Superior Industries explains why one-size-fits-all approaches can fail in wet sand processing and how tailored approaches drive performance, profitability and sustainability.
Achieving optimal sand production and fines recovery requires solutions tailored to each operation’s specific parameters. A one-size-fits-all approach often fails because wet processing conditions vary highly across different sites.
To optimise wet processing, it’s essential to choose equipment that matches the application’s specific requirements. Whether you are integrating a new wash plant or improving an existing circuit, finding the correct equipment configuration is critical.
Brett Casanova, washing product manager at Superior Industries, said that to achieve optimal performance, a thorough analysis of plant operations, material properties, and capacity needs is necessary. With the right data and access to a broad range of washing components, Superior’s engineers develop customised solutions designed for maximum efficiency and cost-effectiveness.
Key considerations:
How can efficiency be maximised in wet processing?
What technologies can reduce or eliminate pond maintenance?
Which equipment configurations will best produce clean sand while recovering fines?
Implementing targeted, customised solutions that address specific operational needs can answer these questions. Casanova spoke to Quarry about the benefits of approaching wet processing this way.
Comprehensive equipment toolbox
Solving wet processing challenges requires a wide variety of equipment. Every application has unique requirements, such as material type, moisture content, water availability, and footprint constraints. A broad selection of washing components is necessary to meet the needs of multiple stages, from scrubbing and classifying to washing and dewatering.
Superior offers a complete line of customisable washing components and systems that can be tailored for specific applications.
This flexibility allows producers to maximise cost-efficiency by selecting the appropriate equipment for each stage of wet processing.
Superior’s ability to provide a comprehensive suite of equipment is a distinct advantage, allowing for seamless integration across plant systems without relying on external vendors for key components.
Effective washing removes unwanted particles such as lignite, mica, and silts while ensuring products meet specifications. Below is an overview of critical sand washing technologies used in various applications.
Fine material washers
Fine material washers are widely used for removing silts and dewatering material. These systems are easy to maintain and reliable, capable of handling silt cut points ranging from #200 to #100 mesh. Often, they are used after classifying tanks for further dewatering.
However, given the increasing presence of dirtier pits, more advanced solutions may be necessary to address challenging material conditions.
Classifying tanks
Classifying tanks are ideal for separating fine materials based on size while removing silts. These tanks use water and gravity to separate material, which is then blended to meet specific requirements. Precision control through automated valve systems ensures accurate material specifications.
Classifying tanks are frequently used in dredging operations, where they help remove excess water from sand.
Spirit sand plant
The Spirit sand plant is a modular system that provides efficient sand production, fines recovery, and dewatering. It combines components such as Superior’s helix cyclones, dewatering screens, sump tanks, and slurry pumps. Each plant is configured to the specific application, ensuring the appropriate cyclone and screen combination for the desired cut points.
Cyclones are especially useful in areas with limited water resources or where space for settling ponds is restricted. Cyclones can efficiently remove silts while improving fines recovery.
Alliance low water washer
Many crushing operations face challenges with water usage. The Alliance low water washer addresses this issue by using significantly less water while washing crusher dust directly next to the crushing circuit. This system reduces the need to transport material to separate washing systems, lowering operational costs and improving efficiency.
Aggredry washer
The Aggredry dewatering washer is an energy-efficient alternative for wet processing applications, providing precise sand specifications with low moisture content. The system uses minimal horsepower and significantly reduces drying times by producing a final product with a moisture content as low as 8 per cent.
The Aggredry also recycles water within the system, making it an ideal solution for operations with limited water availability.
Producing cleaner sand
As easily accessible sand reserves become depleted, producers are forced to process dirtier deposits. The right combination of washing technologies can help optimise efficiency across multiple stages of wet processing. For example, adding a fine material washer after a classifier can improve dewatering, while installing a cyclone ahead of a classifying tank can handle material with high fines content.
Superior’s modular Spirit sand plant provides flexibility by allowing producers to configure washing systems based on specific site conditions. This adaptability ensures that sand washing systems are capable of handling increasingly challenging applications.
Total plant efficiency
Achieving total plant efficiency requires careful management of all components in the processing chain.
A poorly maintained piece of equipment, such as a faulty sand screw, can result in valuable material being lost to the settling pond. It’s critical that all equipment is functioning optimally to ensure material is properly processed and recovered.
Selecting the right wet processing solutions is only part of the equation. Expert support is essential throughout the entire process, from initial design to installation and ongoing maintenance.
Superior provides both innovative equipment and the necessary expertise to ensure reliable and efficient plant operation.
Optimising wet processing requires more than standard equipment choices. It demands a thorough analysis of site-specific conditions, the use of tailored washing solutions, and the support of experienced engineers to ensure the right fit for every application.
Superior Industries’ application specialists collaborate closely with producers to fine-tune total plant performance.
Whether the customer is adding a new wash plant or tweaking an existing circuit, it’s vital to find the right fit.
“It all depends on a thorough, expert analysis of your application, overall plant operations, and capacity requirements – and properly addressing each unique parameter and product specification,” Casanova said.
He said that when armed with the correct data – and a “complete toolbox” of washing components, systems, and equipment combinations – Superior’s expert sand processing engineers “dial in” desired specifications with customised solutions that deliver maximum efficiency at the lowest costs per tonne.
The right solutions require a complete toolbox. Not just one or two commonly-used equipment options.
Application parameters are numerous – from material type, moisture content, specification requirements, footprint size, permitting restrictions, financial limitations, water rates, water availability, and more. Plus, equipment solutions are required for multiple stages of wet processing from scrubbing, to classifying, washing, and dewatering. Obviously, the latter is best supported by a toolbox that includes a complete array of customisable washing components, plants, and equipment configurations – combined with the expertise of washing application engineers.
Whether manufacturing sand or washing the dirt out of an already in-spec product, accessing a complete toolbox ensures not only the right solution, but also the most cost-efficient one. Consider that certain more affordable solutions can be substituted for a higher capital equipment investment in various applications.
Casanova said that since Superior provides the “complete toolbox,” the company can “package” plant solutions far more effectively than those manufacturers who must rely upon outsourcing key plant components.
“Certainly, the washing side of the aggregate market is one of the biggest growth areas. Demand is across the board – not only for new wash plants, but for all wash-related products. Also, producers are looking for wash plants that require less water and a minimal footprint. They want solutions that reduce waste and maintenance, while recovering fines and gaining more saleable products,” Casanova said.
“Today’s producers require a complete toolbox, combined with the right expertise, throughout the plant’s lifecycle.”
For more information, visit superior-ind.com
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