1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Chi phí hoạt động ngày càng tăng và thời gian ngừng hoạt động không thể đoán trước đang làm xói mòn tỷ suất lợi nhuận từ cát và sỏi của bạn? Common industry challenges include:
Độ mòn cao & Chi phí bảo trì: Abrasive materials rapidly degrade crusher liners, màn hình, và linh kiện bơm, dẫn đến việc thay thế bộ phận thường xuyên và ngừng hoạt động ngoài kế hoạch.
Phân loại vật liệu không hiệu quả: Inconsistent particle size separation results in offspec product, tái xử lý tốn kém, and lost revenue from premium aggregate grades.
Tạo tiền phạt quá mức: Overcrushing in primary and secondary stages creates an oversupply of lowvalue fines, diminishing the yield of highvalue concrete and asphalt sand.
Tiêu thụ năng lượng cao & Nhân công: 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. TỔNG QUAN SẢN PHẨM: SAND CLASSIFICATION AND DEWATERING SYSTEM

This sand classification and dewatering system is engineered for the precise washing, định cỡ, 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.

Quy trình hoạt động:
1. Cho ăn & Phân bổ: Slurry from a wash screen or attritioner is evenly distributed into the system’s feed box.
2. Phân loại thủy lực: 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. Dự trữ & Tái chế nước: Onspec dewatered sand is conveyed to stockpile, while effluent water is channeled to a clarifier for recycling.

Phạm vi ứng dụng & Hạn chế:
Phạm vi: Ideal for producing concrete sand, cát xây, specialty sands, and glass sand from natural deposits or crushed rock. Effective for operations processing 50 ĐẾN 500 tons per hour of sand feed.
Hạn chế: 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. TÍNH NĂNG CỐT LÕI

Precision Hydraulic Classifier | Cơ sở kỹ thuật: Controlled rising current water velocity | Lợi ích hoạt động: Achieves accurate cut points for consistent product gradation meeting ASTM C33 or other specifications | Tác động ROI: Giảm lượng từ chối sản phẩm lên tới 15% and increases premium product yield

HighFrequency Dewatering Screen | Cơ sở kỹ thuật: Linear vibratory motion with steep discharge angle | Lợi ích hoạt động: Reduces moisture content in finished sand to 812%, minimizing hauling costs and preventing stockpile freezing | Tác động ROI: Lowers drying fuel costs if thermal drying is required; improves customer satisfaction with dripfree loads

Linh kiện mài mòn Polyurethane | Cơ sở kỹ thuật: Abrasionresistant cast polyurethane liners, nozzles, and screen panels | Lợi ích hoạt động: Provides 35x longer service life than standard rubber or steel in highwash environments | Tác động ROI: Cuts component replacement costs by over 60% annually and reduces changeout downtime

Variable Speed Drive System | Cơ sở kỹ thuật: Integrated VFDs on feed pumps and screen vibrators | Lợi ích hoạt động: Allows operators to finetune classification cut point and dewatering intensity based on feed material changes in realtime | Tác động ROI: Optimizes efficiency across varying deposit strata without manual component swaps

Modular Construction | Cơ sở kỹ thuật: Bolttogether subassemblies with prefitted piping | Lợi ích hoạt động: Cho phép lắp ráp tại chỗ nhanh chóng với lượng hàn tối thiểu; đơn giản hóa việc sắp xếp lại hoặc di dời nhà máy trong tương lai | Tác động ROI: Giảm thời gian cài đặt lên tới 40%, giảm chi phí nhà thầu và đẩy nhanh thời gian sản xuất

Integrated Flocculant Dosing Ports | Cơ sở kỹ thuật: Preplumbed injection manifolds at key slurry points | Lợi ích hoạt động: Facilitates optimal chemical mixing for enhanced fines capture in closedwater circuits | Tác động ROI: Improves water clarity for recycling, reduces pond cleaning frequency by an estimated 30%

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Tiêu chuẩn ngành (Conventional Cyclone & Màn hình) | This Sand Classification System | Lợi thế (% Sự cải tiến) |
| : | : | : | : |
| Product Moisture Content (Concrete Sand) | 1520% typical discharge moisture| Nhất quán 912% discharge moisture| Lên đến 40% reduction in free water weight |
| Hiệu quả thu hồi tiền phạt (200 lưới)~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% kWh/tấn thấp hơn |
| Footprint Requirement (for equal capacity)~Multiple units with separate supports~Single integrated structure with shared supports~Approximately 25% less floor space |

5. THÔNG SỐ KỸ THUẬT

Phạm vi công suất: Các mẫu có sẵn từ 50 TPH đến 400 TPH of dry solids feed (slurrydependent).
Yêu cầu về nguồn điện: Total connected power ranges from 45 kW (cho các mô hình nhỏ hơn) ĐẾN 150 kW (for largest models), utilizing standard industrial voltages (460V/3Ph/60Hz).
Thông số vật liệu: 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.
Kích thước vật lý (Model SC200): chiều dài tổng thể: ~9 phút; Chiều rộng: ~4m; Chiều cao (to top of feed box): ~5m; Approximate shipping weight: ~14,000 kg.
Phạm vi hoạt động môi trường: Designed for ambient temperatures from 29°C to +45°C (20°F đến +113°F). Electrical components rated for NEMA 4X (hosedown, corrosion resistant) môi trường.

6. KỊCH BẢN ỨNG DỤNG

Nhà máy sản xuất cát bê tông

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. CÂN NHẮC THƯƠNG MẠI

Bậc định giá thiết bị
Tier pricing is based on capacity (TPH). Entrylevel systems (250 TPH) are quoted on project specifications.

Tính năng tùy chọn
Advanced features include remote monitoring PLC packages with gradation trend tracking , automated flocculant dosing systems , kết cấu thép không gỉ cho môi trường ăn mòn ,và thùng giảm âm .

Gói dịch vụ
Threetier service plans are available:
1.Basic Warranty covering parts .
2.Platinum Plan extending warranty coverage .
3.Platinum Plus Plan adding annual inspections .

Tùy chọn tài chính
Flexible commercial terms include capital lease , thuê hoạt động ,and loan structures through partner financial institutions . Renttoown programs may be available .

8. Câu hỏi thường gặp

Cần có thiết bị thượng nguồn nào?
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 .

Khung thời gian cài đặt điển hình là gì?
For modular units installation typically requires days not weeks assuming prepared foundations are ready . Our project managers provide detailed site preparation guidelines .

Có đảm bảo hiệu suất được cung cấp?
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