Sand Gravel Mining Maker Datasheet
1. PAINPOINT driven اوپننگ
آپريشنل خرچن کي وڌائي رهيا آهن ۽ غير متوقع وقت ختم ڪري رهيا آهن توهان جي ريت ۽ بجری جي منافعي جي مارجن کي? Common industry challenges include:
اعليٰ لباس & سار سنڀال جا خرچ: Abrasive materials rapidly degrade crusher liners, اسڪرين, ۽ پمپ اجزاء, بار بار حصو مٽائڻ ۽ غير منصوبابندي بند ٿيڻ جي ڪري.
غير موثر مواد جي درجه بندي: غير متضاد ذرات جي ماپ جي علحدگيءَ جا نتيجا آف اسپيڪ پراڊڪٽ ۾, قيمتي ٻيهر پروسيسنگ, and lost revenue from premium aggregate grades.
وڌ ۾ وڌ فائنس پيدا ڪرڻ: Overcrushing in primary and secondary stages creates an oversupply of lowvalue fines, diminishing the yield of highvalue concrete and asphalt sand.
اعلي توانائي واپرائڻ & مزدوري: Inefficient plant layout and manually intensive processes, like feeder regulation and belt monitoring, drive up power costs and require constant operator intervention.
Water Management Complexity: Ineffective slurry handling and dewatering systems lead to water recycling issues, sediment pond overflows, and potential environmental compliance risks.
Is your operation equipped to transform these cost centers into controlled, predictable processes? The right core processing equipment is not an expense but a direct lever for profitability.
2. پيداوار جو جائزو: SAND CLASSIFICATION AND DEWATERING SYSTEM
This sand classification and dewatering system is engineered for the precise washing, ماپ ڪرڻ, and moisture reduction of sand products in sand gravel mining operations. It is a closedloop solution designed to maximize product value and minimize water consumption.
آپريشنل ڪم فلو:
1. کاڌو & ورهائڻ: Slurry from a wash screen or attritioner is evenly distributed into the system’s feed box.
2. هائيڊولڪ درجه بندي: Material enters a rising current cyclone or hydraulic classifier, separating sand particles by size and specific gravity.
3. Deck Dewatering: Classified sand is discharged onto a highfrequency dewatering screen, where vibration forces remove surface moisture.
4. ذخيرو ڪرڻ & واٽر ريسائڪلنگ: Onspec dewatered sand is conveyed to stockpile, while effluent water is channeled to a clarifier for recycling.
ايپليڪيشن جو دائرو & حدون:
دائرو: Ideal for producing concrete sand, ٺڪر واري ريت, خاص ريتون, and glass sand from natural deposits or crushed rock. Effective for operations processing 50 جي طرف 500 tons per hour of sand feed.
حدون: Not a substitute for primary washing or scrubbing of heavily claybound material. Feed slurry consistency must be controlled for optimal classification. Requires a consistent water supply and complementary settling pond or clarifier system.
3. بنيادي خاصيتون
Precision Hydraulic Classifier | ٽيڪنيڪل بنياد: Controlled rising current water velocity | آپريشنل فائدا: Achieves accurate cut points for consistent product gradation meeting ASTM C33 or other specifications | ROI اثر: تائين جي پيداوار جي رد ڪرڻ کي گھٽائي ٿو 15% and increases premium product yield
HighFrequency Dewatering Screen | ٽيڪنيڪل بنياد: Linear vibratory motion with steep discharge angle | آپريشنل فائدا: Reduces moisture content in finished sand to 812%, minimizing hauling costs and preventing stockpile freezing | ROI اثر: Lowers drying fuel costs if thermal drying is required; improves customer satisfaction with dripfree loads
Polyurethane لباس اجزاء | ٽيڪنيڪل بنياد: Abrasionresistant cast polyurethane liners, nozzles, and screen panels | آپريشنل فائدا: Provides 35x longer service life than standard rubber or steel in highwash environments | ROI اثر: Cuts component replacement costs by over 60% annually and reduces changeout downtime
Variable Speed Drive System | ٽيڪنيڪل بنياد: Integrated VFDs on feed pumps and screen vibrators | آپريشنل فائدا: Allows operators to finetune classification cut point and dewatering intensity based on feed material changes in realtime | ROI اثر: Optimizes efficiency across varying deposit strata without manual component swaps
Modular Construction | ٽيڪنيڪل بنياد: Bolttogether subassemblies with prefitted piping | آپريشنل فائدا: گھٽ ۾ گھٽ ويلڊنگ سان تيز آن سائيٽ اسيمبليء کي قابل بڻائي ٿو; simplifies future plant reconfiguration or relocation | ROI اثر: تائين انسٽاليشن وقت گھٽائي ٿو 40%, ٺيڪيدار جي خرچن کي گھٽائڻ ۽ وقت جي پيداوار کي تيز ڪرڻ
Integrated Flocculant Dosing Ports | ٽيڪنيڪل بنياد: Preplumbed injection manifolds at key slurry points | آپريشنل فائدا: Facilitates optimal chemical mixing for enhanced fines capture in closedwater circuits | ROI اثر: Improves water clarity for recycling, reduces pond cleaning frequency by an estimated 30%
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (Conventional Cyclone & اسڪرين) | This Sand Classification System | فائدو (% سڌارو) |
| : | : | : | : |
| پيداوار جي نمي مواد (ڪنڪريٽ واري ريت) | 1520% typical discharge moisture| مسلسل 912% discharge moisture| تائين 40% reduction in free water weight |
| جرمانه وصولي جي ڪارڪردگي (200 ميش)~7080% recovery rate~Consistent >92% recovery rate~Up to ~22% more saleable material retained |
| Wear Life on Primary Liners~Rubber liners lasting ~4 months~Polyurethane liners lasting ~14 months~250% longer service life |
| Power Consumption per Ton~Fixed speed drives at constant load~Variable speed drives optimizing load~Field data shows 1018% گھٽ kWh/ton |
| Footprint Requirement (for equal capacity)~Multiple units with separate supports~Single integrated structure with shared supports~Approximately 25% less floor space |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: مان موجود ماڊلز 50 TPH کان 400 TPH of dry solids feed (slurrydependent).
بجلي جي گهرج: Total connected power ranges from 45 ڪلواٽ (ننڍن ماڊلز لاء) جي طرف 150 ڪلواٽ (for largest models), utilizing standard industrial voltages (460V/3Ph/60Hz).
مواد جي وضاحت: Contact surfaces utilize ASTM A36 structural steel with abrasionresistant AR400 steel at highimpact points. Classification chambers feature cast polyurethane. Screen decks are polyurethane modular panels.
جسماني طول و عرض (Model SC200): مجموعي ڊگھائي: ~9 م; ويڪر: ~ 4 م; اوچائي (to top of feed box): ~5 م; تقريبن شپنگ وزن: ~14,000 kg.
ماحولياتي آپريٽنگ رينج: Designed for ambient temperatures from 29°C to +45°C (20°F کان +113°F). Electrical components rated for NEMA 4X (hosedown, corrosion resistant) ماحول.
6. درخواست جا منظر
ڪنڪريٽ ريل جي پيداوار جو پلانٽ
Challenge A Midwest producer struggled with inconsistent gradation yielding only ~65% ASTM C33compliant concrete sand from their deposit; the remainder was downgraded as fill material at significant revenue loss.
Solution Implementation of a Model SC150 Sand Classification System with precision hydraulic classifiers replaced their outdated rake classifier system.
Results Within one month of commissioning:
Production of spec concrete sand increased to over 92%.
Fines loss was reduced by twothirds.
Annualized revenue increase exceeded $280k based on increased premium product volume.
DredgeFed Mining Operation
Challenge A river dredging operation faced high pumping costs due to transporting excess water long distances from the dredge pond to the processing plant.
Solution Installation of a compact Sand Classification System directly on the dredge discharge allowed for primary dewatering at the pit face.
Results The system delivered:
A reduction in slurry volume pumped by over 35%, significantly lowering fuel consumption per ton produced.
Direct loading of dewatered sand onto haul trucks at the pit site versus pumping it miles away.
7. تجارتي خيالات
سامان جي قيمت جا درجا
Tier pricing is based on capacity (ٽي پي ايڇ). Entrylevel systems (250 ٽي پي ايڇ) پروجيڪٽ جي وضاحتن تي حوالو ڏنو ويو آهي.
اختياري خاصيتون
Advanced features include remote monitoring PLC packages with gradation trend tracking , automated flocculant dosing systems , stainless steel construction for corrosive environments ,۽ آواز attenuation ملفوظات .
سروس پيڪيجز
Threetier service plans are available:
1.Basic Warranty covering parts .
2.Platinum Plan extending warranty coverage .
3.Platinum Plus Plan adding annual inspections .
فنانسنگ جا اختيار
Flexible commercial terms include capital lease , آپريٽنگ ليز ,and loan structures through partner financial institutions . Renttoown programs may be available .
8. FAQ
ڪهڙو اپ اسٽريم سامان گهربل آهي?
The system requires a consistent slurry feed typically provided by a wash screen log washer or attrition scrubber . Feed pumps can be included as part of the package .
How does this system integrate with our existing clarifier or settling pond?
It is designed as a complementary component . By removing most solids it significantly reduces the load on your clarifier improving its efficiency . Standard discharge flanges connect directly .
عام تنصيب جو وقت ڇا آهي?
For modular units installation typically requires days not weeks assuming prepared foundations are ready . Our project managers provide detailed site preparation guidelines .
پيش ڪيل ڪارڪردگي جي ضمانت آهن?
Yes performance guarantees based on achieving specified product gradation bands are included in commercial contracts subject .
What spare parts inventory should we maintain?
We provide recommended critical spares list which typically includes polyurethane wear parts specific screen panel modules .
Can this handle very coarse material like pea gravel?
No this system is optimized specifically for sandsized particles . For coarse aggregate rinsing separate solutions are recommended .
What ongoing operator training do you provide?
Comprehensive training during commissioning covers operation maintenance troubleshooting procedures . Training manuals digital resources are provided
