30TPH Silica Sand and Silica Powder Processing Line

Silica sand raw material undergoes processing in washing equipment where mechanical forces and intergranular abrasion remove surface iron coatings, clay-bound minerals, and adhered impurities. This process further disintegrates unliberated mineral aggregates. Subsequent classification through hydraulic separation achieves enhanced silica sand purification. Below is a structured overview of its key stages:

1. Washing Process

The material enters the hopper that feeds a washing cylinder 30 tons per hour. A pulp of approximately one ton of sand is formed for every 1.5m³ of water. Here the material is mixed and passed into a hydrocyclone.

2. Classification Process

In the hydrocyclone, a sieve 200 cut is made and two flows are created. The low flow containing material larger than 75 micrometers goes to the washing screw and then to a multi-level screen. This material, after being separated into two or several products according to the customer’s requirement, goes to a drainage site to leave with a humidity of less than 10% and go to the drying process.

Equipments:

– Hydrocyclone: for cutting 200 Mesh ASTM

– Screw Washer

– Sieves: Three sieves (50/100/150): depending on customer requirements

3. Gravity Thickening

On the other hand, the overflow of the hydrocyclone carries the material smaller than 75 micrometers (200 sieve) to the thickener, to which the flocculant is added to accelerate the sedimentation of the solids. The material that comes out of this thickener is expected to have a composition of 45% dry base and 55% water. This pulp enters the dehydration process in the filter press to leave with a humidity of 15% to go to the drying process.

4. Dewatering & Drying

The drying process aims to reduce humidity to less than 1% in both products – sand (+200) and powder (-200). These materials are stored in separate silos to finish the packaging process. These processes, drying and packaging, must have a bag filter capture system to recover the very fine particles exposed in the air.

Equipments:
– Filter Press (5 tph)
– Dryer Rotary Cylinder – Gas (10 tph): Reduces moisture to <0.5–1%

5. Storage & Packaging

– Pulse Dust Collector

– Bucket Elevator

– Final Product Silo (80 m³)

– Electrical Control Cabinet

– Digital Scale and Packing Area (25 kg, 1000 kg)

6. Final Products

The main objective of the process is to classify the +75 µm (sand size) and -75 µm (impalpable – powder) fractions using a hydrocyclone. The +75 µm fraction will be classified on the multi-level screen according to size ranges in line with market needs.

The powder material will undergo filter-pressing and gas-drying processes for sale. Both products will be packaged in 25 kg and 1000 kg packages.

7. Environmental Indicators

Zero shedding. The process has the objective of zero discharge, recirculation of the water resource used in the process of approximately 80%. Only water that enters the atmosphere by evaporation is replenished as new water for the process.

Zero emissions of particles into the atmosphere. There is no crushing process and the operation will be done wet. It is clarified that the raw material leaves the source (quarry) with a humidity of 3%, which allows the unloading of material from the trucks without producing particles into the atmosphere.