stone sand and gravel washing equipment

Addressing Critical Washing Challenges in Aggregate Production

Are you facing persistent bottlenecks and rising costs in your washing plant? Inefficient stone sand and gravel washing equipment directly impacts your bottom line through:

• High Fines Loss: Are you losing up to 8-12% of saleable fines (passing #200 mesh) to settling ponds, representing significant revenue loss?
• Inconsistent Product Quality: Do fluctuating feed gradations result in out-of-spec sand, leading to product rejection and damaged customer relationships?
• Excessive Water Consumption: Are your water intake and recycling costs escalating due to inefficient, high-volume water usage in traditional screw washers?
• Frequent Downtime: Are you experiencing unplanned shutdowns for component wear or blockages, halting your entire processing line?
• High Operating Costs: Is the combined expense of water pumping, waste handling, and manual clean-out consuming your profit margins?

What if your washing circuit could consistently deliver in-spec material, minimize resource consumption, and operate with greater reliability?

Product Overview: Advanced Log Washer and Fine Material Screw Washer Systems

Our engineered stone sand and gravel washing equipment is designed for heavy-duty scrubbing and classification of aggregate materials. The system integrates robust log washers for tough clays and fine material screws for precise classification.

Operational Workflow:

1. Feed & Scrubbing: Raw feed enters the log washer section, where its twin shafts with paddles aggressively disintegrate and scrub tough plastic clays, cemented gravels, and other agglomerations.
2. Separation & Classification: Partially cleaned material transitions to the fine material screw washer. Here, rising current water and the screw's action separate lightweight contaminants and classify particles by size.
3. Product Dewatering & Discharge: The rotating screw lifts clean, classified sand and gravel from the bottom of the trough, allowing free surface moisture to drain away before discharge as a commercially viable product.

Application Scope:
This equipment is suitable for a wide range of hard rock and sand deposit applications, including crushed stone, silica sand, and construction aggregates. It is particularly effective on materials with difficult, plastic clays that cannot be processed by simple screening.

Limitations:
The system is not designed for highly abrasive ores without specific alloy upgrades. Feed size is typically limited to 2.5 inches (63mm). Optimal performance requires a consistent feed rate controlled by a preceding feeder.

Core Features: Engineered for Performance and Profitability

• Twin-Shaft Log Washer | Technical Basis: Counter-rotating shafts with replaceable Ni-Hard paddles | Operational Benefit: Positive agitation scrubs and breaks apart tough clay balls and soft rock that would bypass other washers | ROI Impact: Enables development of otherwise unusable clay-bound deposits; reduces downstream screen blinding by over 90%

• Hydro-Cyclone Feed System | Technical Basis: Pressurized slurry feed with adjustable inlet | Operational Benefit: Creates a dense particle bed for more efficient fines separation and reduces short-circuiting | ROI Impact: Improves fines recovery by up to 15%, turning waste into saleable product

• Weir Plate Level Control | Technical Basis: Adjustable overflow weirs on the fine material screw washer | Operational Benefit: Operators can fine-tune retention time to match specific feed material characteristics | ROI Impact: Ensures consistent product spec compliance, eliminating costly load rejections

• Bolt-On Wear Shoes | Technical Basis: Abrasion-resistant steel shoes attached with high-tensile bolts | Operational Benefit: Reduces maintenance time; individual components can be replaced without dismantling the shaft assembly | ROI Impact: Cuts planned maintenance downtime by up to 50% compared to welded-on designs

• Integral Water Recycling Manifold | Technical Basis: Closed-loop piping design that recirculates process water from the overflow weir tank | Operational Benefit: Significantly reduces fresh water make-up requirements | ROI Impact: Lowers water consumption costs by approximately 40% in closed-circuit plants

• Heavy-Dust Gear Reducer | Technical Basis: In-line helical gear drive with oil bath lubrication and external cooling fins | Operational Benefit: Provides high-torque drive with greater efficiency and reliability than chain-driven systems | ROI Impact: Reduces power consumption by 8-12% and extends service intervals to over 10,000 hours

Competitive Advantages

Performance Metric	Industry Standard (Screw Washer Only)	Our Log Washer & Screw System Solution	Advantage
Fines Recovery Efficiency (% passing #200 mesh)	70-80% Recovery	92-95% Recovery	~20% Improvement
Clay & Contaminant Removal Efficiency	Limited on Plastic Clays >95% on Plastic Clays	Enables processing of previously unsuitable materials
Specific Water Consumption (m³/tonne)	2.5 - 3.5 m³/tonne	1.5 - 2.0 m³/tonne	~40% Reduction
Mean Time Between Failure (Drive System)	~6,000 hours (Chain Drive)	>10,000 hours (Gear Drive)	~67% Improvement
Maintenance Downtime (Wear Parts Replacement)8 hours (Welded Shoes)	4 hours (Bolt-On Shoes)	50% Reduction

Technical Specifications

• Capacity/Rating: Model-dependent capacities from 50 to 250 tonnes per hour.
• Power Requirements: Total connected power ranges from 75 kW to 225 kW, depending on model size and material density.
• Material Specifications: Mainframe constructed from high-strength carbon steel; wear surfaces feature AR400 steel liners; paddles and wear shoes available in Ni-Hard or Xtralloy® for severe abrasion.
• Physical Dimensions: Lengths from 8m to 14m; widths from 2.5m to 4m; weights between 12,000 kg and 45,000 kg.
• Environmental Operating Range: Designed for ambient temperatures from -30°C to +50°C. Dust covers are standard for environmental compliance.

Application Scenarios

Crushed Granite Quarry | Challenge: A significant portion of the reserve contained clay pockets that clogged primary crushers and produced out-of-spec concrete sand with excessive particulate coating.

Solution: Integration of a heavy-duty log washer ahead of the existing fine material screw washer in the circuit.
Results: The plant achieved consistent production of washed concrete sand meeting ASTM C33 specs. Crusher clogging incidents were eliminated, increasing overall plant availability by 15%. Revenue increased through the sale of a new washed sand product line.

Sand & Gravel Pit Operations Manager Challenge: The operation was losing an estimated $120,000 annually in unrecovered fine sand to settling ponds while facing high costs for pond dredging and water procurement.

Solution: Installation of a new fine material screw washer system equipped with a hydro-cyclone feed package for enhanced fines recovery.
Results: Fines recovery improved from 75% to 93%. This added over $100k in annual revenue from recovered material. Freshwater consumption was reduced by one-third, lowering pumping costs.

Commercial Considerations

Equipment Pricing Tiers:

• Standard Series: For standard duty cycles (<100 TPH), offering core reliability features.
• Heavy-Duty Series: For high-tonnage operations (>100 TPH) or highly abrasive materials; includes upgraded wear components.
• Custom Engineered Solutions: For unique site layouts or specific material challenges; includes custom hoppers or chute work.

Optional Features:

• Variable Frequency Drive (VFD) for soft-start and speed control
• Automated grease lubrication system
• Advanced polymer or ceramic liners for extreme abrasion
• Integrated moisture sensor on discharge chute

Service Packages:

Service packages are available separately or bundled with financing options:

1. Platinum Support (24/7 remote monitoring)
   2.Gold Support (Annual inspection)
   3.Silver Support

Financing options include capital lease agreements

Frequently Asked Questions

Q1: Is this stone sand and gravel washing equipment compatible with our existing plant footprint?
Our engineering team can provide detailed layout drawings based on your site plan. Modular designs often allow for integration into existing circuits with minimal structural modification.

Q2: What is the typical operational impact during installation?
A well-planned installation typically requires a scheduled shutdown of 5-7 days for foundation work mechanical tying-in electrical connection

Q3 How does this equipment handle variations in feed material quality?
The adjustable weir plates allow operators to control retention time compensating for normal fluctuations Field data shows these systems maintain product specification even with feed variation up to ±15%

Q4 What are the commercial terms lead times payment structure?
Standard lead time is currently weeks A deposit secures production scheduling balance payment due prior shipment We also accept Letters of Credit

Q5 What training is provided for our operations maintenance teams?
We provide comprehensive onsite training covering normal operation troubleshooting routine maintenance procedures Documentation includes detailed parts manuals schematic diagrams