameters: Requires consistent feed pressure of 2045 PSI； compatible with slurry densities up to 50% solids by weight； temperature range： 20°F至+140°F (29°C至+60°C).
Connection Sizes: Flanged connections from 3"至10" depending on capacity.

6. APPLICATION SCENARIOS

[Concrete Sand Production Plant] Challenge： Inability to consistently reduce fines content below 7%， leading to rejected loads from readymix customers due to noncompliance with ASTM C33. Solution： Installation of a primary hydrocyclone cluster ahead of dewatering screens specifically targeted at removing 200 mesh material。 Results： Achieved consistent fines content below 5%， eliminated product rejections，并 recovered saleable fine sand from the overflow stream via secondary cyclones， increasing overall yield by 8%。

[DredgeFed Gravel Wash Plant] Challenge： Highly variable feed from dredging operations caused constant blinding of dewatering screens和ineffective settling ponds due to fluctuating silt load。 Solution： Implementation of a primary scalping hydrocyclone bank designed for highvolume， variablefeed duty。 Results： Stabilized the process flow downstream， reduced screen blinding incidents by over 70%，并 significantly decreased the frequency of settling pond cleanouts。

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers：
Standard Duty: Laminated polyurethane construction； fixed configuration； suitable for less abrasive materials或lower volume operations。
Heavy Duty: Includes modular ceramic liners和adjustable controls； designed for highabrasion， continuousduty applications。
Custom Cluster Systems: Engineered multicyclone manifolds with integrated pumps， valves，和controls。

Optional Features:
自动化控制包with pressure transmitters和motorized apex actuators。
备用Wear Parts Kits。
特殊合金Apex Assembliesfor extreme abrasion conditions。

Service Packages:
预防性维护计划including annual inspection和wear measurement。
现场培训for operations和维护staff。

Financing Options:
Equipment financing leases are available through partnered financial institutions，
通常ranging from24to84months，
以preserve capital expenditure budgets。

8.FAQ

Q1： How do I determine the correct size和numberof hydrocyclones needed formy plant？
A1：
Sizingis basedon slurry flow rate(GPM)，desiredcut point，
andsolids concentration。
Aprocess reviewusingyourfeedmaterial sampleis recommendedfor precise specification；
standardcapacity chartsprovideinitial guidance。

Q2：
Arethesehydrocyclones compatiblewithour existingpumpandscreen setup？
A2：
Yes，
theyare designedto integrateintostandardwashingandclassification circuits。
关键compatibility factorsareyourpump'savailablepressureandflowrate，
whichour engineering teamcan evaluateagainstthe cyclone'srequirements。

Q3：
Whatisthe typical operational impacton ourwaterconsumption？
A3：
Properlysizedhydrocyclonesimprovewaterefficiencybyallowingfor greaterrecirculationof process water。
Theyproduceathickenedunderflow，
reducingthewaterloadondewateringscreensandincreasingclarificationefficiencyinsettlingponds。

Q4：
Whatarethe lead timesfor delivery？
A4：
Lead timesvarybymodelandconfiguration。
Standardheavydutymodelsare typicallyavailablein810weeks；
customclustersystemsrequire1214weeksforengineeringandfabrication。

Q5：
Howdoes themodularceramicliner systemaffectlongtermoperatingcosts？
A5：
Ittransformsliner maintenancefroma majorcomponentreplacementtoa localizedwearitem swap。
Thisreducesthepartscostper replacementbyoverhalfanddramaticallycutsdowntime labor costs。

Q6：
Doyouofferperformanceguarantees？
A6：
Yes，
weprovideperformanceguaranteesforcapacityandseparationefficiencybasedon agreeduponfeedconditionsspecifiedduringthe application review。

Q7：
Whatsupportis availableafterinstallation？
A7：
Comprehensivesupportincludesstartupassistancebyafieldservice technician，
detailedoperationalmanuals，
andoncalltechnical support。
Extendedservice agreementsare availablefor ongoingpreventivemaintenance。