Process Overview
Foundry & Construction Grade Sand Washing & Classification
This flow chart illustrates the complete beneficiation cycle of raw silica sand into high-purity Foundry & Construction Grade Silica—suitable for foundry applications and construction works. Our plants are designed to produce consistent, specification-compliant sand that improves Mold performance and mix quality—while minimizing rejection rates and waste.
Each stage in the process is engineered to maximize impurity removal and maintain controlled particle sizing:
● Raw Material Intake & Initial Screening Removal of oversized particles, stones, and organic debris to streamline further processing.
● Scrubbing & Washing Eliminates clay, silt, and other surface impurities. Supports cleaner separation and improved sand performance.
● Wet Classification Segregates usable fractions by grain size—critical for shaping mold flow and concrete workability.
● Attrition Scrubbing Surface polishing and liberation of fine contaminants to improve grain shape and roundness.
● Hydro cyclone / Spiral Classification Enhances separation accuracy and removes ultra-fines—fine-tuning sand specifications for industrial use. (This equipment we Out sourced from experts and collaborate it with our Plant layout).
● De-Watering & Drying (Optional) Moisture control for ease of storage, transport, and immediate application in foundry or batching plants.
● Final Screening & Quality Control Ensures finished product aligns with target mesh sizes and physical property benchmarks.
● Packaging / Storage / Dispatch Sand is securely stored, packed, and delivered per operational timelines.
The result: Consistent silica output as per customer’s requirements with respect to the supplied Raw Material.
End-to-End Solutions for High-Purity Glass
Grade Silica Washing & Classification
Shiv Shakti Engineering Company delivers end-to-end turnkey plants for processing Foundry and Construction Grade Sand, engineered to meet the demanding specifications of metal casting, concrete production, and infrastructure development. These systems combine material handling, scrubbing, washing, classification, dewatering, drying, final screening and packaging systems— engineered to meet customer’s requirements.
● Function: Produce clean, size-controlled, low-impurity sand for foundry Molds and concrete aggregates.
● Scope: Feed handling, attrition scrubbing, hydro-classification, dewatering, drying, and storage.
● Features: Modular design, PLC/SCADA automation, wear-resistant construction.
● Benefits: Consistent grain shape, reduced binder demand, improved concrete workability, sustainable reuse.
| 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: Improved product pricing potential, reduced defect rates, and best in yield consistency across production cycles.
* All Given Performance Metrics might be varied with respect to feed quality of raw material.
