Sand Gravel Mining Producer Brochure
1. PAINPOINT driven اوپننگ
آپريشنل خرچن کي وڌائي رهيا آهن ۽ غير متوقع بند وقت توهان جي ريت ۽ بجری جي مارجن کي ختم ڪري رهيا آهن? عام صنعت جا چئلينج سڌو سنئون توهان جي هيٺئين لائن تي اثر انداز ڪن ٿا:
اعليٰ لباس & متبادل خرچ: Constant abrasion from silica sand and aggregate rapidly degrades standard components, بار بار جي اڳواڻي, expensive part replacements and maintenance shutdowns.
غير موثر مواد جي درجه بندي: Inconsistent screen performance or poor cyclone separation results in offspec product, قيمتي ٻيهر پروسيسنگ, ۽ پريميئم مادي حصن مان آمدني وڃائي وئي.
اضافي توانائي واپرائڻ: پراڻو, mechanically inefficient equipment drives unsustainable power costs, which represent a primary operational expense in highvolume processing.
سار سنڀال لاءِ اڻ رٿيل وقت: 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, موثر, and predictable? The solution lies in specifying equipment engineered specifically for the demands of modern aggregate production.
2. پيداوار جو جائزو: {{لفظ}}
جي {{لفظ}} 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.
آپريشنل ڪم فلو:
1. فيڊ جو تعارف: Dry feed material is introduced centrally and mixed with controlled process air.
2. سينٽرفيوگل علحدگي: 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 مائڪروون.
ايپليڪيشن جو دائرو & حدون:
دائرو: Ideal for classifying crushed rock, ٺاهيل ريت (کولڻ واري مٽي), natural sand, ۽ صنعتي معدنيات. Effective for dedusting, improving grain shape distribution, and creating specification sands.
حدون: Requires feed material to be surface dry (عام طور تي <1% نمي جو مواد). Not suitable for wet process streams or for separating materials with very similar densities but different sizes.
3. بنيادي خاصيتون
Patented DualStage Rotor | ٽيڪنيڪل بنياد: ٿلهو & fine classification zones with independent aerodynamic optimization | آپريشنل فائدا: Sharper particle size cuts and higher classification efficiency compared to singlestage designs | ROI اثر: Increases yield of inspec product by up to 8%, فضول گھٽائڻ
Abrasion Resistant لائنر سسٽم | ٽيڪنيڪل بنياد: Interchangeable ceramic composite wear plates in highimpact zones | آپريشنل فائدا: Liner service life extended by 35x over standard steel plates | ROI اثر: Lowers costperton for wear parts and reduces annual planned maintenance events
Intelligent Process Control Interface | ٽيڪنيڪل بنياد: PLCintegrated system linking rotor drive VFDs, fan controls, and feed rate monitors | آپريشنل فائدا: Operators can save/recall recipes for different products; automated feedback loops maintain set points | ROI اثر: Reduces transition time between products by 60% and minimizes operatorinduced variability
LowPressure Drop Air Design | ٽيڪنيڪل بنياد: Optimized volute geometry and inlet configuration reduces system resistance | آپريشنل فائدا: Requires lower fan horsepower (ڪلواٽ) to achieve required internal airflow | ROI اثر: Cuts specific energy consumption per ton classified by an estimated 1525%
Modular Maintenance Access | ٽيڪنيڪل بنياد: Large bolted access doors and a cartridgestyle rotor assembly mounted on sliding rails | آپريشنل فائدا: Complete rotor inspection or liner change can be performed by a twoperson crew in under four hours | ROI اثر: Minimizes downtime duration during planned maintenance intervals
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (Dynamic Classifiers) | {{لفظ}} حل | فائدو (% سڌارو) |
| : | : | : | : |
| Classification Sharpness (κ Index) | 0.55 0.65 | 0.72 0.78 | +15% Sharper Cut |
| Wear Liner Life (in Silica Sand) | ~ 1,500 آپريٽنگ ڪلاڪ | ~ 6,000 آپريٽنگ ڪلاڪ| +300% ڊگھي زندگي |
| مخصوص توانائي واپرائڻ (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. ٽيڪنيڪل وضاحتون
گنجائش جي حد: مان موجود ماڊلز 15 tph ڏانهن 250 tph dry feed capacity.
بجلي جي گهرج: Main classifier drive from 45 kW کان 355 ڪلواٽ; total system power dependent on fan configuration.
مواد جي وضاحت: Primary housing constructed from mild steel; highwear zones lined with Alumina ceramic composite (AR400 اسٽيل اختياري). Rotor blades are hardened steel or cast chrome alloy.
جسماني طول و عرض (Model CFS120): قطر: 3.8م; اوچائي (to inlet): 5.2م; پيرن جو نشان: لڳ ڀڳ. 18 sq.m.; وزن (empty): ~ 12,500 ڪلو.
ماحولياتي آپريٽنگ رينج: Ambient operating temperature: 20°C کان +45°C. Feed material must be below <1% surface moisture for optimal performance.
6. درخواست جا منظر
Manufactured Sand Production from Crusher Dust
چيلنج: 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.
حل: Installation of a {{لفظ}} in closed circuit with the crushing screen, treating the undersize material.
نتيجا: The plant recovered 18% of total feed as premium concrete sand, نئين آمدني جو وهڪرو ٺاهي. Field data shows overall plant yield increased by over $12 per processed ton.
Natural Sand Dedusting & Quality Enhancement
چيلنج: A dredging operation’s natural sand contained excessive silt (گذرڻ 200 ميش), leading to poor concrete performance specs and limited marketability.
حل: اي {{لفظ}} was deployed as a dry finishing stage after dewatering screens but before final stockpiling.
نتيجا: The system reduced the sub75µm content consistently from >9% هيٺ <4%, allowing the product to meet strict state DOT specifications without washing plant modification.
Lightweight Aggregate Fines Removal
چيلنج: Postkiln expanded clay aggregate contained fragile fines that created handling dust issues and compromised bulk density ratings.
حل: Integrating a {{لفظ}} into the cooling circuit provided gentle dry classification without further particle degradation common with vibrating screens.
نتيجا: Achieved over 95% removal efficiency of sub100µm material while maintaining structural integrity of the main product.
7.تجارتي خيالات
اسان جي {{لفظ}} solutions are offered under three primary tiers:
1.معياري ڊيوٽي پيڪيج: Includes base classifier with standard liners/rotor options for moderateabrasion materials like limestone or lightweight aggregate.
2.HeavyDuty پيڪيج: Recommended for granite/silica applications; includes full ceramic liner package upgraded rotor components extended bearing warranty
3.Turnkey System Package: Includes classifier cyclone(ايس) 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 {{لفظ}}
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
