Sand Washing Plants

SBM 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, SBM can offer a plant specifically designed to suit your needs.

Why SBM Sand Washing Plants

SBM 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, SBM 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.

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How Sand Washing Plants Work

Feed Preparation - Before the raw feed can be processed, it must be prepared using a combination of Attrition Cells, Blade Mills, Coarse Material Screw Washers, Log Washers and Rotary Scrubbers. The objective is to bring all materials into suspension, essentially breaking down any clays and clay-bound materials and removing superficial surface contamination.

Sizing – Prior to and immediately after the feed preparation step, the raw feed must be screened into fractions appropriate for both the downstream process and the products to be produced. Vibratory Screens are typically used.

Pumping – Centrifugal Slurry Pumps are the preferred means by which slurry is transferred from one plant/process to the next. Pumps are also used for effluent disposal. Although there can be resistance to using a pump over a gravity-fed unit, a gravity-fed unit may not be able to capture saleable materials. These losses go straight to waste and will end up costing you money in the long term.

Desliming - If a significant amount of liberated ultra-fine material is present in the feed, it is typically desirable to remove this deleterious fraction before classification. Classification efficiency can be adversely impacted by high levels of suspended clays, leading to losses of saleable materials and dirty products. Cyclones are the preferred desliming device due to their high shear and efficient classification. Feed Regulating Sumps are also very appropriate especially where there are high volumes such as would be found in dredging applications. Their controlled overflow can reduce the power consumption for pumping to downstream classification. Occasionally, desliming or simply washing is all that is needed to create the final product by removing the <75µm (<200 mesh) down to a certain level, such as 3-5% passing.

Classifying – This is the process of separating particulates from one another based on either size or specific gravity. In sand washing, this applies to the <4mesh (<5mm) particulates. The procedure may involve making single sharp separations with our Hydrosizer™, or multiple size classifications with our Classifying Tanks. Where a specialty sand is being produced, such as for glass, frac, sports, filter, foundry, etc., a Hydrosizer™ provides the accuracy needed for the splits in product gradation. Cyclones and Separators™ are also classification devices operating in the 140mesh (105µm) and finer size separation range typically finer than that where a Hydrosizer might be used.

Deligniting/Organics Removal - This process is the classification of materials based on their specific gravity. In an aggregate application, depending on the overall process design, either a Hydrosizer™ or a LitesOut™ is used to reject +50 x 4mesh organics of 1.4 – 1.8 SG. We use the ASTM C123 test for lightweight materials where a heavy liquid is used to define the specific gravity of the contaminant. Under some circumstances where the specific gravity differential between the sand and the lignite is marginal, we may run a test in our lab to evaluate dense medium separation as in a Hydrosizer™. It should always be understood that final products will not be lignite-free but will pass based on ASTM C123.

Densifying and Dewatering – Certain types of equipment, like Hydrosizers and Attrition Cells, require a dilute slurry to be concentrated. Cyclones or Separators™ are most commonly used for this purpose. Separators™ are especially suited for this duty with the ability to dial in and under flow density. In the case of dewatering, Fine Material Screws, Dewatering Screens or Separators™ are the most common devices. The lowest moisture content, by far, is obtained with a Dewatering Screen. With improved safety (less cleanup around the conveyors), better housekeeping (almost no water drainage from the stockpile) and more immediate availability, Dewatering Screens have become the equipment of choice for final product dewatering.

Effluent Treatment – Water is a very valuable commodity, so it is becoming a requirement to include a water recovery circuit as part of any permitting process. The device most common for this purpose is a Thickener. In most cases, 85% of the process water can be recovered for reuse. The most cost-effective storage method is a dedicated water tank to reduce the percolation and evaporation losses associated with ponds. These tanks also save on the power requirement to pump the water out and back.

Waste Solids Management – While Thickeners can recover process water, the underflow is relatively dilute and is typically be pumped to containment ponds. To finish off the sand washing process and have the waste solids in a conveyable and stackable condition, Filter Presses are typically employed.

Sampling - Every system requires monitoring and sampling to provide the best results. SBM can design a sampling system up front to focus on the key areas. The ability to react faster to process changes helps eliminate waste, improve product quality and troubleshoot problems.

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Washing plant estructure:

New sand washing plant improves sand quality

Reddal Sand, located in Grimstad, Aust-Agder, has supplied a variety of construction materials to major projects in the area since 1989, including materials for use in the manufacture of roofing tiles, concrete, road construction and various types of ground works (sports fields, playgrounds and golf courses).

Morten and Jan Tore Pedersen of Reddal Sand began looking for suitable wash plants as they believed they could recover more material than was currently the case from the sand and gravel reserve.

A particular area of concern was the top 3-4m of the deposit, which contained a high level of fines and clay contamination that was compromising the final quality of their sand product.

After looking into a number of potential suppliers it chose the Evowash sand washing plant from Northern Ireland company, SBM Global.

The new sand washing plant includes the Evowash 71 and Evowash 151 supplied by Ankerløkken Equipment who represents SBM in Norway.

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“The Evowash allows us to maximise the production of quality sand. The new installation has ensured that we are able to offer a higher quality sand product to our customers, which sets us apart from other suppliers in the area,” says Morten Pedersen.

Reddal Sand is supplying material to a diverse range of customers including roof tile manufacturer Skarpnes as well as Skarpnes Rør (concrete pipes), and Ribe Betong, Digernes Betong and Betong Sør (all concrete). The company also supplied all the aggregates used on the construction of the new E18 road between Grimstad and Kristiansand through Ølen Betong (concrete).

Samples taken of material from the site suggest it to be one of the best reserves of natural sand and gravel in the south of Norway. The current processing licence is initially for a 20-year period with an option to extend for several more years.

Current production capacity at the site following the addition of the two Evowash sand washing plants is 200,000tonnes per year.

Reddal Sand is a member of PGL (the Norwegian Federation of Crushed Rock and Sand and Gravel Suppliers) and all the concrete aggregates produced meet the relevant Norwegian quality standards in cooperation with the Control Council for Concrete Products.

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