1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your sand and gravel margins? Common industry challenges directly impact your bottom line:
High Wear & Replacement Costs: Constant abrasion from silica sand and aggregate rapidly degrades standard components, leading to frequent, expensive part replacements and maintenance shutdowns.
Inefficient Material Classification: Inconsistent screen performance or poor cyclone separation results in offspec product, costly reprocessing, and lost revenue from premium material fractions.
Excessive Energy Consumption: Older, mechanically inefficient equipment drives unsustainable power costs, which represent a primary operational expense in highvolume processing.
Unplanned Downtime for Maintenance: Reactive repairs to critical processing stages create cascading bottlenecks, halting entire plant output and missing shipment deadlines.
LaborIntensive Oversight: Systems requiring constant manual adjustment and monitoring tie up skilled personnel and increase the risk of human error in grade control.

What if your key processing stage could be more resilient, efficient, and predictable? The solution lies in specifying equipment engineered specifically for the demands of modern aggregate production.

2. PRODUCT OVERVIEW: {{keyword}}

The {{keyword}} is a highefficiency centrifugal classifier designed for the dry separation of fine particles in sand and aggregate processing plants. It provides precise cutpoint control to remove unwanted fines or to extract valuable fine sand fractions from crusher dust.

Operational Workflow:
1. Feed Introduction: Dry feed material is introduced centrally and mixed with controlled process air.
2. Centrifugal Separation: The dualstage classification process uses adjustable rotor speeds and airflow to generate precise centrifugal forces.
3. Particle Separation: Coarse particles reject to the perimeter for collection as the "rejects" stream, while fines remain entrained in the air.
4. Fine Product Collection: The fineladen air stream is directed to a downstream cyclone or baghouse for efficient product recovery.
5. Process Control: Operators adjust rotor speed and airflow rates to target specific cut points between 75 microns and 250 microns.

Application Scope & Limitations:
Scope: Ideal for classifying crushed rock, manufactured sand (crusher dust), natural sand, and industrial minerals. Effective for dedusting, improving grain shape distribution, and creating specification sands.
Limitations: Requires feed material to be surface dry (typically <1% moisture content). Not suitable for wet process streams or for separating materials with very similar densities but different sizes.

3. CORE FEATURES

Patented DualStage Rotor | Technical Basis: Coarse & fine classification zones with independent aerodynamic optimization | Operational Benefit: Sharper particle size cuts and higher classification efficiency compared to singlestage designs | ROI Impact: Increases yield of inspec product by up to 8%, reducing waste

AbrasionResistant Liner System | Technical Basis: Interchangeable ceramic composite wear plates in highimpact zones | Operational Benefit: Liner service life extended by 35x over standard steel plates | ROI Impact: Lowers costperton for wear parts and reduces annual planned maintenance events

Intelligent Process Control Interface | Technical Basis: PLCintegrated system linking rotor drive VFDs, fan controls, and feed rate monitors | Operational Benefit: Operators can save/recall recipes for different products; automated feedback loops maintain set points | ROI Impact: Reduces transition time between products by 60% and minimizes operatorinduced variability

LowPressure Drop Air Design | Technical Basis: Optimized volute geometry and inlet configuration reduces system resistance | Operational Benefit: Requires lower fan horsepower (kW) to achieve required internal airflow | ROI Impact: Cuts specific energy consumption per ton classified by an estimated 1525%

Modular Maintenance Access | Technical Basis: Large bolted access doors and a cartridgestyle rotor assembly mounted on sliding rails | Operational Benefit: Complete rotor inspection or liner change can be performed by a twoperson crew in under four hours | ROI Impact: Minimizes downtime duration during planned maintenance intervals

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Dynamic Classifiers) | {{keyword}} Solution | Advantage (% improvement) |
| : | : | : | : |
| Classification Sharpness (κ Index) | 0.55 0.65 | 0.72 0.78 | +15% Sharper Cut |
| Wear Liner Life (in Silica Sand) | ~1,500 operating hours | ~6,000 operating hours| +300% Longer Life |
| Specific Energy Consumption (kWh/t) | 1.8 2.4 kWh/t processed| 1.4 1.7 kWh/t processed| ~25% Lower Energy Use |
| Target CutPoint Adjustment Time| Manual adjustments taking >30 mins.| Automated recipe recall in <5 mins.| ~85% Faster Changeover |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Models available from 15 tph to 250 tph dry feed capacity.
Power Requirements: Main classifier drive from 45 kW to 355 kW; total system power dependent on fan configuration.
Material Specifications: Primary housing constructed from mild steel; highwear zones lined with Alumina ceramic composite (AR400 steel optional). Rotor blades are hardened steel or cast chrome alloy.
Physical Dimensions (Model CFS120): Diameter: 3.8m; Height (to inlet): 5.2m; Footprint: approx. 18 sq.m.; Weight (empty): ~12,500 kg.
Environmental Operating Range: Ambient operating temperature: 20°C to +45°C. Feed material must be below <1% surface moisture for optimal performance.

6. APPLICATION SCENARIOS

Manufactured Sand Production from Crusher Dust

Challenge: A granite quarry’s VSI crusher produced a highvolume dust (150µm) fraction that was being wasted (~22% of output). The goal was to convert this into a saleable concrete sand product meeting ASTM C33 fines modulus specifications.
Solution: Installation of a {{keyword}} in closed circuit with the crushing screen, treating the undersize material.
Results: The plant recovered 18% of total feed as premium concrete sand, creating a new revenue stream. Field data shows overall plant yield increased by over $12 per processed ton.

Natural Sand Dedusting & Quality Enhancement

Challenge: A dredging operation’s natural sand contained excessive silt (passing 200 mesh), leading to poor concrete performance specs and limited marketability.
Solution: A {{keyword}} was deployed as a dry finishing stage after dewatering screens but before final stockpiling.
Results: The system reduced the sub75µm content consistently from >9% down to <4%, allowing the product to meet strict state DOT specifications without washing plant modification.

Lightweight Aggregate Fines Removal

Challenge: Postkiln expanded clay aggregate contained fragile fines that created handling dust issues and compromised bulk density ratings.
Solution: Integrating a {{keyword}} into the cooling circuit provided gentle dry classification without further particle degradation common with vibrating screens.
Results: Achieved over 95% removal efficiency of sub100µm material while maintaining structural integrity of the main product.

7.COMMERCIAL CONSIDERATIONS

Our {{keyword}} solutions are offered under three primary tiers:

1.Standard Duty Package: Includes base classifier with standard liners/rotor options for moderateabrasion materials like limestone or lightweight aggregate.

2.HeavyDuty Package: Recommended for granite/silica applications; includes full ceramic liner package upgraded rotor components extended bearing warranty

3.Turnkey System Package: Includes classifier cyclone(s) airlock feeders interconnecting ductwork structural support platform PLC control panel installation commissioning services

Optional features include advanced particle size monitoring feedback loops explosion venting designs special alloy constructions

Service packages range from basic preventative maintenance plans comprehensive multiyear coverage including wear parts financing options include capital purchase equipment leasing powerbythehour throughput agreements tailored project financing through our industrial partners

FAQ

Q What upstream equipment is required before installing a {{keyword}}
A An effective drying system is critical if your material is not naturally surfacedry Reliable volumetric feeding such as via rotary valve or weigh belt feeder also ensures stable operation Properly sized primary collection cyclones baghouse are part of our system design recommendations

Q How does this integrate with my existing screening circuit
A Typically installed parallel bypass line around fine screens treat screen undersize directly It can also process final crushed product before stockpiling Our engineering team provides integration drawings specific layout

Q What ongoing operator training maintenance required
A We provide initial onsite training covering daily checks basic adjustments control interface use Routine maintenance primarily involves periodic inspection wear liners scheduled bearing lubrication all documented detailed manual provided

Q Can you guarantee final product specifications
A While final specs depend on feed characteristics we provide performance test protocols based on pilot plant data guarantee mechanical performance availability rates based defined operating conditions Process guarantees are established during project feasibility phase

Q What typical delivery lead time after order placement
A Lead times vary model Standard models typically ship within weeks Custom configurations may require weeks Delivery schedule confirmed upon project engineering review