classfier plant for quarry at south africa

classfier plant for quarry at south africa

Danoher Construction, South Africa Invest in 60tph E...

Bloemspruit Quarry is Danohers flagship commercial operation supplying Bloemfontein and the surrounding areas with high quality construction aggregates. The company, which offers among other services crushing and screening solutions, was operating traditional bucket wheel technology at its Bloemspruit site. Once widely adopted in the materials processing industry, at a time when sand resources were abundant and construction materials commanded a high price tag, bucket wheel technology is now being replaced by more advanced and efficient technological solutions. This technology is increasingly under the spotlight for many materials processors who are seeking to address inefficiencies in their operations, says Willem du Plooy, Business Development Manager at CDE.

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The solution, du Plooy says, is cyclone based technology. High and variable moisture content, the loss of quality fines to settling ponds, inaccurate material classification. These are some of the many shortcomings stemming from bucket wheels that are addressed by CDE cyclone technology. Cyclone technology, du Plooy explains, involves the use of centrifugal force to classify materials as opposed to bucket wheels which rely on gravity as the means of separation. Commenting on the then existing plant set up at Danohers Bloemspruit Quarry, du Plooy says the outdated technology had further limitations that were impacting the business and restricting its growth potential. This is a very competitive market, du Plooy explains, The demand for high quality washed sand and aggregates is high. In order to fulfil that increasing demand and grow your business, materials processors need to ensure theyre extracting every valuable grain of sand from their feed material. To achieve that, an e...

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With the support of CDE cyclone technology, Danoher is now producing two grades of sand fine and coarse compared to only the one grade of sand its bucket wheel was capable of producing. Our production is up by 30% and water usage down by 15%, says Van Niekerk. This has opened up a new revenue stream for us and the superior products are attracting new customers, too. He says the quality of the sand produced by the EvoWash is equal to that of natural sand. We recently secured an order for 600 tons a month of washed super sand from one customer whose sand was previously dredged from riverbeds, says Van Niekerk. This is a testament to the quality of the sand being produced by the EvoWash. According to another of Danohers largest customers, its sand product is now the most consistent washed crusher sand in the market in Bloemfontein.

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Ground Breakers South Africa Combo Sand Washing Pl...

To fully achieve the sustainable and profitable vision of the companys owners, an upgrade of the existing bucket wheel system was required to tackle the loss of valuable materials to ponds and excess moisture in the final products. JC Janse van Vuuren and Johan Meintjes explain: Our quarry site in Lanseria faced a lot of challenges; we had water sources and space to put up a proper wash plant. Any silt dams we dug was taking away valuable mining area. The market required a clean washed concrete sand, and our bucket wheel was not delivering a quality product. We also lost a lot of fines to the settling ponds, wasting material that we could not sell without dredging the ponds and re processing it through the bucket wheel. We knew that to grow the business we had to find a more sustainable and efficient washing solution.

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Although bucket wheel technology was widely used in its prime when sand resources were abundant and the price of construction materials was high, it is now being replaced by more advanced technology to address shortcomings such as the difficulty to control the volumes of water required for accurate material classification due to the capacity at the feed point. Indeed, as bucket wheels struggle to process sufficient volumes of water to achieve the desired cut points, fines are not efficiently removed and 100 300 micron fractions are lost to ponds or to the water treatment phase along with the overflow, making the sand product coarser. To mitigate the risk of inaccurate material classification, bucket wheels settings must be adjusted on a regular basis. Diverting excess material to settling ponds requires considerably more space to accommodate the latter, and classification efficiency decreases as the proportion of fines in the feed material grows. The time then required for...

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Following a visit by CDE experts, Ground Breakers feed material was tested at CDEs laboratory. Based on the analysis results, CDE engineers established that the customer could make significant savings by adopting cyclone technology to eliminate the loss of fines to ponds. This would help to retain every valuable grain of sand available in the system and reduce the size of the settling ponds as well as maintenance time. In addition, CDE technology could add a plaster sand product to the companys offer, which has higher commercial value than the river sand currently processed. After considering the sites footprint and the customers requirements, CDE presented the Combo all in one wet processing and water recycling system as the most appropriate solution to the customers requirements. The Combo would allow them to produce two high quality sands simultaneously from the raw feed including plaster sand and river sand, for a much faster return on investment. Incorporated cutting ed...

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Although bucket wheel technology has been undeniably essential to the growth of the construction industry in South Africa, cyclone technology is now replacing it on the market as ultra colour HD has replaced black and white TV as a natural evolution of materials processing brought about by modern innovations from forward thinking research engineers. A leading innovator in cyclone technology, CDE has been designing and delivering over 2,000 projects globally since 1992 to increase the efficiency of materials washing operations. Cyclone technology involves the use of centrifugal force to classify materials rather than gravity. After extensive testing to determine the proportion of silt material to be removed from the raw feed, the specification of a cyclone set up is precisely calculated to ensure that each clients new hydrocyclone based system, such as the Ground Breakers all in one Combo wet processing and water recycling plant, provides unrivalled control over silt cut points...

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Willem du Plooy, Business Development Manager for CDE Southern Africa said: CDE is fast growing its footprint in Africa as sand and aggregates producers are upgrading their installations to enjoy the benefits of wet processing technology in terms of more efficient production and higher product quality. With the respective successes met by the CDE EvoWash sand washing plantand the AquaCycle thickener in South Africa, more operators are now looking for a user friendly solution that incorporates both plants. ead of the curve, CDE expert engineers have created a patented all in one system, the Combo. Pre wired and pre tested before dispatch to allow for rapid set up, the Combo has a capacity range of 50 to 500 tonnes and boasts a unique modular design to combine feeding, grading, washing, water recycling and stockpiling onto one compact chassis. The Combo technology is so efficient that the final products are ready to be sold directly on exiting the system.

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The Ground Breakers bucket wheel was not effectively reducing moisture in the sand products and fines were lost to ponds. To address these limitations, the Combo high frequency dewatering screendewaters the material in one pass, removing the need for re processing and double handling. Once the sand slurry with the silt material is discharged from the hydrocyclones, it is delivered to the screen which is sized according to the customers specific capacity requirements. This allows for the production of a sand product with a moisture content typically ranging from 10% to 15%. As a result, the product is ready for market straight from the belts, in turn converting sand into revenue in the shortest possible time. An added benefit of the Combo system is that although the plant packs a powerful punch, it only requires a very small footprint, which makes it easy to relocate, even in remote areas and urban settings. JC Janse van Vuuren and Johan Meintjes agree: Our CDE Combo is compac...

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