Process Overview
Customized Silica/Sand Washing & Classification
we specialize in delivering fully customized turnkey solutions for Silica/Sand Washing & Classification —engineered to meet specific purity targets, plant capacities, and operational layouts with respect to feed raw material.
Each stage in the process is engineered to maximize impurity removal and maintain controlled particle sizing:
● Process Design & Flow Engineering Tailored flow diagrams based on raw silica characteristics, desired mesh size, and purity benchmarks.
● Integrated Equipment Supply Custom-built feeders, scrubbers, classifiers, magnetic separators, dryers, and screening units—optimized for desired throughput/capacities, impurity removal, and energy efficiency.
● Automation & Control Systems PLC/SCADA integration for real-time monitoring, process stability, and minimal manual intervention.
● Site-Specific Layout & Installation Plant design adapted to available space, terrain, and utility access—with full commissioning and operator training (optional).
● Post-Commissioning Support Includes spare parts, process audits, and upgrade pathways to scale with future demand.
End-to-End Solutions for High-Purity Glass
Grade Silica Washing & Classification
● Feeders Hopper, belt, screw, and vibratory feeders sized for your material flow rate and moisture content.
● Screening Units Rotary, vibrating, and dewatering screens customized for mesh size, throughput, and wet/dry operation.
● Scrubbing Systems Attrition scrubbers and log washers configured to remove clay, silt, and embedded impurities—optimized for your raw sand profile.
● Classification Equipment Spiral classifiers, hydro cyclones (This equipment we Out sourced from experts and collaborate it with our Plant layout), and wet sieving systems tuned to your desired mesh size distribution.
● Magnetic Separators Low and high-intensity units for Fe₂O₃ removal—calibrated to meet purity targets like ≤ 0.02%.
● Drying Systems Rotary dryers and fluid bed dryers designed for energy efficiency and moisture control (≤ 5% or nil).
● Material Handling & Conveyance Custom conveyors, elevators, and storage systems integrated with plant layout and automation needs.
● Automation & Control Panels
PLC systems for real-time monitoring, process optimization, and minimal manual intervention.
| Stage | Function | Performance Metrics* |
| Initial Screening | Size reduction of raw lumps (quartzite, sandstone, reclaimed sand) | Output size: 0–10 mm; Throughput: 20–100 TPH |
| Attrition Scrubbing & Washing | Removes surface clay, coatings, and organic matter | Clay removal efficiency: ≥85%; Turbidity <50 NTU |
| Hydro cyclone & Classifier/Wet Sieving | Separates fines and controls particle size distribution | D₅₀ cut size: 150–600 µm; Recovery rate: ≥90% |
| Dewatering Screens | Reduces moisture for downstream drying | Final moisture: <12%; Capacity: 15–80 TPH |
| Magnetic Separation | Removes iron & magnetic contaminants | Fe₂O₃ content reduced to ≤ 0.02% |
| Rotary/Fluid Bed Dryer (Optional) | Lowers moisture to storage-ready levels | Final moisture: <0.5%; Energy use: 0.8–1.2 kWh/kg |
| Final Screening, QC & Silo Storage | Segregates sand by size; stores for dispatch | Size fractions: 0.15–2 mm; Silo capacity: 50–200 m³ |
| Bagging & Dispatch | Packs sand in bulk bags or 50 kg sacks | Accuracy: ±0.5%; Bagging rate: 200–600 bags/hr |
📈 Outcome: Higher Silica/Sand purity, reduced rejection rates, optimized energy use, and seamless integration with your plant’s footprint and production goals.
