Fine Material Washers are low horsepower (kW) sand dewatering devices that are used for washing, classifying and dewatering sand in construction aggregate wet washing plants. They are available in single or double screw configurations, with selection being determined by sand solids capacity and water volume flow.
Fine Material Washers are equipped with an Eagle gear reducer, conveyor shaft, wear shoes, washer tub and feed box. Optional equipment includes a discharge chute, washer supports, safety covers and pillow-block rear bearings.
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Washing is the primary function of the Fine Material Washer. It is achieved by the continuous rotation of the conveyor shaft and the velocity of the overflowing wastewater. The rotating shaft causes the feed material to roll and tumble, providing particle-on-particle attrition that allows many deleterious coatings to be removed from the sand product and discharged with the wastewater.
The second function of the Fine Material Washer is classification. Classification is achieved by adjusting the volume of water that flows over the back and side weirs of the washer tub. To achieve maximum material retention, the three weirs should be set level to each other to provide a low overflow velocity. A calm pool area is key to efficient classification. This allows the product sized solids to settle out and any fine particles to overflow with the waste.
The third function of the Fine Material Washer is dewatering. Dewatering is accomplished by conveying the product from the washer tub up the inclined dry deck area, which allows a lot of the free water to drain from the material. The use of a close-clearance curved plate on one side of the dry deck area and a drainage trough on the other also aids in the dewatering process.
Fine Material Washers are a tried-and-true method for washing, classifying and dewatering sand. While they have been used in wet processing plants for decades and many aggregate producers are familiar with how they work, here are some operational tips and best practices for helping you get the most out of your Fine Material Washer.
Screw speed can be calculated by dividing 1,500 by the percent passing 50 mesh. For example, if 15% of the material is passing 50 mesh, the screw should be operated at 100% speed for optimum operation. If the sand is slightly finer and contains 20% or 30% passing 50 mesh, the screw should be run slower at 75% and 50% speed, respectively, for optimum operation.
Keep in mind that slower screw speeds result in less capacity and less tons per hour coming off the end of the machine. However, it is important you do not run your screw at higher speeds just to meet capacity, as excessive screw speeds can hurt an operation.
With excessive shaft speed, fine material can build up in the corner of the washer tub. This occurs because the screw is moving too fast for the fine sand to be conveyed toward the discharge. After a few hours of operation at excessive speeds, you will see the resulting tub corner buildup as well as the entire pool area filling with fine sand that eventually overflows product-sized fine sand to waste.
Additional processing steps are required when a sand feed has a high amount of minus 200 mesh or 0.075mm material. Generally, when you have more than 12-15% of minus 200 mesh material, you should consider a two-step process. A two-step process involves two stages of washing and can be accomplished with two screws or by a Hydrocyclone feeding a screw.
Water is imperative for washing aggregate material, and you need to be sure your equipment is supplied with the appropriate amount of water for optimal operation. As a rule of thumb, Fine Material Washers require 50 gallons of water per minute to remove 1 ton per hour of silt.
Rising current allows for fine-tuning via water injection beneath the pool areas. The addition of clean water improves the classification process. Introducing an upward rising current of water helps to keep the ultra-fines in suspension while the product-sized particles can settle out to be conveyed out of the tub area as product.
Level the weirs on your Fine Material Washer for optimum performance. If you want to get rid of a small amount of excess fines, you can raise the side weirs and lower the back weir. This allows more velocity to overflow the back of the washer to remove excess minus 200 mesh fines.
Adding water to the dry deck area of your Fine Material Washer can result in drier sand discharging onto the conveyor and into the product pile. How? The water flushes out any fine sand that has accumulated to allow a clear channel for the water to drain from the sand as it is conveyed up the screw.
Too much turbulence in the feed area of the washer tub can cause the loss of excess minus 200 mesh fines and potentially some plus 200 mesh fines as well. A feed chute or flume with a velocity break box allows for some turbulence, but not too much.
It is important to have a calm pool area to ensure maximum fines retention so that your sand is making it to the product pile rather than overflowing with the wastewater destined for the settling pond.
Performing routine maintenance and following a regular inspection schedule are important ways to maintain the operating efficiency of your Fine Material Washer. Proper lubrication of bearings is key to ensure optimal performance and unexpected downtime.
When you have sand equivalency issues, such as too much clay with your feed, and/or too much moisture in your final product, your operation may require additional equipment and processing to remove the undesirable material and/or water.
Some sand deposits will have a slight amount of unsound grains. These unsound grains will break down after several days of exposure to water and air. Even a slight amount of unsound sand becomes dust/excess and can throw your sand out of spec.
Removing this unsound material is often needed to keep your sand product in spec. This can be accomplished with scrubbing equipment, such as a Blade Mill or Attrition Scrubber. Attrition Scrubbers offer more vigorous scrubbing than Blade Mills.
In a typical concrete sand application, Fine Material Washers discharge a product that has 20% moisture content. You can add a skid-mounted Dewatering Screen under the end of your screw to make a drier sand. Generally, using a Dewatering Screen after a sand screw reduces the moisture content by half, resulting in a drip-free product.
CONDOR Fine Material Washers can also be used instead of Classic Fine Material Washers. The two pieces of equipment are similar in size, but a CONDOR machine has a Dodge gear box instead of the classic gear reducer as a more economical and readily available option.
EIW, LLC has been providing aggregate beneficiation equipment of exceptional quality for over 150 years. EIW begins by engineering equipment for the defined needs of each customer. We provide support from point of sale throughout the life of the machine, including readily available replacement parts.
I am having an issue where the Time material node returns the incorrect time if the material is set up for use in the UI. All other uses of the Time material node return the game time in seconds but if you set the material to the user interface domain it returns the editor time in seconds. This means I am unable to do basic triggered time based changes within a UI material. (like fading out now)
Unfortunately that does not work. The GetRealTimeSeconds blueprint node returns the same value that a Time material node does UNLESS the material is set to the user interface material domain. There is no way I can see to get the same time that the Time material node does in this setup from blueprints thus making it impossible to sync them up.
Even if there is a way to do an internal storage of editor time triggered externally on spawn, that is just saying that for all uses of materials and time except one do this simple thing and in this one do something much more complex for no apparent gain.
I was able to reproduce this issue on our end. I have written up a report and I have submitted it to the developers for further consideration. I have provided a link to the public tracker. Please feel free to use the link provided for future updates.
Chain disc conveyors are mechanically driven conveyors that drag materials along the inside of a tube. The system consists of a chain with close-running discs spaced along its length, forming an endless loop that is pulled by a motor-driven sprocket within an enclosed tube. The system is designed to transfer flowable bulk materials from in-feed points to discharge points through an enclosed conduit.
While chain disc conveyors are a popular choice in many industries, they have some limitations when it comes to maintenance and material handling. As chains experience friction at points of direct contact, wear and tear can take place at those points along the entire length of the chain. To prevent excessive wear and keep the system properly aligned, the chain-drive components must be frequently adjusted. In order to maintain the appropriate chain tension, a tension turnaround unit is employed.
Cablevey disc conveyors operate similarly to chain disc conveyors but use a coated, flexible stainless steel drag cable instead of a chain. The cable is fitted with solid circular discs that push the food through the tube. This system has the capability to convey up to 80,000 pounds of product per hour at low speed and significantly reduce product degradation.
Material breakage is an incredibly important factor in food processing applications, especially where product integrity and quality are crucial. By reducing material breakage and damage, Cablevey Conveyors can help maintain the quality and appearance of the product. This will increase customer satisfaction and reduce waste.
Chain disc conveyors utilize a chain with discs that move materials inside a tube, requiring regular maintenance due to wear and tear from friction. Cable disc conveyors, on the other hand, use a flexible stainless steel cable fitted with discs, offering reduced maintenance, system downtime, and material breakage. They are energy-efficient, fully enclosed, and adaptable to variable speeds, ensuring product quality and operational efficiency. 152ee80cbc
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