PowerX supply an Advanced Sand Classification Plant for Sandsfield at Brandesburton Quarry
PowerX Equipment Ltd has introduced a specialized sand processing plant at Sandsfield Gravel Company's Brandesburton facility, featuring an innovative system that effectively addresses one of the sand industry's most challenging quality control issues. The installation represents a significant advancement in sand processing, combining efficient organics removal and fine sand reclamation.
Mark Mewburn, the owner of Sandfield states that ”we are family business established in 1964, based in Driffield and are excited to be back processing sand and gravel after a period of diversification. Our aim is to supply the local market with quality products, also utilising in house material to supply our concrete plants in Beverley Hull and York. PowerX, listened to our exact requirements and delivered”
The plant processes up to 80 tons per hour of feed material through a carefully engineered system that prioritizes the quality of the Sand, whilst maintaining the required production rates. At its heart is a 1.6mØ TAK classifier, utilizing sophisticated upward current technology to remove lightweight particles, particularly lignite, from the sand fraction. This advanced classification system ensures the final products meet stringent market requirements.
" Sand is a very precious resource so selecting the correct equipment is crucial, so that modern market specifications can be met, whilst ensuring maximum sand retention in the saleable product," explains John Collins, Technical Director at PowerX Equipment. "Our system ensures consistent quality while maintaining the required production rate of 60 tons per hour for the 0-4mm sand. PowerX have previously supplied sand systems handling in excess of 200tph, with regards to organics removal. This balance of quality and productivity is essential in today's competitive market."
The process begins at the 7.5m³ feed hopper which has a variable speed belt drive ensuring a consistent material flow to the processing plant. The feed conveyor, which is fitted with a belt weigher, sends the material to a robust 4m x 1.5m triple-deck rinsing screen. This initial screening stage splits the aggregate into 10mm, 20mm and +20mm as well as sending the sand to the classifier. All screen decks are fitted with polyurethane media and have magnetic polyurethane protection
The TAK classifier, the cornerstone of the sand plant, employs precisely controlled upward current technology to specifically, if required size the sand and effectively, if required remove any organics. The system's efficiency is enhanced by an automatic discharge valve with automatic discharge control, ensuring optimal separation without manual intervention. The internally rubber-lined construction of the classifier ensures durability while maintaining separation efficiency.
Both of the sand products are dewatered on a single split 2.4m x 1.2m dewatering screen powered by dual vibratory motors. The fine sand being sized once passing through a vibratory sieve bend. This specialized configuration allows separate handling of clean 0-4mm sand with a and fine sand, maximizing the valuable concrete sand product, whilst maintaining the quality standards achieved. The fine sand plant cuts at circa 40µm and has 2 x 325mmØ Hydrocyclones which greatly reduce the amount of silt going to the lagoon system, which is of limited size. The concrete sand is processed by a 500mmØ Hydrocyclone.
The entire operation is monitored and controlled through a sophisticated PLC system with HMI interface, housed in a climate-controlled 20ft container. This automation ensures consistent lignite removal performance while allowing operators to fine-tune parameters for optimal results across varying feed conditions.
The plant produces five distinct products: clean 0-4mm sand, fine sand, 10mm, 20mm, and +20mm aggregates. Product stockpiling is managed via a network of conveyors, including three 12m static channel frame units and a radial driven conveyor, all featuring tungsten-tipped scrapers and external tracking adjustment, reducing maintenance time.
PowerX Equipment's commitment to quality extends beyond the installation phase. The company provides comprehensive operator training focused on maximizing the efficiency of the system and maintaining optimal production rates. This is supported by a nationwide network of 15 service vans and qualified, specialist engineers, ensuring reliable operational support throughout the plant's lifetime.
The installation at Brandesburton Quarry demonstrates how modern technology can effectively address ensure sand quality challenges. PowerX Equipment's BSI-accredited status (ISO 45001, 14001 & 9001) underscores their commitment to quality and operational excellence in aggregate processing solutions.
Contact PowerX Equipment at 02476 405100 for detailed information about any sand processing, washing plants, in particular, C&D Waste, Scalpings, Crushed Rock Fines, Trommel Fines or general Sand & Gravel to arrange a site visit to see the technology in action.