what is sand washing plant process | ldhb
Sand screening and washing equipment is widely used in mining, aggregate processing and other industries to process materials. In some cases, it is limited. It needs a kind of equipment with small floor area, simple operation, large processing capacity and better cleaning effect. In order to solve the shortcomings existing in the market, it is urgent to improve the technology of screening and washing device, which can better screen and clean, and promote the development of screening and washing industry. LDHBdouble screw screen washing plant is a multi-functional sand washing equipment with functions of water sand washing, sand material dehydration and recovery. The equipment is composed of spiral sand washing machine, dewatering screen and cyclone, which are combined together by ingenious design.
Firstly, the material is sent into the cleaning box of the spiral sand washer, and the material is pushed to the front-end discharge port through the internal blade of the double screw sand washer, and then through the discharge port after being washed with clean water. Double screw sand washing machine is a kind of spiral cleaning equipment, which uses screw principle to push sand and stone to separate from water and soil. The other end is provided with tailing dry discharge, and the internal materials fall onto the tailings dry discharge. The single direction excitation force generated by the vibration exciter on the tailings dry discharge screen makes the screen box move in a reciprocating straight line. The water on the material falls into the drop water tank through the screen mesh. The drop water tank is connected with the cleaning box of the spiral sand washing machine through a pipeline, and the feed inlet of the cyclone is connected with the water drop box through the pipeline and the slurry pump Under the action of centrifugal sedimentation, most coarse sand particles are discharged through the bottom flow port of the cyclone, while most of the fine particles are discharged by the overflow pipe, so as to achieve the purpose of separation and classification. The sand settling nozzle of the cyclone is located above the tailings dry discharge screen, forming a structure in which the concentrated materials of the cyclone fall into the tailing dry discharge. The water separated by the cyclone flows into the inner part of the recovery box, and the water flow inside the recovery box It enters into the cleaning box of the spiral sand washer to complete the cleaning, grading and dehydration of materials.
silica sand washing plant equipment manufacturer-sinonine
Sinonine silica sand processing & sand washing plant specializes in producing sand products suitable for various industries, such as quartz sand, foundry sand, slab sand, fracturing sand, glass sand, construction sand, etc. The configuration of sand washing machines for sand washing plant will depend on the situation of raw materials and final products. The common process flow of most silica/quartz sand processing & washing plant consists of crushing, cleaning, classifying, scrubbing, sorting, desliming, dewatering, drying and wastewater treatment.We can customize sand washing plant according to customer requirements, and provide EPC turnkey basis service, including but not limited to the following contents:Technical consulting According to the composition of original sand, provide the market direction and processing direction, provide the corresponding silica sand processing & sand washing plant and technical support information.Sand processing laboratory testAccording to the requirements of sand processing, the original sand is tested and the reliable analysis report of sand processing test laboratory is provided for the configuration of sand processing and sand washing plant.Engineering design Sinonine will organize the design team to carry out comprehensive engineering design of the sand processing & sand washing production line and the overall design of the whole project.Sand processing machines manufactureAccording to the sand processing and washing plant process, customize the complete set of sand processing equipment.Installation and CommissioningSinonine will organize technicians to guide the installation and commissioning of sand plant until the production line runs smoothly.
Sionine is a professional manufacturer of silica sand processing & sand washing plant equipments. Sinonine is the only earliest silica sand processing & sand washing plant EPC provider in China, its products cover the whole filed of silica sand processing and purification.
frac sand processing | mws washing systems
Producing specification Frac sand is a challenge that requires focus on yield and efficiency, with a clear understanding of the feed material. Typically only a small fraction in the middle of the feed gradation is product material (i.e. 20/40 mesh, 30/50 mesh, 40/70 mesh, 70/140mesh), so maximizing recovery of particles in that range is essential to maximize the downstream dry screening efficiency.
Some Frac Sand deposits require two stages of coarse separation that require hindered settling classification (density separators) to produce coarse Frac sand products (i.e 30/50, 40/70), while other Frac sand deposits are naturally fine and simply require scalping off top end material (at nominally 20mesh) on the wet sizing screen and washing out the bottom end material (nominally -140mesh) via larger diameter cyclones to produce an industry accepted 100-mesh product [product that has nominally 10-12% +70 mesh and 10-12% minus 140 mesh].
Whether the plant requires the density separation stages (McCloskey Washing Systems CombiSand range) or just a single stage of cyclone separation (McCloskey Washing Systems SandStorm range), MWS offers the solution fit for each application. The standard plants are fully inclusive starting at the feed hopper all the way through to the sand product radial stacker. The sizing screen is fully urethane-lined, double or triple deck, with a modular urethane panel layout on each deck for easy changing of panels. The pumps, cyclones, and density separators are all Linatex, rubber-lined, and all piping is rubber or ceramic lined. The high frequency dewatering screens produce an absolute drip-free product onto the radial sand stackers, significantly reducing the amount of natural stockpile decanting time required for the sand to be dry enough to feed the dry plant.
The systems are completely modular, and delivered to site in semi-assembled form, meaning the customer has absolutely no structural design or civil work to worry about, other than pouring a concrete pad on which to set the plant. Within 5 days of the MWS systems arriving on site, the plant can be producing spec Frac sand, beginning the very short ROI period that comes with the production of valuable Frac Sand.
McCloskey Washing Systems have designed these plants with the operator in mind: productive, safe, efficient, and accessible. All these factors come together with the MWS Sandstorm and MWS Combisand sand plants.
sand washing plants | mclanahan
McLanahan Sand Washing Plants process sand from its raw state into products that meet various specifications. The process requirements vary depending on the input and desired output, but plants typically scrub, liberate, deslime, wash, classify, decontaminate and dewater the sand, as well as process the effluent stream that results.
For customers who are interested in maximizing yield and producing precisely graded products to the end-user's needs and specifications, it is more likely that a custom sand plant is the correct solution. Whether the sands are natural or manufactured, fine or coarse, well or poorly graded, or required for specialty applications, McLanahan can offer a plant specifically designed to suit your needs.
McLanahan is best known for creating process solutions to address the specific needs of each customer's application. We have one of the largest ranges of robust, field-proven equipment, and we are constantly innovating. Our background and expertise in applications is second to none.
Depending on the application, McLanahan can perform lab scale tests on materials, including sieve analysis, percent solids, attrition scrubbing, sink/float, sand equivalency and durability, Hydrosizer based classification, static and dynamic flocculation/settling and Filter Press testing.
With our proprietary simulations, in-house lab and industry expertise, you get a plant designed specifically for your site with capacities to match your need. Our expertise is the envy of the industry, so when you couple this with one of the largest ranges of equipment offerings, we can offer a solution.
Sand Washing comes in many forms and covers a range of feed and products produced, including construction aggregates such as concrete, asphalt, mason, mortar, and plaster sands; sports sands such as for golf courses, ball parks, and race courses; industrial sands, such as glass, filter, foundry, and frac; specialty sands and materials such as anti-skid, roofing granules; deligniting/organics removal; and soils washing for environmental projects.
First, consider the following questions: What do you have? What do you want to make? If the answer is a very specialized gradation and a difficult natural sand deposit, then consider a Recipe Plant. If the answer is a manufactured sand and you are making concrete sand all day every day, then an Ultra Sand Plant or Modular Wash Plant may be your answer.
Many other factors, such as available investment, local competition and expanding markets, will influence this decision. Through a process of elimination starting with the simplest configuration, McLanahans experienced personnel will guide you through to the best options.
Ultra Sand Plants, which utilize Dewatering Screens, Pumps and Cyclones, offer greater separation efficiency and provide a higher product yield that can be reused almost immediately due to the effectiveness of the Dewatering Screen. Ultra Sand Plants are commonly used to wash and dewater industrial and specialty sands, as well as asphalt, concrete and masonry sands.
For high-quality sand that meets strict specifications, look no further than McLanahan Recipe Sand Plants. These sand plants make use of every grain of sand to offer customized blending for concrete, foundry, glass and plaster sands. The resulting sand product is consistent, uniform and will meet even the tightest of specifications.
McLanahan In-Line Blending Sand Plants provide high product yields, offer flexible blending options, produce drier products and improve product consistency. They are simple to operate, create accurate splits and are field-proven.
McLanahan designs each of its Frac Sand Plants to meet the specific needs of each customer. Using field-proven McLanahan equipment, Frac Sand Plants can be designed for classifying, desliming, dewatering, pumping, scrubbing, sizing, tailings management and waste solids management. McLanahan Frac Sand Plants are engineered to make the critical separations required for frac sand. They produce the highest product yield at the lowest moisture.
Classifying Tank Based Sand Plants can create multiple products from a single feed as well as remove slimes and excess water. Feed material enters the Sand Classifying Tank first, and sand grains settle in sections according to size down the length of the tank. Valves at the bottom of each section release the grains into one of several flumes used to create a primary, secondary or tertiary product, depending on the application. The discharged products are then dewatered by Dewatering Screens and/or Fine Material Screw Washers. The addition of Cyclones and/or rising current water can be used to deslime the feed.
McLanahan Industrial Sand Plants are designed with a combination of McLanahan equipment to provide extremely sharp classification of various industrial sands. This equipment can include Attrition Cells, Dewatering Screens, Hydrocyclones, Hydrosizers, Filter Presses, Fine Material Screw Washers, Pumps, Separators and Thickeners.
Although Portable Plants, which can be wheel-mounted or skid-based to provide an ease of transport, are limited in capacity, they do not limit the process. Portable Sand Plants can be used for classifying, dewatering, sizing and removing oversize and organics from feeds to produce aggregates, construction and demolition materials, and specialty sands.
McLanahan Ultra Fines Recovery Plants can recover +400 mesh material for use in many industries. UFRs are especially well-suited in the aggregates industry for effluent streams containing <100 mesh fractions and for recovering valuable coal from effluent streams in the coal industry.
p&q university lesson 9- washing & classifying : pit & quarry
Materials engineers constantly strive to improve concrete and bituminous mixes and road bases, and clean aggregate is a vital part of that effort. Yet, aggregate producers often find it difficult to meet all the requirements for cleanliness. While hydraulic methods are most satisfactory for cleaning aggregate to achieve desired results, they are not always perfect. It is still necessary to accept materials on the basis of some allowable percent of deleterious matter.
In broadest terms, construction aggregate is washed to make it meet specifications. Specifically, however, there is more to the function of water in processing aggregate than mere washing. Among these functions are:
Because no washing method is flawless, and because some materials may require too much time, equipment and water to make them conform to specifications, it is not always economically practical to use such materials.
Further, many manufacturers of washing equipment will examine and test samples to determine whether their equipment can do the job satisfactorily. No reputable equipment manufacturer wants to recommend equipment if it has reasonable doubt about satisfactory performance on the job.
The ideal gradation is seldom, if ever, met in naturally occurring deposits. Yet, the quality and control of these gradations is absolutely essential to the workability and durability of the end use. Gradation, however, is a characteristic that can be changed or improved with simple processes, and is the usual objective of aggregate-preparation plants.
With specifications becoming increasingly stringent, washing and classifying of aggregate materials is ever increasing. As pits and quarries progress into their reserves, the more easily extracted material is less available, often forcing operations particularly sand and gravel operations to process material with a greater amount of clay and silt. While some materials may require only rinsing to remove small silt particles, other materials may require scrubbing to remove clay and other deleterious materials.
Sand and gravel typically are mined in a moist or wet condition by open pit excavation or by dredging. Open pit excavation is often conducted with power shovels, front-end loaders, bucket-wheel excavators or draglines. Alternatively, dredging involves mounting equipment on boats or barges and removing the sand and gravel from the bottom of a body of water by suction or bucket-type dredges. After mining, the materials are transported to the processing plant by suction pump, earthmovers or trucks, or by the method of automated belt conveyor systems.
Processing sand and gravel products for a variety of specific market applications requires the use of different combinations of equipment, which may include portable and stationary washing and screening plants; sand classification tanks and systems; dewatering screens and screws; coarse and fine material washers; blade mill washers; log washers; rotary and vibrating screens; and more.
Manufactured sand is produced from the crushing of hard stone such as granite. As an alternative to river sand, the use of manufactured sand is becoming more prevalent because of dwindling natural sand reserves or the constraints and expense of extracting natural sand and gravel near urban areas where material is most needed.
Washing and classifying also may be used in processing manufactured sand. The crushing process creates a significant amount of fines, which are undersized fine particles that pass through the smallest screen openings (which are measured by mesh sizes). The minus-#100 and minus-#200 mesh fines require washing to be removed. While these fines are allowable in the bottom-end of asphalt sand products, it is common to wash manufactured sand in this application. Most concrete sand products require the removal of fines. Equipment choices vary in the removal of fines from the use of a wet screen to the use of a classifying system.
Manufactured sand is widely accepted in asphalt mixes. In concrete mixes, manufactured sand is often blended with natural sand. Washing (versus air separation) is recommended when classifying material for concrete mixes. When blending natural and manufactured sand, it is best to use a classifying tank.
The initial material feed that passes through the coarsest screen (largest screen openings) is washed in a log washer before it is further screened. The name log washer comes from the early practice of putting short lengths of wood logs inside a rotating drum filled with sand and gravel to add to the scrubbing action. A modern log washer consists of a slightly inclined horizontal trough with slowly rotating blades attached to a shaft that runs down the axis of the trough. The blades churn through the material as it passes through the trough to strip away any remaining clay or soft soil. The larger gravel particles are separated out and screened into different sizes, while any smaller sand particles that had been attached to the gravel may be carried back and added to the flow of incoming material.
The water and material that pass through the finest screen are pumped into a horizontal sand classifying tank. As the mixture flows from one end of the tank to the other, the sand sinks to the bottom where it is trapped in a series of bins. The larger, heavier sand particles drop out first, followed by the progressively smaller sand particles, while the lighter silt particles are carried off in the flow of water. The water and silt are then pumped out of the classifying tank and through a clarifier where the silt settles to the bottom and is removed. The clear water is recirculated to the feeder to be used again.
It is important to take a closer look at sand classification systems. Sand classifying and re-blending systems allow material producers to modify a raw natural sand blend into a high-quality, industry-standard specification mix; or blend a natural sand and a manufactured sand to a desired specification product mix. Classifying systems are available in either stationary, portable or semi-portable configurations. The choice of a particular configuration depends on the physical characteristics of the sand mining site and any relocation needs.
Classifying and re-blending systems allow producers to do the following:
Scalp (remove) excess water from dredged material.
Reject deleterious (harmful) material.
Separate sand particles.
Re-blend sand particles to create more than one spec product simultaneously.
Sand classification systems use water and the principles of gravity and settling to separate and re-blend sand. For a traditional classifying tank, the industry-standard method is based on the principle that coarser sand particles are heavier and will settle near the feed end. Finer and lighter sand particles are carried progressively further down the length of the tank. During this process, the tank is constantly supplied with a feed of water that keeps the top of the tank overflowing. This constant movement of water over the edge of the tank (or weir) helps eliminate organics and other material that should not be present in the final sand blend.
As the sand particles of different sizes settle to the bottom of the tank, they begin to pile up around valves located there. These valves are typically installed in sets of two or three. Valves are grouped together in stations, and each station is equipped with a sensing paddle that turns at a slow but constant speed. As the sensing paddle turns, the sand builds up around it. Once enough sand piles up around the paddle, the paddle begins to stall, sending a signal to the classifying tank controller that this stations area is filling up with sand. In turn, this signal causes the valve or valves in that station to open up to discharge sand.
The sand that is discharged from each station is sent into a flume at the bottom of the tank where the sand is remixed and dumped into one of several dewatering devices. Once the sand has been separated from the water, it is moved with conveyors to large stockpiles. Sand is stored in these stockpiles to dry and then shipped to customers for use in a wide variety of projects, including concrete mixes, masonry mixes, golf course bases, and sand traps and fill sand.
Each of these re-blended products is made of a different mixture or recipe specification of particle sizes. Specifications are created in a variety of ways, but all are measured by the amount of material that either passes through or is retained by different-sized sieves or screens. Within these specifications, the producer must determine sieve sizes, along with just how much material must be of a specified size. To remain competitive and profitable, operations typically rely upon skilled quality control teams to test, monitor and maintain all specification requirements of final products.
Most classifying plants are operated via automated control systems. To meet finished product specifications, the feed rate of incoming material, the vibration rate of the sorting screens, and the flow rate of the water through the sand classifying tank must be carefully monitored and controlled. Automated control systems allow the operator to compensate easily for changes in the feed or slurry mix being fed to the plant, to closely monitor the manufacture of sand products for total tonnage and quality and to automatically make products to a closely defined, predetermined specification with few (if any) operator calculations, minimizing the opportunity for human error.
In the processing and handling of sand, gravel or crushed stone, it is necessary to complete the separation or dewatering of the fine solid materials from the slurry containing them. With that in mind, new solutions to the problem are often developed, such as recently introduced unit that is a combination of a fine material washer and a dewatering screen.
Washing sand and aggregate results in the discharge of dirty water from wet screening decks, sand screws or sand classifiers. The wastewater typically carries fines out to a series of settling ponds. While this is the most common method of treating wash water fines, it is not the most sustainable method. As such, many operations employ equipment such as filter presses, hydrocyclones, water clarifiers and flocculent systems to more efficiently reclaim and reuse wash water and to minimize settling pond use and maintenance.
Water being recovered for washing may be lost to evaporation or percolation in the pond, which may require the operator to provide make-up water (which may be scarce) to the plant.
The real estate for a properly sized settling pond may not exist at the plant site.
The cost and time involved in cleaning the ponds with a dragline or excavator may be excessive. And, cleaning a pond especially the fine material that flows downstream and settles very slowly is extremely inefficient.
Dirty water may get back to the plant, limiting production, producing washed material out of spec, or even shutting down production.
Ponds may present hazards to nearby equipment and to workers.
However, some sites can be ideally suited to the use of settling ponds. Some operations may access an exhausted portion of a large quarry where the dirty water can be deposited and the fines never need to be recovered. Clean water is recovered from the opposite end of the pond and the fines settle down in the deep quarry bottom, never to be dealt with again.
Hydrocyclones are tapered cones that receive the dirty wash water at a high velocity. The water travels in a tight circle within the cone and centrifugal force throws the largest particles to the outside of the cone where they slide down the cone and out the bottom. Rather than discarding all the particles into a settling pond, the cones can recover the #200-mesh and larger material, which can be sold as aglime, mineral filler, lining for utility trenches, mortar, grout additives and more.
Water clarifiers are of value to a producer who wants to minimize settling pond maintenance and reclaim a large percentage of the water immediately. Also, for those producers who have an area that has already been mined and will ultimately be reclaimed, a good clarifier can pump the solids to that area, and it never needs to be conveyed, loaded or hauled again. While clarifiers may require a significant initial capital outlay, they require minimal maintenance and operating costs.
Clarifiers are combined with flocculent systems. Flocculants rapidly settle out virtually all of the suspended solids in a dirty water stream. Liquid flocculants require very little hardware and can be introduced via a small chemical metering pump with some dilution water added. However, liquid flocculants are not always environmentally friendly and often separate or stratify in the container before use. Dry flocculants are more environmentally friendly but require more sophisticated equipment to get them into the solution properly. It is imperative to work with a competent vendor to select the right flocculent for a given application.
Filter presses take the silt that a clarifier has collected and essentially squeeze the water out of it to form a cake that is discharged and can be conveyed or transported by a loader to a disposal area; or the cakes can be used as backfill material. The use of clarifiers and filter presses minimizes fines going into settling ponds, while making waste material easier to handle.
Lastly, it is important to conduct periodic water audits to determine the best and most sustainable use of water within the aggregate washing process. Operations should develop a maintenance program that routinely inspects all plumbing equipment and fixtures, water lines, spray systems, valves and pumps. Metering at strategic points in the facility helps to detect leaks and maintains minimum flow rates. But, above all, operations should employ the optimal reuse and recycling systems for aggregate washing.
Selecting equipment for washing and classifying can seem like a daunting task. There are countless solutions using a variety of equipment that can be put together based on a producers needs. Although some of this equipment was detailed earlier, following is a more-complete overview of wet processing equipment available to aggregate producers.
Aggregate conditioners are designed to help producers start to liberate light, loamy clay or dirt from either coarse rock or sand before further processing. They can be placed ahead of a wash screen or other washing equipment, such as sand classifying tanks or fine material screw washers. Using a combination of paddles and flights arranged in alternating format along the length of the shaft, aggregate conditioners begin to scour, abrade and break down deleterious material.
Although similar in appearance to coarse material screw washers, aggregate conditioners function very differently. For example, all material and water entering the aggregate conditioner must exit through the discharge opening at the bottom of the box opposite the feed end. There is no overflow. They sit on a slope of zero to 5 degrees, which gives them much greater capacities.
Built primarily to wash crushed stone and gravel, coarse material screw washers effectively remove light, loamy clays, dirt, crusher dust and coatings that cannot be removed by wet screening alone. They also can be used to remove floating vegetation and soft aggregate from the material feed.
Coarse material screw washer paddles are used in conjunction with screw flights to provide scouring and agitation. The turbulent washing action combined with rising current water, which is introduced at the feed-end at the bottom of the box, results in separation of the lighter fraction from the sound aggregate.
Lighter fractions float to the surface due to water rising in the box and then overflow the weir located at the back of the box. Desired clean product is then scrubbed and conveyed by the paddles and flights to the discharge end of the box.
Paddle configurations can vary based on the design and length of the coarse material screw washer. More paddles increase washing action but decrease capacity because paddles do not convey material up the washer box as fast as flights. When using additional paddles, it is necessary to lower the slope of the box and increase motor horsepower, which will help convey material to the discharge end. Additionally, reversing some of the paddles will retain material in the box longer.
Fine material screw washers are used primarily to dewater, classify and wash minus-3/8in. sand or other fine material. They are designed to accept feeds from sand classifying tanks, belt conveyors, other fine material screw washers or slurry feeds.
In a fine material screw washer, as material enters the feed box, heavier material sinks to the bottom of the box, while finer fractions float to the surface and over the back weir. Material that sinks is then conveyed from the pool area up an 18-degree slope toward the discharge end.
As material is conveyed, it enters the dry deck section of the washer box at which point the water begins to separate from the material. Curvature of the rotating screw flights conform to the curved section of the washer box to efficiently convey, wash and dewater.
Log washers are used in aggregate processing to remove tough, plastic-type clays from natural and crushed gravel, stone and ore feeds. When in operation, log washers sit at a slope of between zero to 14 degrees, depending on the severity of the washing application. As the percentage of deleterious material increases, the slope must be raised to increase retention time. In some cases, lower slopes are able to increase capacity while decreasing horsepower and wear.
One limitation of log washers is that they must have a controlled top size. In general, 36in.- and 38in.-diameter units can accept feed material up to 4 in., while a 46in.-diameter unit can accept feed material as large as 6 in. cubed. It is recommended that sand-sized fractions be removed prior to the log washer as finer material tends to cushion the washing action.
When selecting a log washer, the amount, type and percentage of deleterious material to be removed from the aggregate must be considered. As the percentage of deleterious material increases, consider longer-length units to increase the washing action. In some severe applications, two or more log washers in a series may be required.
Sand classifying tanks provide several results, including removing excess water, classifying material by removing excess of certain mesh sizes, retaining finer mesh sizes and making multiple products from a single feed material. They are effective, low-maintenance units that produce one or more specific products. With either slurry or a dry feed, they are capable of handling sand gradation swings in the average plant, while minimizing waste.
Sand classification is based on the different settling rates of various grain sizes. As water and aggregate material enter the feed end, coarser grains settle first, and finer grains settle in successive sizes down the length of the tank. At the top of the tank, a series of hydraulic control mechanisms operate the discharge valves at the bottom of the tank. Depending on the type of control system and product produced, one, two or three discharge valves are located at each station.
Attrition scrubbers, also known as attrition cells, are used to liberate deleterious material and remove it from competent aggregate material. They are also proven to liberate clays, reducing product turbidity, and to break apart loosely conglomerated clusters in frac sand plants. Attrition scrubbers also can be used in glass sand, frac sand, clay and sand and gravel production, as well as in preparation of flotation feeds and reagent washing.
Attrition scrubbers produce a high-shear environment where particles scrub against themselves to scour their surface and liberate deleterious materials. All internal parts are completely rubber lined to maximize wear life and minimize maintenance time and costs of replacement parts.
They are designed to produce a consistent drip-free product, which is typically significantly drier than other dewatering equipment, such as fine material screw washers. Materials such as sand, gravel, crushed aggregates, frac sand, industrial sands, mineral sands, etc., are all capable of being processed through a dewatering screen.
To dewater material effectively, slurry is fed onto a steep, downward-inclined screen surface at the feed end of the dewatering screen to achieve rapid drainage. A pool of water begins to form in the valley as material builds up on the slightly upward inclined surface.
Counter rotating motors create a linear motion, driving solids uphill, while liquid drains through the screen media. The uphill slope of the screen, along with a discharge weir, creates a deep bed that acts as a filter medium, allowing retention of material much finer than the screen openings.
frac sand | mclanahan
the industry in the design and manufacture of complete wet processing solutions
to produce the frac sand needed for oil and gas well drilling. With the demand
for frac sand rapidly increasing, producers are under constant pressure to meet
those demands, as well as the ever-changing specifications, all while keeping
production costs low. Frac sand production plants must be flexible enough to
adapt to these changes by incorporating the latest equipment technology
available. McLanahan can help producers meet these demanding requirements and specifications with their frac sand solutions.
McLanahans wide range of crushing solutions allows the frac sand producer to liberate silica quartz from large rocks and boulders of sandstone while keeping internal stress fractures in the sand particles to a minimum. The company offers both primary and secondary crushers that employ the basic reduction principles commonly used in the frac sand industry compression and impact to break up the sandstone clusters for further processing. McLanahan crushers are able to free silica particles at maximum volume using a minimum amount of power and with less wear on the machine.
McLanahan offers both stationary and portable screening and sizing equipment effective for making the coarse-end separation required for frac sand, as well as scalping off the unwanted fractions. With McLanahans screening equipment, the smaller particles of sand fall through the screen media, and the larger particles of sand remain on the screen media to be further processed. McLanahan screening equipment also provides an opportunity for water to be introduced to the process to hydrate the sand in preparation for the fine-end separation to follow.
Frac sand must be exceptionally clean in order to meet the end users specifications. McLanahan washing and classifying equipment can be used to deslime the sand particles, as well as make the fine-end separation to prepare the feed for the dry processing stage. McLanahan offers equipment that can make the extremely sharp classification required in the frac sand industry. This equipment can determine what material goes into the frac sand and what material goes into waste, and separate it accordingly.
Attrition Cells/Scrubbers I Blade Mills I Dewatering Screens I Filter Presses I Frac Sand Plants I Hydrocyclones I Hydrosizers I Modular Wash Plants I Sand WashingPlants I Screw Washers I Slurry Pumps I Thickeners I Ultra Fines Recovery Plants I Vibratory Screens
The sand used for fracking must be pure and relatively free of the impurities that can block the passageways for gas and oil to escape. McLanahan scrubbing equipment uses particle-on-particle attrition to remove clay and other deleterious material to improve the turbidity of the sand. It can also be used to break apart any remaining sand particle clusters.
McLanahan dewatering equipment can remove moisture from frac sand material so it can be stacked for further processing in the dry processing stage. Efficient dewatering can reduce fuel consumption at the dry processing stage, reduce trucking of water, reduce residual fines and improve turbidity of final sand. McLanahan dewatering equipment provides a consistently stackable and conveyable material with a low moisture content.
Dewatering Screens I Filter Presses I Hydrocyclones I Modular Wash Plants I Sand Washing Plants I Screw Washers I Slurry Pumps I Thickeners I Ultra Fines Recovery Plants I Vibratory Screens
Recovering the plus 140 to 400 mesh non-frac sand material that is not retrieved by the Cyclone or Dewatering Screen is possible with McLanahan Fines Recovery equipment. Their equipment helps frac sand producers recover as many fines as possible to create a potentially saleable product. McLanahan fines recovery equipment also keeps this material from going into settling ponds, which can allow the frac sand producer to potentially reduce or eliminate their settling pond.
With many environmental regulations in place today, it is common for most frac sand processing facilities to have some sort of tailings management system in place. Typical effluent or tailings from frac sand plants can include the minus 70-mesh composed of fine sand, silts and clays; water; and solids concentrations of 3 to 10% solids by weight. McLanahan tailings management equipment helps frac sand producers reclaim as much process water as possible for reuse, and get the solid fractions into a state that can be easily/safely handled, stored or sold. It also allows producers to reduce or eliminate settling ponds, as well as lower the energy costs associated with pumping the material to the settling ponds.
Because sand particles must meet certain requirements to be considered for frac sand, sampling for quality and consistency is an important part of the production process. Mechanical Sampling Systems from McLanahan ensure that the end user will receive a sand that can withstand the crushing forces of the earth and allow the natural gas trapped in those rocks to escape by offering frac sand producers the best solution for their sampling application. McLanahan Mechanical Sampling Systems also ensure that the sampling standards of organizations like the American Petroleum Institute are being met.
McLanahan engineers complete wet processing plants designed specifically to make the critical separations required for frac sand in the oil and gas well drilling industry. Frac Sand Plants include a combination of McLanahans field-proven, state-of-the-art equipment that ensure silica deposits are processed to meet the strict demands of the industry. Based on the characteristics of the deposit as determined by McLanahans accredited lab, McLanahan will design a custom Frac Sand Plant to liberate silica particles, remove non-silica contaminants, remove clay impurities, remove non-frac sand size fractions and break up clusters.
The production of oil and natural gas from shale deposits relies on the use of proppants to maintain the openings induced by hydraulic fracturing. The most common proppants are produced from high quality silica and sand deposits and are known as frac sand. In order to be used as frac sand, the naturally occurring silica sand must exhibit many unique natural qualities, including roundness, high strength and purity. In addition, frac sand must be carefully processed to very demanding specifications with very tight tolerances.
With years of process team knowledge, McLanahan is the most experienced manufacturer of wet processing plants for frac sand production in North America. The company has a solution for all stages of the frac sand process, including crushing, screening, washing and classifying, and dewatering, as well as fines recovery, sampling and water management. With their equipment, McLanahan can make your site more efficient, more productive and more profitable.
materials wet processing equipment - cde
used wet processing and sand washing equipment, cde