IE85489B1 - A sand and gravel washing process - Google Patents
A sand and gravel washing processInfo
- Publication number
- IE85489B1 IE85489B1 IE2005/0609A IE20050609A IE85489B1 IE 85489 B1 IE85489 B1 IE 85489B1 IE 2005/0609 A IE2005/0609 A IE 2005/0609A IE 20050609 A IE20050609 A IE 20050609A IE 85489 B1 IE85489 B1 IE 85489B1
- Authority
- IE
- Ireland
- Prior art keywords
- sand
- stage
- water
- screen
- delivering
- Prior art date
Links
- 239000004576 sand Substances 0.000 title claims description 79
- 238000005406 washing Methods 0.000 title claims description 17
- 239000000463 material Substances 0.000 claims description 54
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 29
- 239000004575 stone Substances 0.000 claims description 19
- 239000000356 contaminant Substances 0.000 claims description 14
- 238000000034 method Methods 0.000 claims description 9
- 238000003860 storage Methods 0.000 claims description 9
- 238000004064 recycling Methods 0.000 claims description 8
- 238000005201 scrubbing Methods 0.000 claims description 8
- 239000004927 clay Substances 0.000 claims description 7
- 229910052570 clay Inorganic materials 0.000 claims description 7
- 238000011084 recovery Methods 0.000 claims description 7
- 239000002689 soil Substances 0.000 claims description 7
- 210000003462 Veins Anatomy 0.000 claims description 3
- 230000001112 coagulant Effects 0.000 claims description 3
- 239000000701 coagulant Substances 0.000 claims description 3
- 230000015556 catabolic process Effects 0.000 claims description 2
- 238000001035 drying Methods 0.000 claims description 2
- 238000005086 pumping Methods 0.000 claims description 2
- 239000002351 wastewater Substances 0.000 claims description 2
- 241000196324 Embryophyta Species 0.000 description 11
- 235000000836 Epigaea repens Nutrition 0.000 description 5
- 240000005149 Epigaea repens Species 0.000 description 5
- 238000010276 construction Methods 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 210000001847 Jaw Anatomy 0.000 description 3
- 238000004140 cleaning Methods 0.000 description 3
- 238000011068 load Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000011435 rock Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 239000010426 asphalt Substances 0.000 description 1
- 238000009412 basement excavation Methods 0.000 description 1
- 239000002360 explosive Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
Description
A sand and gravel washing process
Introduction
The present invention relates to a sand and gravel washing plant and in particular
relates to a sand and gravel washing plant which also includes a crushing assembly.
In the quarrying industry, deposits are generally divided into either sand and gravel
pits or quarries. In quarrying, it is usually a totally hard rock face which has to be
drilled and detonated with explosives to provide stone which is then crushed and
graded. In quarrying, deposits do not usually require the material to be washed.
However, the other typical type of situation is one which includes what is a relatively
soft deposit of sand and mixed gravel. i.e. easily excavated, which has to be washed
prior to use and further, very often, oversized stone has to be crushed.
The present invention relates to the latter sand and gravel deposits.
There are certain problems arising in relation to sand and gravel plants, even in
relatively remote areas, in that it is now no longer acceptable to dig or excavate sand
and gravel without reinstating the countryside after the vein of sand or gravel has
been used. Thus, there is a need for the reinstatement of the site after use.
Further, heretofore the usage of water was relatively uncontrolled in sand and gravel
plants. At present, particularly where there is extensive washing required, there is a
need for the conservation of water and ideally for it's reuse. Finally, there is a need to
ensure that the minimum amount ol waste, silt and contaminants are generated. in
the sense that useful materials should not be mixed up with the contaminants
subsequent to the preparation of the aggregate. Such contaminants will simply be
soil, clay, dobe (a word used in the industry for clay), marl or other clay material.
There is a further operational problem in that certain types of sand are more useful
for certain products than other types.
While the term “sand” should only be used for what is actually sand. it is often used
for fine crushed materials and thus the more general term in the industry for sand is
product passing through a fine screen and for the purpose of this invention is material
which passes through a 5mm or less screen. However, for certain uses such as, for
example, for fine plastering or asphalting, fine sand such as 3mm sand is particularly
useful and it becomes more useful when the amount of very fine sand such as, for
example, 1mm or even less, forms a good proportion of it. Unfortunately, washing
generally removes the finer sand with contaminants such as clay. In some instances,
the use of fine sand can reduce the quantity of more expensive materials used in the
manufacture of concrete or asphalt. It is also necessary to reduce the amount of
waste material requiring disposal. Therefore, there is a need, for example, to be able
to recover this fine sand, not alone to reduce the amount of unwanted material, but
also to improve the quality of the sand itself. Needless to say, the more sand that is
recovered. the less unwanted product there is to dispose of and therefore the easier it
is to clean the recovered water after the washing operation.
The present invention is directed towards overcoming these problems.
According to the invention, there is provided a sand and gravel washing process
comprising:
(a) an initial dry screen and crushing step is performed in an intake stage
and material over a predetermined size is removed and crushed for
recycling through the intake stage;
(b) the material is sent to an initial wet screening stage where it is screened
and washed and material above a predetermined size is removed for
crushing and recycling through the initial dry screening stage;
(c) the undersize material and water is delivered to a washing drum in a
scrubbing stage to agitate, separate and abrade contaminant materials
from the stone and sand and to breakdown the contaminant materials;
(d) a subsequent material screening and washing step is performed to
provide predetermined sizes of stone in a subsequent screening and
washing stage while removing sand in two separate sizes from the other
material;
(e) delivering the sized stone to separate stone storage stations;
(t) then delivering the sand and water into two separate tanks;
{g) dewatering the sand in a sand dewatering stage by removing the sand
from the tanks while allowing most of the water to remain in the tank;
(h) storing the washed and dried sand as two separate sizes of sand in two
sand storage stations;
(i) delivering the water and residual sand and contaminant materials to a
cyclone to remove fine sand in a fines recovery stage;
(j) delivering the fine sand to a screen to further remove water;
(k) delivering the dried fine sand to one of a separate tine sand storage
station and the two sand storage stations; and
(I) pumping the resultant water and contaminants to a settling station.
There are certain advantages of the present invention. while it may seem relatively
obvious, the feeding of oversized material via Crushers back into the separating
system is novel and inventive. By using this, the whole system operates in a virtual
close loop. Further, it is very important, in the generation of the various grades of
sand to add further fine sand and this adds to the production of a much better quality
material. The use of the water settling, etc. ensures that the minimum amount of
water is used in the plant and that as much water as possible is recovered for
subsequent re-use.
In a further way of carrying out the invention, the subsequent material screening and
washing step comprises delivering the material through a double decked ilat vibratory
screen, while simultaneously delivering additional water onto the screen to wash the
material through the screen.
Further. in accordance with the invention, prior to carrying out the initial screening
step, the steps are perfomted of:
removing top soil from the area to be excavated;
storing the top soil for future reinstatement;
removing the subsoil and storing for future reinstatement; and
digging out any veins of clay or other contaminant material.
Ideally, prior to the delivery of material to the intake stage, an additional dry screening
is provided to remove oversize stone too big to crush in the intake stage.
In this latter process, from time to time, a portable crushing plant is used to crush the
oversize stone for delivery to the intake stage.
In one process according to the invention, the dewatering of the sand in the
dewatering stage comprises the use of one of:
a perforated bucket wheel assembly for lifting material out of the tank;
and
a vibratory sand drying screen having a line mesh.
In another embodiment of the invention, a coagulant is added to the waste water.
Detailed Description of the Invention
The invention will be more clearly understood from the following description of some
embodiments thereof, given by way of example only, with reference to the
accompanying drawings, in which:
Fig. 1 is a layout of a sand and gravel plant according to the invention, and
Fig. 2 is a layout of an alternative construction of plant.
Referring to the drawings and initially to Fig. 1 thereof, there is illustrated portion of a
sand and gravel plant, indicated generally by the reference numeral 1. The sand and
gravel plant 1 comprises a number of stations, namely, an intake station 2, a
recycling station 3. a scrubbing station 4. a wet screening station 5 and a sand
dewatering and recovery station 6. In the drawings, the various stockpiles of sand
and gravel and crushed stone are identified by the reference letters and numerals S1
to 810 (inclusive).
The intake station 2 comprises a hopper 20 mounting transverse screening bars 21
deiivenng oversize stone to a chute 22 which feeds a stockpile S1 of oversize
material. The hopper 20 feeds a further chute 23 which delivers onto a main feed
conveyor 24. The main feed conveyor 24 feeds a screen 40 forming pan of the
scrubbing station 4.
The screen 40 feeds oversized material from a chute 41 to a jaw crusher 42 and
screen (not shown). The screen fed from the jaw crusher 42 feeds a return conveyor
31 forming part of the recycling station 3. The screen also feeds the stockpile S3.
The conveyor 31 feeds a weigh box 32 which can feed either directly to the stockpile
S2 or can feed a cone crusher 33 which in turn feeds by a chute 34 for the conveyor
24. The weigh box 32 is a conventional weigh box on load cells.
Referring now to the scrubbing station 4, the screen 40 feeds a log washer 45 to
which water is also delivered. The log washer 45 then delivers onto a series of
screens 51 of various sizes. some of which are mounted below the log washer 45.
The screens 51, in turn, deliver sized stones to the stockpiles S4 to 88 inclusive.
Water is delivered continuously onto the screens 51 by a watering system of pipes
and nozzles {not shown). Obviously, some of the water is also delivered into the log
washer 45.
From beneath the various screens 51, a pair of chutes 52 and 53 and a pair of pipes
54 and 55 deliver water, silt and line sand from the wet screening station 5 to the
sand dewatering and recovery station 6. The sand dewatering and recovery station 6
comprises a pair of tanks 61, a cyclone 63. dewatering screens 64, and conveyors
65. The water, silt and fine sand is pumped to the cyclone 63. The cyclone 63
separates the silt from the sand and delivers the sand to the screens 64. The sand is
then delivered by the conveyors 65 to the stockpiles S9 and 810. The silt is delivered
by a pipe 62 to settling ponds. not shown.
A central control tower 70 is also illustrated which has control equipment, including
PC controls, and has various electrical connections to the screens, conveyors.
Crushers, etc. to allow the operation of the plant.
In operation, when a new area of land is to be extracted, the topsoil is carefully
peeled back from the land and stored in a topsoil pile. This is stored for subsequent
reinstatement oi the land. Then the sub-soil is removed by an excavator carefully
ensuring that no good gravel or sand is removed and wasted. This relatively useless
soil is stockpiled separate from the topsoil, again for reinstatement. Then, the land is
inspected to make sure there is no vanes of dobe or marl to contaminate the raw
material. Any such vanes are removed. Then the excavation of the raw material is
carried out by wheeled loading shovels which dig into the lace of the pit from the
lower levels and transfer the material to the intake station 2 of the plant. Optionally,
dump trucks may be used.
when digging out the face. the rougher materials are mixed with the liner materials to
achieve a consistent grade of material for the intake stage. Generally, the material is
mixed sufficiently to ensure consistent intake of material. Then the raw material is
brought to the intake stage 2 where it is loaded into the hopper 20. Any stones or
rocks bigger than the spacing between the bars over the hopper. usually somewhat
of the order of 250mm, are rejected and delivered to the oversized stockpile S1. The
material from the oversized stockpile S1 is either removed and sold as oversized
material for foundations and the like, or is further broken up either by pneumatic
hammers, drop or swing balls or a portable crushing plant. The accepted raw
material is delivered up the conveyor 24 to the scrubbing station 4 where the material
is screened and delivered either into the stockpile S3 or back to the recycling stage 3
for subsequent storage in the stockpile S2 or crushing in the cone cmsher 33 for
delivery again onto the main teed conveyor.
In the washer 45, the material arrives as a slurry because of the amount of water that
is delivered into the log washer 45 by spray bars (not shown). The material is
abraded and tossed around the log washer 45 such that any pieces of clay, dobe,
marl or other fines that might have been missed in the first cleaning at the screen 40
are dislodged and washed away. All of the material that is washed through from the
log washer and the screens 51 is delivered through one of the chutes 52 and 53 or
pipes 54 and 55 out of the screening station 5. As explained already, the various
stockpiles S3 to 88 inclusive are then filled for subsequent removal. All the water, silt
and dirt is delivered, as stated above, from the scrubbing station 4 and the screening
station 5 to the sand dewatering and recovery station 6 where, because it is delivered
down chutes and pipes. it is reasonably well agitated such that when it arrives in the
tanks 61. The fine sand is delivered out oi the cyclone 63 to the screens 64 where it
is dewatered and delivered to the stockpiles S9 and 810. All the silt is delivered from
the cyclone 63 out the pipe 62 to the various settling ponds (not shown).
Referring now to Fig. 2, there is illustrated an alternative construction of plant in which
parts similar to those described with reference to the previous drawings are identified
by the same reference numerals. Again, the plant is identified by the reference
numeral 1. In this embodiment, the intake station 2 and the recycling station 3 are
essentially identical in construction and operation as in the previously described plant
with reference to Fig. 1. In the scrubbing station 4, there is provided a barrel washer
46 and there is also illustrated a screen 44 which feeds, through a chute 47, a jaw
Crusher 43 which in turn feeds through another chute 48 the conveyor 31. In this
embodiment, it will be noted that there are also some additional sizes of stone
produced.
in the wet screening station 5, there is provided a plurality of conveyors 57 feeding
the various stockpiles S3, S4, S7 and 38. There is also provided a conveyor 58
which feeds a screen 59 which then feeds, through two chutes 59a and 59b, the
stockpiles S5 and S6.
The sand dewatering and recovery station 6 comprises a tank 67 mounting a pair of
bucket wheels 68, which bucket wheels have perforated buckets to allow water to be
drained from them. The bucket wheels deliver, through chutes 70, to the conveyors
69 which feed the stockpiles S11 and 812. The remainder of the sand and silt which
settles in the bottom of the tank 67 is delivered into a hopper (not shown) beneath the
cyclone 63 and is pumped up into the cyclone 63 where sitt is removed. Then the
sand is delivered to the screen 71 and transferred by a conveyor 72 to the conveyors
69 to the stockpiles S11 and S12 . The silt is delivered into the tank 75 where a
coagulant is added such that the coagulated material is delivered out the pipe 62 to
settling ponds, while clean water can be removed for recirculation.
In the specification the terms “comprise, comprises, comprised and comprising" or
any variation thereof and the terms “include, includes, included and including" or any
variation thereof are considered to be totally interchangeable and they should all be
aiforded the widest possible interpretation and vice versa.
The invention is not limited to the embodiment hereinbetore described, but may be
varied in both construction and detail within the scope of the claims.
Claims (1)
1.A sand and gravel washing process comprising: (a) an initial dry screen and crushing step is performed in an intake stage and material over a predetermined size is removed and crushed for recycling through the intake stage; (b) the material is sent to an initial wet screening stage where it is screened and washed and material above a predetermined size is removed for crushing and recycling through the initial dry screening stage; (c) the undersize material and water is delivered to a washing drum in a scrubbing stage to agitate. separate and abrade contaminant materials from the stone and sand and to breakdown the contaminant materials; (d) a subsequent material screening and washing step is performed to provide predetermined sizes of stone in a subsequent screening and washing stage while removing sand in two separate sizes from the other material; (e) delivering the sized stone to separate stone storage stations; (t) then delivering the sand and water into two separate tanks; (g) dewatering the sand in a sand dewatering stage by removing the sand from the tanks while allowing most of the water to remain in the tank; (h) storing the washed and dried sand as two separate sizes ot sand in two sand storage stations; (i) delivering the water and residual sand and contaminant materials to a cyclone to remove fine sand in a fines recovery stage; (j) delivering the fine sand to a screen to further remove water; (k) delivering the dried tine sand to one of a separate fine sand storage station and the two sand storage stations; and (l) pumping the resultant water and contaminants to a settling station. A process as claimed in claim 1, in which the subsequent material screening and washing step comprises delivering the material through a double decked flat vibratory screen, while simultaneously delivering additional water onto the screen to wash the material through the screen. A process as claimed in claim 1 or 2, in which prior to carrying out the initial screening step, the steps are performed of: removing top soil from the area to be excavated; storing the top soil for future reinstatement; removing the subsoil and storing for future reinstatement; and digging out any veins of clay or other contaminant material. A process as claimed in any preceding claim, in which prior to the delivery of material to the intake stage, an additional dry screening is provided to remove oversize stone too big to crush in the intake stage. A process as claimed in claim 4, in which from time to time, a portable crushing plant is used to crush the oversize stone for delivery to the intake stage. A process as claimed in any preceding claim, in which the dewatering oi the sand in the dewatering stage comprises the use of one of: a perforated bucket wheel assembly for lifting material out of the tank; and a vibratory sand drying screen having a fine mesh. A process as claimed in any preceding claim, in which a coagulant is added to the waste water. A process substantially as described herein with reference to and as illustrated in the accompanying drawings.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IE2005/0609A IE85489B1 (en) | 2005-09-14 | A sand and gravel washing process |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IE2005/0609A IE85489B1 (en) | 2005-09-14 | A sand and gravel washing process |
Publications (2)
Publication Number | Publication Date |
---|---|
IE20050609A1 IE20050609A1 (en) | 2007-03-21 |
IE85489B1 true IE85489B1 (en) | 2010-04-14 |
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