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Design & Development of Sand Washing

Machine

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Birhanu
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Design & Development of Sand Washing Machine

Introduction
The Sand Washer machine is used to wash off impurities like clay, silt, and other unwanted
particles from sand to make it fit for use. This sand washer is specially designed to wash sand
used in construction and make it comply with Indian Standard. The USP of this machine is that it
combines all three steps; screening, conveying, and washing, into one robust, compact machine.
The screening is done with the help of a wire mesh. Sand is conveyed and washed
simultaneously by a paddle screw conveyor. The rotary bucket elevator scoops up the sand from
the tub and on its way to delivery, drains water from sand. In this context, the objective of this
work was to design the transmission system to drive the machine to maintain the output of
washed sand at 6m3/hr. by A particular design was subsequently narrowed down with reference
to certain criteria viz. Relative ease of use, ruggedness, space constraints and availability. While
doing so, we explored manual as well as computer-assisted design. A comprehensive account of
such design-centric efforts and finite element analysis is furnished in the present work. The
design, analysis, manufacturing and testing work is carried at Deccan Construction Equipment
and Machinery, Pune.

Problem Formulation and Objective

According to foundry material standards, the sand used for foundry purpose must meet the
quality stated by IS 1918 (1966): Methods of physical tests for foundry sands. For different
construction of works requires different standards of sands. For brick works requires the finest
module of fine sand should be 1.2 to 1.5 and silt content should not be more than 4 %. For
plastering works requires the finest module of fine sand, it should not be less than 1.5 and silt
content should not be more than 4 %. For Concerting Works requires the coarse sand with the
finest modulus 2.5 to 3.5 and silt contents should not be more than 4%.Silt is granular material of
a size somewhere between sand and clay whose mineral origin is quartz and feldspar. In this
context, the project team at Deccan Construction Equipment and Machinery was asked to
maintain the output of washed sand at 6m3 /hr. In order to satisfy these requirements following
objectives were set:

 Calculating power required to drive the sand washing machine by considering the various
power losses in the system.
 Ensuring a sand delivery at rate of 6m3/hr. by selecting the appropriate prime mover
based on power calculation.
 Designing a single stage worm type reduction gearbox and a roller chain drive.
 To accommodate the power line within an area of 1x1m and design the required
mountings.
 To perform structural analysis of chassis.

Initial Specifications
Feeding Size (mm)

Capacity (t/h)

Impeller Size (mm)

Hydrocyclone (mm)

Screen Panel (mm)

Power (kw)

Overall Size (mm)

Main parts

 Drum

 Screening net

 Shaft

 Motor

 Hopper

 Water Container
 conveyor Screw

 Water drain

 Water inlet

 Deflector plate

 Motor (1Hp)

 Collector

 Sand Strainer (7.5 micron)

Screen

A sand screen is typically categorized based on the size of hole of the weld mesh. This helps in
preventing large stone particles present in sand from getting into the screw conveyor. The screen consists
of a two rectangular frame arranged at right angles to each other. A mesh is formed by arranging 3mm
wire diameter in rectangular array as shown in the Fig.2. The screen designation for this machine is
decided based on gap between the screw blade and tub, which is 20mm. If a particle with larger size
enters the machine it might jam it, hence causing damage to the machine.

Quartz Silica Sand Introduction

Quartz silica sand is a hard, wear-resistant, and chemically stable silicate mineral. Its
main mineral component is SiO2. The color of quartz sand is milky white or colorless
and translucent, with a hardness of 7, which is brittle and has no cleavage. Shaped
fracture, grease luster, density 2.65, bulk density (1-20 mesh is 1.6-1.8), 20-200 mesh is
1.5, its chemical, thermal and mechanical properties have obvious anisotropy, insoluble
in acid, slightly soluble in KOH solution, melting point 1750 °C.
Due to the unique physical and chemical properties of quartz silica sand, it has high-
temperature resistance, low thermal expansion coefficient, high insulation, corrosion
resistance, piezoelectric effect, resonance effect, and unique optical properties. It is
mainly used in glass, ceramics, and refractory materials, metallurgy, construction,
chemicals, mechanical casting, electronic aerospace, rubber and plastics, coatings,
water purification, etc.

Ordinary Volt Method Glass

Flat glass has good perspective and good light transmission performance (3mm and
5mm thick colorless transparent flat glass has a visible light GB11614-2009, flat glass is
based on its The appearance quality is divided into three grades: excellent product,
first-class product, and qualified product.
The requirements of ordinary flat glass for quartz sand are: SiO2 (silicon
dioxide) = 90-98.5%; Fe2O3 (iron trioxide) = 0.05-0.30 %; A12O3 (alumina) = 5.5-1.0%;
particle size: 0.710mm-0.106mm (26-140 mesh).
Photovoltaic Glass Sand
Photovoltaic glass is also ultra-white glass, also known as low iron glass, colorless glass,
high transparency glass, with high light transmittance and high transparency. The light
transmittance of the glass determines the quality of glass. The light rate is 6%, and the
light transmittance of photovoltaic glass can reach more than 92%.
The requirements for quartz sand for photovoltaic glass are generally: S1O2
(silicon dioxide) = 99.5%; Fe2O3 (ferric oxide) =0.0080%; Particle size: 0.710mm-
0.106mm (about 26-140 mesh);

Electronic Glass
Generally refers to ultra-thin float glass with a thickness of 0.1 〜2mm° which is mainly
used for the production of integrated circuits and glass materials with photoelectric,
thermoelectric, acousto-optic, magneto-optical, and other functional components;
substrate glass is currently used in microelectronics, One of the most widely used and
fastest-growing special glass in high technology such as optoelectronics and new
energy. Mainly include substrates for liquid crystal and solar cells.
Electronic glass requirements for quartz sand are: S1O2 (silicon dioxide) 99.6-
99.8%; Fe2O3 (ferric oxide) 0.0020-0.0050%; particle size: 0.60mm-0.065mm( 30-220
mesh), the number of segments required is different according to different grades.

Quartz Silica Sand Process Plant

Material: Quartz Silica Sand Ore
Raw Condition: Raw ore is 4-200 mesh. The iron content of the ore is 200ppm,
SiO2:99.58%.
Capacity: 100TPH
Requirements for Finished Sand Products: particle size 50-200 mesh, SiO2
content: >99.8%, iron content≦lOOppm.
Tail Waste Discharge Standard: all production water is recycled and tail sludge is
reused.

Silica Sand Washing Plant Flowchart

Silica Sand Washing Plant Explanation &
Equipment List
This flowchart design is based on the requirements of the customer. The general
process is as follows.
1. Vibrating screen: Raw materials to the screening to remove the large particles of
materials
2. Scrubbing machine: remove the mud in the raw materials
3. Hindered settling machine: To separate +50 mesh products
4. Trommer screen: In order to check again whether there is coarse material
5. Thickening bucket: dry the water in the products
6. Hydraulic classifier: To separate -200 mesh products
7. Spiral chute: to remove the heavy minerals
8. Thickening bucket: dry the water in the products
9. Dewatering screen: recycle the water in the production
10. Finished products: 50-200 mesh

Silica Sand Mining Equipment

• Circular Vibrating Screen
The basic working principle of the GTYZ high-efficiency vibrating screen is that the
screen machine is started, and two vibrating motors or vibrators of the same model and
specification arranged in a symmetrical arrangement are synchronized and reversed,
and the exciting force generated by the vibrating body passes through the vibration
transmission body. 一 Motor or vibration exciter base is transmitted to the entire
vibrating body 一 the screen box, so that the screen box drives the screen surface to
periodically vibrate so that the material on the screen surface will move with the screen
box in a directional jumping motion, during which it is smaller than the screen surface
The material with the pore size falls to the lower layer through the sieve holes and
becomes under the sieve. The material larger than the sieve surface aperture is
discharged from the discharge port after continuous jumping motion, and the screening
operation is finally completed.

Advantages

1. The screen surface has a variety of forms such as metal woven mesh, rods, punching,
etc. The screen surface has a single-layer structure or a multi-layer arrangement to
meet different screening requirements.
2. The structure is simple and easy to operate, the appearance is beautiful, the rigidity
of the whole machine and the strength of each part are large, the relative energy
consumption is low, and the screening efficiency is high.
3. Relatively small in size, light in weight, and large in processing capacity per unit of
equipment volume and weight, which is convenient for system process layout.
4. The modular design of screen surface structure and type, easy to replace, can meet
the needs of different environments.
5. Convenient installation and debugging, stable and reliable operation, simple
operation, and maintenance.
• Scrubber Machine
The ore pulp enters the scrubbing machine cavity through the feed pipe, and under the
strong stirring action of the impeller, the slurry produces violent turbulence. The mineral
particles have huge momentum in them, and they generate violent friction and collision
with each other. The impurity film wrapped on the surface of the mineral grains is not
strong, so it is easily peeled off the mineral surface after friction and impact. The
cement on the mineral surface will loosen and disintegrate after being soaked in water
and then through strong friction and collision between mineral particles, so as to
achieve the separation of clay and mineral particles. These film impurities and clay are
disintegrated and peeled off into the slurry, and the slurry can be separated after
subsequent desliming. In the actual production process, different agents should be
added according to the actual situation of minerals.
Advantages

1. With high scrubbing strength, unique tank structure, and impeller configuration, the
scrubbing strength is about 30% higher than the traditional scrubbing machine of the
same specification.
2. Wear-resistant and corrosion-resistant, the lining of the tank and the impeller are
made of wear-resistant materials, which have high corrosion and wear resistance.

• Desilting Bucket
The separation of sand and mud by means of specific gravity reduces the turbidity of
the material and improves classification accuracy.
Vulnerable parts: none.

• Hindered Settlement Machine

The main function is to separate the 20-mesh coarse product. The mixture of sand and
water is fed from the upper part through a feeding trough, and moves downwards in the
cylinder under the action of gravity. There is a porous water spray plate at the lower
part of the cylinder, and the rising water flow interacts with the falling solid particles to
gradually form In a fluidized bed, particles of different sizes will fall or move upwards at
the hindered drop speed under the volume concentration. With the help of an electronic
pressure sensor, the pressure status of the sulfide bed can be measured and the
opening of the discharge valve can be automatically adjusted. So as to ensure accurate
classification according to the required separation.
Features

1. The large handling capacity of the blocked settlement machine.

2. The blocked settling machine is professionally designed with a low flow rate, low
wear, and low maintenance rate in the equipment.
3. The hindered settlement machine runs stably and has a longer service life.
4. The sub-mesh count of the blocked settlement machine is more stable, the failure
rate is low, and the waste of production resources caused by equipment damage is
eliminated.
5. The screening mesh number is accurate, and the hindered settler can achieve precise
mesh number classification through adjustment and control.

• Hydraulic Classifier
The main function is to separate the 120 mesh products. The mixture of sand and water
is fed from the upper part through a feeding trough and moves downwards in the
cylinder under the action of gravity. There is a porous water spray plate at the lower
part of the cylinder, and the rising water flow interacts with the falling solid particles to
gradually form In a fluidized bed, particles of different sizes will fall or move upwards at
the hindered drop speed under the volume concentration. With the help of an electronic
pressure sensor, the pressure status of the sulfide bed can be measured and the
opening of the discharge valve can be automatically adjusted. The degree to ensure
accurate classification according to the required separation.
Features

1. Under the action of rising water flow, the materials in the cylinder can achieve the
purpose of particle size classification or specific gravity separation, with high
production efficiency and low energy consumption.
2. Equipped with an automatic control system, which can change the classification
granularity by adjusting the parameters of the automatic control system, which is
easy to operate and control.
3. The water tank at the bottom of the cylinder is equipped with a special device, and
the upper water hole is automatically closed when the water is stopped, which
prevents the material in the cylinder from blocking the hole and entering the water
tank.

• Trommer Screen
Inspect the finished materials from the blocked settler to prevent large particles from
entering the back-end equipment and improve accuracy.
Vulnerable parts: stainless steel screen. The replacement cycle is about 14 days.

• Concentration Bucket
Equipment introduction: Concentrate the finished sand and reduce the slurry
concentration.
Vulnerable parts: none.

• Spiral Chute
The uniform slurry is slowly fed to the surface of the spiral trough through the feed
trough installed at the head end of the spiral trough for sorting. The end of the spiral
groove is inserted into the valve block-type product intercepting groove, and the sorted
products are radially separated according to grade size and size. The position of the
regulating valve block is used to change the intercepting width of each product, and the
product accumulation bucket collects the intercepted multi-head ore streams
separately.

Features

1. The spiral chute has high efficiency, high recovery rate, and accurate ore
separation;
2. Light weight, rust-proo^ wear-resistant, and corrosion-resistant;
3. It occupies a small space, consumes less water, has a simple structure, and does
not require power;
4. Low operating cost and long service life;
5. Strong adaptability to fluctuations in ore supply, concentration, particle size and
grade;
6. The spiral chute is inexpensive, simple to install, easy to operate, small investment,
and quick return.

• Dewatering Screen
Equipment Introduction: Dehydrate the finished materials to reduce the water
content of the materials.
Technical Features

1. Professionally designed frequency, amplitude, and low-consumption power sources

are suitable for 24-hour continuous dry drainage operations for various dehydration
needs. V-shaped screen surface design, -5° screen surface climbing dewatering.
Dry tailings have low water content, high efficiency, and large processing capacity
per unit area.
2. The polymer composite screen has a long service life, modular assembly design,
convenient replacement, and cost-saving, The screen hole size can be selected
according to requirements.
3. The method of riveting and welding the section steel components constitutes a
frame body with no internal stress, high strength, lightweight, and durability.

Vulnerable parts: polyurethane screen. The life span is 6-9 months.

• Thickener
The water used in the whole process is separated from mud and water so that the water
source of the whole system is reused and zero discharge of wastewater is realized.
High-efficiency thickener: and adding chemicals as coagulant and flocculant to
improve the precipitation effect. The load of the thickener is 4〜5t/nf d, the
concentration of the underflow is controlled above 30%, and the underflow is supplied
to the next-stage mud dewatering system or filter press; the solid content of the
effluent of the thickener is controlled at about 100〜150’mg/L, The effluent water
quality meets the requirements of beneficiation production and is all recycled to the
clean water tank for use as the beneficiation production water.