امپورٽ ريت بجری مائننگ آر&ڊي
1. PAINPOINT driven اوپننگ
Are escalating operational costs and unpredictable downtime eroding your sand and gravel margins? 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.
تيز پاڻي & بجلي جو استعمال: 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, بيئرنگ, ۽ لينر, resulting in unplanned maintenance stops and high parts replacement budgets.
محدود فيڊ لچڪدار: Can your system handle variable feedstock—from cemented aggregates to sticky claybound gravel—without choking or losing efficiency?
خلا & Setup Constraints: Are you sacrificing processing capacity because your current equipment layout is inefficient or your site footprint is limited?
پلانٽ مينيجرز لاءِ مرڪزي سوال هي آهي: how can you increase tons per hour of inspec material while systematically reducing cost per ton in water, توانائي, ۽ سار سنڀال?
2. پيداوار جو جائزو
جي Log Washer is a core mineral processing machine designed for the tough duty of breaking down, ڇڪڻ, 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.
آپريشنل ڪم فلو:
1. کاڌو & Retention: Contaminated feed (مثال, 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. جدائي & خارج ٿيڻ: 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.
ايپليڪيشن جو دائرو & حدون:
دائرو: Ideal for durable aggregates requiring intense scrubbing (پٿر ٿيل پٿر, بجری), difficulttohandle materials with plastic clays, and feed with soft rock or shale contaminants.
حدون: 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. بنيادي خاصيتون
HeavyDuty Tub Design | ٽيڪنيڪل بنياد: Continuous weldment from abrasionresistant steel plate | آپريشنل فائدا: Withstands constant abrasive wear without fatigue cracking, ڊگھي مدت جي تعميراتي سالميت کي يقيني بڻائي | ROI اثر: Eliminates midlife tub replacement costs; فيلڊ ڊيٽا ڏيکاري ٿو 4060% longer service life versus standard plate construction
NiHard Paddle & Shaft System | ٽيڪنيڪل بنياد: Cast NiHard paddles on a forged alloy steel shaft with replaceable bolton log washers | آپريشنل فائدا: Maximizes abrasion resistance where wear is highest; simplifies maintenance by allowing individual paddle replacement | ROI اثر: Reduces downtime for shaft/paddle service by up to 70%; lowers longterm inventory cost for wear parts
Dual Shaft Gear Drive | ٽيڪنيڪل بنياد: Synchronized helical gear drive housed in an oilbath chamber | آپريشنل فائدا: Provides positive timing of counterrotating shafts for consistent material movement; eliminates chain drive stretch and breakage risks | ROI اثر: Reduces driverelated downtime to near zero; gearbox efficiency yields up to 15% lower power consumption compared to equivalent chaindriven units
Adjustable Overflow Weirs | ٽيڪنيڪل بنياد: Manually adjustable weir plates along the discharge end | آپريشنل فائدا: Operators can finetune retention time and slurry density in realtime based on feed variation | ROI اثر: Optimizes product grade control, reducing offspec yield by an average of 812% as reported by plant managers
Modular Bearing Cartridges | ٽيڪنيڪل بنياد: مهربند, prealigned roller bearing cartridges mounted externally to the tub | آپريشنل فائدا: Isolates critical bearings from water ingress and contamination; allows for cartridge replacement without major shaft disassembly | ROI اثر: Extends bearing service life by 3x; reduces critical path repair time from hours to minutes
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (ChainDriven Log Washer) | Our Log Washer Solution (GearDriven) | فائدو (% سڌارو) |
| : | : | : | : |
| Drive System Efficiency | Chain & Sprocket (~85% efficient) | Enclosed Helical Gear Drive (~98% efficient) | ~15% Lower Power Draw |
| ناڪامين جي وچ ۾ وچولي وقت (ڊرائيو) | 4,000 6,000 ڪلاڪ (chain stretch/breakage) | 20,000+ ڪلاڪ (gearbox service interval) | >300% واڌارو |
| Abrasion Wear Life (Paddles) | Standard AR Steel Castings (~1,200 hrs avg.)| NiHard Castings with optimized profile (~2,200 hrs avg.)| ~ 80% واڌارو |
| سار سنڀال بند وقت (Bearing Service)| 68 ڪلاڪ (disassembly required) | <2 ڪلاڪ (cartridge swap) | ~70% Reduction |
| Feed Size Flexibility Max Recommended| 4" (100ايم ايم) due to chain stress limitations| 6" (150ايم ايم) due to hightorque gear drive| 50% Larger Capacity
5. ٽيڪنيڪل وضاحتون
ماڊل رينج جي گنجائش: 50 400 ٽي پي ايڇ (ٽين في ڪلاڪ), depending on material density and contamination level.
بجلي جي گهرج: 75 400 HP dual motor configuration across model range. Electrical supply must match motor nameplate specifications (مثال, 460V/60Hz/3Ph).
مواد جي وضاحت: Tub constructed from ¾” AR400 abrasionresistant steel. Paddles are Grade III NiHard cast iron. Shafts are forged alloy steel.
جسماني طول و عرض (Model LW200): Overall Length: 28’. Overall Width: 9’. خارج ٿيڻ جي اوچائي: 12’. لڳ ڀڳ وزن: 48,000 lbs.
ماحولياتي آپريٽنگ رينج: Designed for continuous outdoor operation in temperatures from 20°C to +50°C (4°F کان +122°F). Sealed components protect against dust and moisture ingress.
6. درخواست جا منظر
Aggregate Producer – Sticky Clay Contamination
چيلنج: 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. ٻوٽن جي پيداوار وڌي وئي 22%, pond maintenance frequency decreased by twothirds.
اڏاوت & مسمار ڪرڻ واري ريسائڪلنگ
چيلنج: 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 تجارتي خيالات
سامان جي قيمتن جا درجا ترتيب ڏنل آهن ذريعي ظرفيت جي چوڌاري:
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 FAQ
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 آهن اسپيئر پارٽس آساني سان دستياب آهن
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 آپريٽر ٽريننگ مهيا ڪئي وئي آهي
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
