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

1. PAINPOINT DRIVEN OPENING

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: Up to 15% of valuable fine sand can be lost to settling ponds or waste piles due to imprecise classification, representing significant revenue left unrecovered.
High Water & Energy Consumption: 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. PRODUCT OVERVIEW

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.

Operational Workflow:
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 (e.g., 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.

Application Scope & Limitations:
Ideal For: 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".
Limitations: Not a dewatering device—extracted sands require further dewatering (e.g., on a dewatering screen). Primary crushing and scrubbing must be completed upstream.

3. CORE FEATURES

Manifold Feed Distributor | Technical Basis: Laminar flow engineering | Operational Benefit: Ensures even slurry distribution across the entire tank width, preventing shortcircuiting and ensuring consistent classification across all hoppers. | ROI Impact: Eliminates product banding, ensuring every ton meets specification and reducing reprocessing.

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

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

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

Fines Recovery Baffle System | Technical Basis: Hydraulic current control baffles | Operational Benefit: Promotes retention of difficulttocapture 70200 mesh fines within the product hoppers before they report to overflow. | ROI Impact: Directly increases recoverable product yield by capturing valuable fines previously lost.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Screw Classifier/Basin) | Our Classifying Tank Solution | Advantage |
| : | : | : | : |
| Fines (100200 mesh) Recovery Rate | Typically 5070% loss to overflow | Consistent recovery >85% into product stream| +3040% yield improvement |
| Water Consumption per Ton Processed| 100150 gallons/ton (recirculating) | 7090 gallons/ton (recirculating) |30% water volume required |
| Product Specification Consistency| Variable due to feed surges & manual adjustment| Consistent grade with automated gate control| Reduces offspec material by ~25% |
| Maintenance Downtime (Annual)| 4060 hours for wear part replacement/cleanout| <20 hours with lined components & accessible gates| ~60% reduction in downtime |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Models from 50 TPH to over 500 TPH sand feed capacity.
Power Requirements: System typically relies on existing plant slurry pumps; no dedicated drive motors required.
Material Specifications: Primary structure: ASTM A36 carbon steel. Highwear areas lined with AR400 steel (12mm) or replaceable polyurethane panels (25mm).
Physical Dimensions (Model CFT200): Length: 24 ft; Width: 12 ft; Height: 8 ft; Weight (dry): ~18,000 lbs.
Environmental Operating Range: 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. APPLICATION SCENARIOS

Concrete Sand Producer Facing Market Expansion Challenge

Challenge: A regional producer needed to separate its single "concrete sand" 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.
Solution: Installation of a Model CFT150 Classifying Tank downstream of their existing wash screen.
Results: The operation now simultaneously produces two inspec products at a combined rate of 150 TPH. Field data shows 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

Challenge: 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.
Solution: Retrofitting a classifying tank as a primary classifier ahead of the existing screws, which were repurposed as dewatering units.
Results: 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. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Solutions are configured based on capacity and material specifications.
Standard Duty: For consistent feeds under 150 TPH with moderate abrasion.
Heavy Duty: For hightonnage operations (>150 TPH) or highly abrasive feeds featuring upgraded liners and gate assemblies.
Modular/Portable: Skidmounted units for lease/fleet operations requiring relocation.

Optional Features & Upgrades: 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.

Service Packages: Extended warranty plans are available covering structural components against defects beyond standard terms.

Financing Options:

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.