1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Managing a sand and gravel operation means contending with constant pressure on margins and predictability. Bạn có đang phải đối mặt với những thử thách dai dẳng này?
Nguyên liệu thức ăn không nhất quán: Variable clay content, độ ẩm, and feed size lead to unpredictable processing rates, product quality issues, and increased wear on downstream equipment.
Nước dâng cao & Tiêu thụ năng lượng: Traditional washing and classification methods are often inefficient, resulting in excessive water usage that requires costly settling ponds and high power draw per ton of processed material.
Thời gian ngừng hoạt động quá mức để bảo trì: Sự cố vòng bi thường xuyên, thay đổi vải màn hình, and pump blockages from abrasive materials stop your production line, tác động trực tiếp đến lợi nhuận của bạn.
Product Specification Inflexibility: Nhu cầu thị trường thay đổi, but your plant struggles to efficiently produce different sand gradations or effectively separate deleterious materials without major reconfiguration.
Không gian & Environmental Constraints: Expanding your settling pond footprint or managing slurry runoff is increasingly difficult due to regulatory and land availability pressures.

What if your processing plant could adapt to variable feed, drastically cut resource consumption, and maintain throughput with less unscheduled maintenance?

2. TỔNG QUAN SẢN PHẨM: White Label Sand & Nhà máy chế biến sỏi

This white label modular processing plant is a fully integrated system designed for the primary washing, phân loại, khử nước, and stockpiling of sand and gravel aggregates. Engineered for midtohigh volume producers (150600 TPH typical range), it provides a configurable alternative to custombuilt installations.

Quy trình hoạt động:
1. Cho ăn & Sàng lọc trước: Runofquarry material is introduced via a feed hopper with a vibrating grizzly to scalp oversize rock before primary washing.
2. Primary Washing & Tiêu hao: Material enters a log washer or rotary scrubber (có thể cấu hình) to break down clay nodules and disperse contaminants.
3. Phân loại kích thước & Khử nước: Screw classifiers or cyclones separate sand fractions by size; specialized dewatering screens produce dripfree, conveyable sand products.
4. Quản lý nước & Tuần hoàn: Slurry is sent to a compact fines recovery system; nước trong được tuần hoàn, minimizing fresh water makeup requirements.

Phạm vi ứng dụng & Hạn chế:
Phạm vi: Lý tưởng cho các trầm tích phù sa, băng giá cho đến khi, river run material, and crushed stone sands requiring washing. Effective for producing concrete sand, cát xây, gravel chips, and specialty sands.
Hạn chế: Not designed for hard rock primary crushing or metallic mineral recovery. Maximum feed size is limited by the configured primary screen (tiêu biểu 46 inch). Highly cemented or conglomerate feeds may require precrushing.

3. TÍNH NĂNG CỐT LÕI

Thiết kế trượt mô-đun | Cơ sở kỹ thuật: Preassembled structural steel skids with integrated wiring/plumbing | Lợi ích hoạt động: Giảm thời gian cài đặt tại chỗ lên tới 60% versus stickbuilt plants; cho phép cấu hình lại hoặc di dời trong tương lai | Tác động ROI: Vận hành nhanh hơn tạo ra doanh thu sớm hơn; protects capital investment against site depletion.

HighEfficiency Cyclone Cluster | Cơ sở kỹ thuật: Bank of smalldiameter polyurethane cyclones for precise hydraulic classification | Lợi ích hoạt động: Delivers superior silt cutpoint control compared to single large cyclones or settling tanks; requires less floor space | Tác động ROI: Consistent production of inspec sand improves product value; reduced footprint lowers site preparation costs.

Điều khiển quá trình dựa trên PLC | Cơ sở kỹ thuật: Centralized programmable logic controller with HMI touchscreen interface | Lợi ích hoạt động: Operators can monitor pump amps, tank levels, and adjust feed rates from a single station for optimal balance | Tác động ROI: Maximizes consistent throughput; reduces operator error leading to lower waste and energy use per ton.

Hệ thống lót chống mài mòn | Cơ sở kỹ thuật: Bolton wear liners of AR400 steel or urethane in highimpact zones | Lợi ích hoạt động: Protects structural components; liners are replaceable without welding or major cutting | Tác động ROI: Extends structural life of the plant by years; reduces maintenance duration from days to hours.

Hệ thống nước khép kín | Cơ sở kỹ thuật: Integrated thickener/clarifier tank with flocculent dosing system | Lợi ích hoạt động: Phục hồi lên đến 90% of process water for immediate reuse; drastically reduces settling pond volume needs | Tác động ROI: Cuts fresh water procurement costs by over 80%; minimizes environmental liability and land use.

Ổ tần số thay đổi (VFD) Critical Motors | Cơ sở kỹ thuật: VFDs installed on feed conveyor, slurry pumps, and classifier motors | Lợi ích hoạt động: Allows softstarting to reduce mechanical stress and electrical demand charges; enables finetuning of pump flow without valve adjustments | Tác động ROI: Lowers peak power demand fees; extends motor and drive component life.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Tiêu chuẩn ngành (Traditional Plant) | White Label Solution Advantage |
| : | : | : |
| Fresh Water Consumption per Ton | ~100150 gallons/ton (vòng lặp mở) / ~50 gallons/ton (basic pond recycle) / ~1015 gallons/ton / Lên đến 85% sự giảm bớt |
| Cài đặt tại chỗ & Thời gian vận hành| 812 tuần / 35 tuần / ~60% nhanh hơn |
| Product Grade Consistency (Sand Fines Content) ±2% spec variation common / ±0.5% spec variation achievable / Improved control by >60% |
| Wear Component Changeout Time (Primary Screen Deck) Ca đầy đủ (68 giờ) / Half shift or less (24 giờ) / Downtime reduced ~50% |

5. THÔNG SỐ KỸ THUẬT

Phạm vi công suất thiết kế: Có thể cấu hình từ 150 ĐẾN 600 tấn mỗi giờ (TPH) of raw feed material.
Yêu cầu về nguồn điện: Total connected load between 400HP 900HP depending on configuration; main supply typically 480VAC, 3giai đoạn.
Thông số vật liệu: Kết cấu thép ASTM A36; wear surfaces in chutes, tiệm giặt là, and hoppers lined with minimum AR400 steel or equivalent polyurethane.
Kích thước vật lý (Typical Modular Footprint): Primary wash module approx. 40' L x 16' W x 22' H; classification/dewatering module approx. 50' L x 14' W x 28' H.
Phạm vi hoạt động môi trường: Được thiết kế cho nhiệt độ môi trường xung quanh từ 20°C đến +45°C (4°F đến 113°F). Dust suppression sprays standard at transfer points.

6. KỊCH BẢN ỨNG DỤNG

Concrete Aggregate Producer in Arid Region

Challenge A producer faced strict water usage quotas from municipal sources and high costs for truckedin water. Their existing system lost significant water to evaporation in large settling ponds.
Solution Implementation of this white label plant featuring the closedloop water system with an automated flocculent dosing unit.
Kết quả Tiêu thụ nước ngọt giảm từ khoảng 125 gallons/ton to under 12 gallons/ton. The system paid for its premium through water cost savings alone within an estimated twoyear period.

Alluvial Gravel Pit Expanding Product Line

Challenge The pit historically sold only coarse aggregate but identified strong market demand for concrete sand. Their existing equipment could not efficiently separate fine sand from silt.
Solution Integration of a cyclone cluster and dewatering screen module into their existing circuit via the plant's modular design.
Results The operation added two new inspec sand products without disrupting core gravel production. Fines content was consistently maintained below the required limit (<7%), allowing entry into the readymix concrete market.

7. CÂN NHẮC THƯƠNG MẠI

Bậc giá: Solutions are priced based on configured capacity:
Cấp I (150250 TPH): Entrylevel configuration focusing on core washing/dewatering.
Cấp II (250450 TPH): Most common configuration including advanced controls and full fines management.
Cấp III (450600 TPH): Highvolume systems with redundancy on critical pumps and advanced telemetry options.

Tính năng tùy chọn: Attrition scrubber cell for tough clays,
Automated product sampling systems,
Gói viễn thông giám sát từ xa,
Additional spare parts packages tailored to expected wear items.

Gói dịch vụ: Available service agreements range from basic preventive maintenance inspections through comprehensive partsandlabor coverage with guaranteed response times.

Tùy chọn tài chính: Equipment financing can be arranged through partner institutions,
typically offering terms from
36
84 tháng,
as well as leasetoown structures that may preserve working capital lines

8.Câu hỏi thường gặp

Q How do I know if my site's raw feed material is suitable?
A We provide a detailed feedstock evaluation questionnaire covering gradation,
clay type/content,
and moisture
Laboratory testing of your samples is strongly recommended prior final configuration

Q What level of operator training is required?
A The PLC control system simplifies operation
Comprehensive training for your shift supervisors
and operators is included during commissioning

Q Can this plant integrate with my existing crushing circuit?
A Có
The modular design allows it be fed directly from your secondary/tertiary crusher discharge
Key interface points like feed conveyor dimensions
and surge capacity are engineered during the design phase

Q What are the typical ongoing operational costs?
A Primary costs are power
wear liners/media,
and flocculent polymer where used
Field data indicates operational cost range between $0 .75$1 .25 per ton processed depending local utility rates

Q What is the expected delivery timeline after order?
A Đối với cấu hình tiêu chuẩn,
delivery typically occurs within
16
20 weeks from finalized engineering drawings;
expedited options may be available

Q Có đảm bảo hiệu suất được cung cấp không?
A Có
Performance guarantees covering throughput capacity,
product specification adherence,
and specific resource consumption e g ,
water/power per ton are provided as part contract based final system design