GB2583460A - Method and modular system for washing and grading sand and aggregate - Google Patents
Method and modular system for washing and grading sand and aggregate Download PDFInfo
- Publication number
- GB2583460A GB2583460A GB1904893.3A GB201904893A GB2583460A GB 2583460 A GB2583460 A GB 2583460A GB 201904893 A GB201904893 A GB 201904893A GB 2583460 A GB2583460 A GB 2583460A
- Authority
- GB
- United Kingdom
- Prior art keywords
- grading
- sand
- aggregate
- unit
- feed material
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000004576 sand Substances 0.000 title claims abstract description 81
- 238000005406 washing Methods 0.000 title claims abstract description 57
- 238000000034 method Methods 0.000 title claims abstract description 22
- 239000000463 material Substances 0.000 claims abstract description 60
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 27
- 239000000203 mixture Substances 0.000 claims abstract description 19
- 239000000356 contaminant Substances 0.000 claims abstract description 18
- 239000010802 sludge Substances 0.000 claims abstract description 18
- 238000011144 upstream manufacturing Methods 0.000 claims abstract description 7
- 239000002351 wastewater Substances 0.000 claims description 7
- 238000011109 contamination Methods 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 239000011236 particulate material Substances 0.000 description 4
- 239000002002 slurry Substances 0.000 description 3
- 239000002562 thickening agent Substances 0.000 description 3
- 239000000701 coagulant Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 241000168096 Glareolidae Species 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 239000011362 coarse particle Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 239000008394 flocculating agent Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000006194 liquid suspension Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03B—SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
- B03B5/00—Washing granular, powdered or lumpy materials; Wet separating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03B—SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
- B03B11/00—Feed or discharge devices integral with washing or wet-separating equipment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03B—SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
- B03B9/00—General arrangement of separating plant, e.g. flow sheets
Landscapes
- Treatment Of Sludge (AREA)
Abstract
A modular system for washing and grading material comprising a mixture of sand, aggregate, coarse and fine contaminants comprising two or more of; a feed unit 1 to remove coarse contaminants, at least one sand washing and grading unit 2, at least one aggregate rinsing and grading unit 5, a water treatment unit 3, and a sludge treatment unit 4. The aggregate rinsing may be upstream of the sand washing and grading unit, the aggregate grading may produce aggregate of at least two different sizes, it may comprise a multi-deck screen 6. The sand washing may produce products of at least two different sizes, where it may comprise a split deck dewatering screen, sump, and hydrocyclones. The feed unit may comprise a scalping screen. The sludge treatment may comprise a filter press. There may further be a scrubber unit, log washer, or classification unit. A method for washing and grading a feed material comprising a plurality of modular units is disclosed.
Description
Method and Modular System for washing and grading sand and aggregate
FIELD OF THE INVENTION
This invention relates to a method and system for washing and grading sand and aggregate and in particular to a method and modular system for washing and grading sand and aggregate with greater efficiency and high throughput.
BACKGROUND OF THE INVENTION
The term "aggregates" is generally used to describe a broad category of coarse particulate material used in construction, including sand, gravel and crushed stone. Aggregates are the most mined materials in the world. Aggregates are typically washed and graded on a combination of vibrating screens and hydrocyclones to produce washed aggregate products having a predetermined grain size or range of grain size. The term "aggregate" is more typically used to describe particulate material having a grain size of over 6mm while the term "sand" is typically used to describe particulate having a grain sand of between 0.075 mm and 6 mm and such terminology will be used to describe such particulate material hereinafter.
A typical vibrating screen comprises a frame, defined by a pair of substantially parallel side walls interconnected by transversely extending bridging members, upon which is mounted one or more polyurethane decks having small openings or slots for water and undersize particles to pass through. Vibrating screens for grading courser material may have decks made from parallel and spaced apart bars or rods. The frame is typically mounted on a base via resilient linkages and the frame, and thus the deck or decks are typically vibrated by means of a pair of counter rotating rotors defining eccentric masses, driven by one or more drive motors, to impart circular or reciprocating vibrating motion to the deck(s). Such screens can be used for grading and/or dewatering particulate material, oversize material passing over the deck(s) of the screen to be collected from a downstream end of the screen while water and undersize material is collected in a sump of the screen for subsequent processing.
A hydrocyclone is a device used to separate particles in a liquid suspension based on the ratio of their centripetal force to fluid resistance. This ratio is high for coarse particles and low for fine particles. A hydrocyclone typically comprises a cylindrical section having an inlet for supplying a feed slurry into the hydrocyclone tangentially, 5 and a conical base. Outlets are provided at upper and lower ends of the hydrocyclone. Underflow, containing the coarser fraction, passes out of the lower outlet while overflow, containing the finer fraction and most of the water, passes out of the outlet at the upper end of the hydrocyclone. Thus, as well as removing fine contaminants, a hydrocyclone also serves to reduce the water content of a 10 sand/water slurry.
Hydrocyclones are often used in combination with vibratory screens for washing and dewatering sand, a slurry of sand and water being cleaned and dewatered in one or more hydrocyclones before the sand, contained in the underflow from said hydrocyclones, is delivered onto a deck of a vibratory screen for grading and/or further dewatering.
Most sand and aggregate washing and grading plants are very large, including different stages comprising multiple grading and dewatering screens and hydrocyclones, and typically require a large volume of water to fluidise the material in each stage of the process and to transfer the material between different stages of the process. For washing and grading plants designed to produce one or more grades of aggregate and one or more grades of sand, the throughput of the plant (in terms of tonnes of material processed per hour) is typically limited by the sand washing and grading part of the plant, typically due to limitations imposed by the pumps, hydrocyclones and screens used to wash and grade the sand. Therefore, often the rinsing section of the apparatus for washing and grading aggregate is operating at considerably less than full capacity. Furthermore, when adapted for high throughput (typically requiring a high volume of water), the sand washing and grading process tends to operate with a high turbidity due to difficulties in removing fines at high sand flow rates.
An object of the present invention is to provide a particularly adaptable modular system and method that can optimise the washing and grading process.
SUMMARY OF THE INVENTION
A modular system for washing a grading a feed material comprising a mixture of 5 sand, aggregate and course and fine contaminants, said system comprising two or more of:-a feed unit adapted to receive said feed material and remove course contaminants therefrom; at least one sand washing and grading unit adapted to produce at least one sand 10 product from said feed material; at least one aggregate rinsing and grading unit adapted to produce at least one aggregate product from said feed material; a water treatment unit adapted to recycle water from waste water for reuse; a sludge treatment unit adapted to dewater sludge; wherein the capacity of each of the modular is selected as a function of the composition and feed rate of the feed material.
In one embodiment at least one aggregate rinsing and grading unit may be provided upstream of at least one sand washing and grading unit.
In one embodiment at least one aggregate rinsing and grading unit may be adapted to produce at least two aggregate products of different size.
At least one sand washing and grading unit may be adapted to produce at least two 25 sand products of different size.
Said feed unit may comprise a scalping screen for removing course contaminants from the feed material.
Said at least one sand washing and grading unit may comprise a split deck dewatering screen and sump and one or more hydrocyclones for removing fine contamination from the sand and dewatering the sand.
Said at least one aggregate rinsing and grading unit may comprise a multi-deck screen to produce several grades of aggregate product.
The sludge treatment unit may comprise a filter press.
The system may further comprise one of more of:-an attrition scrubber unit; a log washer; counter flow classification unit, wherein the capacity of each of the modular is selected as a function of the composition and feed rate of the feed material.
According to a further aspect of the present invention there is provided a method for washing and grading a feed material, said feed material comprising a mixture of sand, aggregate and course and fine contaminants, said method comprising providing a plurality of modular units selected from:-a feed unit adapted to receive said feed material and remove course contaminants therefrom; at least one sand washing and grading unit adapted to produce at least one sand product from said feed material; at least one aggregate rinsing and grading unit adapted to produce at least one 20 aggregate product from said feed material; a water treatment unit adapted to recycle water from waste water for reuse; a sludge treatment unit adapted to dewater sludge; wherein the capacity of each of the modular is selected as a function of the composition and feed rate of the feed material.
Each modular unit may be selected from a plurality of different capacity units to provide an optimised capacity to suit the composition and feed rate of the feed material.
At least one of said plurality of units may be selected as a function of the size and required production rate of one or more products of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
A modular system and method for washing and grading sand and aggregate in accordance with an embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:-Figure 1 is a schematic illustration of a system for washing and grading sand and aggregate in accordance with a first embodiment of the present invention; Figure 2 is a schematic illustration of a system for washing and grading sand and aggregate in accordance with a second embodiment of the present invention; and Figure 3 is a schematic illustration of a system for washing and grading sand and aggregate in accordance with a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
A sand and aggregate washing system in accordance with an embodiment of the present invention comprises an assembly of modular units each having a capacity optimised as a function of the composition and flow rate of the feed material in order to optimise the efficiency and performance of the system.
In prior art systems the capacity of the system is selected based upon the expected "bottleneck" in the system. The relative capacity of the individual processes of the system are typically arranged to be scaled based upon the overall feed rate of the feed material without consideration to the specific composition of the feed material.
For example, where the feed material contains a large proportion of sand, the system has to have sufficient capacity such that the sand washing and grading process of the system can cope with the flow rate of sand required to be dealt with by the system. However, this typically results in the aggregate rinsing and grading process of the system operating significantly below its available capacity. Similarly, where the feed material contains large amounts of fine contaminants, the water treatment part of the system must have sufficient capacity to handle the amounts of fine contaminants present in the waste water from the upstream processes. However, this typically results in they upstream sand washing and grading and/or aggregate rinsing and grading processes operating below available capacity.
In a sand and aggregate washing and grading system in accordance with an embodiment of the present invention the individual processes within the system are selected from different capacity modules based upon the specific composition of the feed material as well as the overall flow rate of the feed material such that each module can operate at an optimum capacity, reducing the cost and overall size of the system and increasing the efficiency and overall performance of the system.
In one embodiment, illustrated schematically in Figure 1, a modular sand washing 10 and grading system comprises a feed unit 1, a sand washing and grading unit 2, a water treatment unit 3 and, optionally, a sludge treatment unit 4.
The feed unit 1 may comprise a feed hopper with an apron feeder feeding a scalping screen comprising grizzly bars or rods for removing large contaminants and a feed conveyor, preferably provided with a belt weigher for feeding the feed material to the sand washing and grading unit 2. The capacity of the feed unit 1 may be selected based upon the feed rate of the feed material. For example, the feed unit may be selected from a plurality of different sized units to provide a feed material capacity of between 120 t/hr to 500 t/hr to suit the expected feed rate of the feed material.
The sand washing and grading unit 2 may comprise a split deck dewatering screen and sump and one or more hydrocyclones for removing fine contamination from the sand and dewatering the sand, as is known in the art. The sand washing and grading unit 2 may be selected from a plurality of different sized units to provide a production capacity to suit the sand content and feed rate of the feed material. For example, the sand washing and grading unit may be selected to have a capacity of between 70 and 250 t/hr.
The water treatment unit 3 may comprise a thickener tank with a flocculent and/or coagulant dosing means for adding a flocculating agent and/or coagulant to the waste water supplied from the sand washing and grading unit such that the thickener tank separates the suspended solids from the hydrocyclone overflow of the sand washing and grading unit 2. The thickener tank is preferably designed such that clean water overflows a peripheral weir of the tank and is collected to be recycled for use in the system, for example in the sand washing and grading unit 2. The water treatment unit 3 may be selected from a plurality of different capacity units to provide a capacity required to suit the feed rate/water content of the feed material and the proportion of fine contaminants therein. For example, the water treatment unit 3 may be selected to handle a feed rate of between 100 m3/hr and 1500m3/hr.
The sludge treatment unit 4 may comprise a filter press or centrifugal separator for dewatering the sludge supplied from the water treatment unit 3. The sludge treatment unit 4 may be selected from a plurality of different capacity units to suit the feed rate/water content of the feed material and the proportion of fine contaminants therein. For example, the sludge treatment unit 4 may be selected to have a press volume of between 4.5 and 18.1 m3 to provide a total filtering surface of between approximately 180m2 and 1500m2.
Figure 2 illustrates a modular sand and aggregate washing and grading system in accordance with the present invention comprises a feed unit 1, which may be similar to the feed unit 1 of the embodiment shown in Figure 1, selected from a plurality of different capacity units to suit the feed rate of the feed material fed to the system, and an aggregate rinsing and grading unit 5 upstream of a sand washing and grading unit 2.
The aggregate rinsing and grading unit 5 may be adapted to produce one or more grades of aggregate product and/or to separate oversize waste material from the feed material. The aggregate rinsing and grading unit 5 may include a multi-deck screen to produce several grades of aggregate product.
The aggregate rinsing and grading unit 5 may be selected from a plurality of different capacity units to provide a production capacity to suit the aggregate content and feed rate of the feed material. For example, the aggregate rinsing and grading unit may be selected to have a feed capacity of between 120 and 350 t/hr and may be selected to produce between 2 and 5 aggregate products, as required.
As with the first embodiment, the sand washing and grading unit 2 may comprise a split deck dewatering screen and sump and one or more hydrocyclones for removing fine contamination from the sand and dewatering the sand, as is known in the art. The sand washing and grading unit 2 may be selected from a plurality of different sized units to provide a production capacity to suit the sand content and feed rate of the feed material. For example, the sand washing and grading unit may be selected to have a capacity of between 70 and 250 t/hr.
Figure 3 illustrates a modular sand washing and grading system in accordance with a further embodiment of the present invention, adapted to produce a plurality of aggregate products and a plurality of sand products while recycling waste water. The system comprises a feed unitl, an aggregate rinsing and washing unit 5 with an additional multiple deck aggregate grading unit 6, a sand washing and grading unit 2, a water treatment unit 3 and a sludge treatment unit 4. Each unit of the modular system is selected based upon the feed material feed rate and composition and the required aggregate and sand products to optimise the capacity of each unit such that, in use, each unit is operating at close to its optimum capacity, reducing the overall size and cost of the system and maximising the capacity and efficiency of the system.
It is envisaged that further units may be added to system based upon the requirements of the feed material, in terms of its feed rate and composition, and the required products to be produced. Multiple aggregate rinsing and grading units and/or multiple sand washing and grading units may be added to the system. A crusher unit may be provided downstream of the feed unit. An attrition scrubber or log washer may be provided upstream of one or more of the sand washing and grading units for separating clay and other fine contamination from the feed material. A counter flow classification unit may be provided for providing density separation of the feed material. Again, each of these additional units may be selected from a plurality of different capacity units to provide an optimised capacity to suit the feed rate and composition of the feed material to optimise the overall capacity and operation of the system.
Claims (12)
- CLAIMS1. A modular system for washing a grading a feed material comprising a mixture of sand, aggregate and course and fine contaminants, said system comprising two or 5 more of:-a feed unit adapted to receive said feed material and remove course contaminants therefrom; at least one sand washing and grading unit adapted to produce at least one sand product from said feed material; at least one aggregate rinsing and grading unit adapted to produce at least one aggregate product from said feed material; a water treatment unit adapted to recycle water from waste water for reuse; a sludge treatment unit adapted to dewater sludge; wherein the capacity of each of the modular is selected as a function of the 15 composition and feed rate of the feed material.
- 2. system as claimed in claim 1, wherein at least one aggregate rinsing and grading unit is provided upstream of at least one sand washing and grading unit.
- 3. A system as claimed in claim 1 or claim 2, wherein at least one aggregate rinsing and grading unit is adapted to produce at least two aggregate products of different size.
- 4. A system as claimed in any preceding claim, wherein at least one sand washing 25 and grading unit is adapted to produce at least two sand products of different size.
- 5. A system as claimed in any preceding claim, wherein said feed unit comprising a scalping screen for removing course contaminants from the feed material.
- 6. A system as claimed in any preceding claim, wherein said at least one sand washing and grading unit comprises a split deck dewatering screen and sump and one or more hydrocyclones for removing fine contamination from the sand and dewatering the sand.
- 7. A system as claimed in any preceding claim, wherein said at least one aggregate rinsing and grading unit comprises a multi-deck screen to produce several grades of aggregate product.
- 8. A system as claimed in any preceding claim, wherein the sludge treatment unit comprises a filter press.
- 9. A system as claimed in any preceding claim, further comprising one of more of:-an attrition scrubber unit; a log washer; counter flow classification unit, wherein the 10 capacity of each of the modular is selected as a function of the composition and feed rate of the feed material.
- 10. A method for washing and grading a feed material, said feed material comprising a mixture of sand, aggregate and course and fine contaminants, said method comprising providing a plurality of modular units selected from:-a feed unit adapted to receive said feed material and remove course contaminants therefrom; at least one sand washing and grading unit adapted to produce at least one sand product from said feed material; at least one aggregate rinsing and grading unit adapted to produce at least one aggregate product from said feed material; a water treatment unit adapted to recycle water from waste water for reuse; a sludge treatment unit adapted to dewater sludge; wherein the capacity of each of the modular is selected as a function of the 25 composition and feed rate of the feed material.
- 11. A method as claimed in claim 10, wherein each modular unit is selected from a plurality of different capacity units to provide an optimised capacity to suit the composition and feed rate of the feed material.
- 12. A method as claimed in claim 11, wherein the at least one of said plurality of units is selected as a function of the size and required production rate of one or more products of the system.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1904893.3A GB2583460A (en) | 2019-04-05 | 2019-04-05 | Method and modular system for washing and grading sand and aggregate |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1904893.3A GB2583460A (en) | 2019-04-05 | 2019-04-05 | Method and modular system for washing and grading sand and aggregate |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB201904893D0 GB201904893D0 (en) | 2019-05-22 |
| GB2583460A true GB2583460A (en) | 2020-11-04 |
Family
ID=66809501
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB1904893.3A Withdrawn GB2583460A (en) | 2019-04-05 | 2019-04-05 | Method and modular system for washing and grading sand and aggregate |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2583460A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11433400B2 (en) * | 2019-11-19 | 2022-09-06 | Cde Global Limited | Method and apparatus for washing and grading sand |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111330731B (en) * | 2020-04-30 | 2023-11-14 | 中建材通辽矽砂工业有限公司 | Sorting device and sorting process for wet-sorting petroleum fracturing sand |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6219260A (en) * | 1985-07-17 | 1987-01-28 | Junko Ishizu | Process and device for sorting and recycling of excavated earth in construction work from sludge |
| CN2799079Y (en) * | 2005-06-13 | 2006-07-26 | 沈阳建筑大学 | Concrete residue recovering and reusing apparatus |
| CN201342378Y (en) * | 2008-11-24 | 2009-11-11 | 郑州一帆机械设备有限公司 | Device for cleaning concrete and fine sand reclaiming device therein |
| JP2016140823A (en) * | 2015-02-02 | 2016-08-08 | 公信 山▲崎▼ | Contaminated soil decontamination apparatus |
-
2019
- 2019-04-05 GB GB1904893.3A patent/GB2583460A/en not_active Withdrawn
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6219260A (en) * | 1985-07-17 | 1987-01-28 | Junko Ishizu | Process and device for sorting and recycling of excavated earth in construction work from sludge |
| CN2799079Y (en) * | 2005-06-13 | 2006-07-26 | 沈阳建筑大学 | Concrete residue recovering and reusing apparatus |
| CN201342378Y (en) * | 2008-11-24 | 2009-11-11 | 郑州一帆机械设备有限公司 | Device for cleaning concrete and fine sand reclaiming device therein |
| JP2016140823A (en) * | 2015-02-02 | 2016-08-08 | 公信 山▲崎▼ | Contaminated soil decontamination apparatus |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11433400B2 (en) * | 2019-11-19 | 2022-09-06 | Cde Global Limited | Method and apparatus for washing and grading sand |
Also Published As
| Publication number | Publication date |
|---|---|
| GB201904893D0 (en) | 2019-05-22 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |