Equipment & Machines For Silica Sand Washing Processing Plant|quartz washing processing plant

A silica sand washing plant is a facility designed to wash, clean, and separate silica sand particles, often used in various industrial applications such as glass manufacturing, casting, hydraulic fracturing (fracking), and water filtration. Silica sand, also known as quartz sand, is composed of silicon dioxide (SiO2) and is one of the most abundant and widely used materials in the world.

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A silica sand washing processing plant typically involves several steps to purify and refine the silica sand for various applications such as glass making, foundry casting, ceramics, and construction materials. Here's an overview of the typical process:

1. Silica Sand Extraction: The process begins with the extraction of raw silica sand from quarries or mines. This sand may contain impurities like clay, iron oxides, and other minerals.

2. Screening and Classification: The extracted silica sand is screened to remove oversized particles and then classified based on particle size. This step ensures uniformity in the size distribution of the sand.

3. Attrition Scrubbing: In this step, the silica sand is subjected to attrition scrubbing, where it is vigorously agitated in water with the help of attrition cells or rotating paddles. This helps to remove surface contaminants and coatings from the sand grains.

4. Desliming: Desliming is the process of removing fine particles, such as clay and silt, from the silica sand slurry. This is typically achieved by passing the slurry through hydrocyclones or classifiers, which separate the finer particles from the coarser sand.

5. Dewatering: After desliming, the silica sand slurry may undergo dewatering to remove excess water. This is usually accomplished using dewatering screens, centrifuges, or filter presses, which help to reduce the moisture content of the sand to the desired level.

6. Dry Screening and Sizing: Once dewatered, the silica sand is often subjected to dry screening to further remove any remaining impurities and to achieve the desired particle size distribution. This step ensures that the final product meets the required specifications for various applications.

7. Final Processing and Product Storage: After the sand has been purified and sized, it may undergo additional processing steps depending on its intended use. For example, it may be dried in rotary dryers to further reduce moisture content, or it may be coated with specialty chemicals for specific applications. The processed silica sand is then stored in silos or stockpiles until it is shipped to customers.

Throughout the entire process, careful monitoring and quality control measures are implemented to ensure that the final product meets the required specifications for purity, particle size, and other properties. Additionally, environmental considerations are taken into account to minimize the impact of the processing plant on the surrounding ecosystem

Here is an introduction to the components and processes typically found in a silica sand washing plant:

1. Feed Hopper: Raw silica sand is typically delivered to the plant in bulk or by conveyor. It is first stored in a feed hopper, where it can be regulated before entering the washing process. for some projects it may need to use stone crusher and sand making machine for silica sand making.

2. Screening and Classification: The first step in the washing process is to remove any oversized or undersized particles from the raw sand. This is typically done through a series of screens or classifiers that separate the silica sand into different size fractions.

3. Washing and Scrubbing: The pre-sized silica sand is then subjected to washing and scrubbing to remove impurities such as clay, silt, and organic matter. This process can be accomplished using various equipment, including attrition scrubbers, log washers, or sand screws. Water is often added to aid in the removal of impurities.

4. Hydrocyclones: After washing and scrubbing, the sand is usually directed through hydrocyclones to further separate and classify the sand particles based on their size and density. This helps to achieve a more uniform and clean product.

5. Dewatering: Excess water is removed from the sand slurry using dewatering screens or centrifuges. Dewatering is an essential step to reduce the moisture content of the final product.

6. Stockpiling or Silo Storage: The clean, dewatered silica sand is typically stockpiled or stored in silos for further processing or transport to customers. It is important to prevent recontamination during storage.

7. Water Recycling: Many modern silica sand washing plants incorporate water recycling systems to minimize water usage and reduce environmental impact. This involves treating and recycling the water used in the washing process, making the plant more sustainable.

8. Control Systems: Silica sand washing plants are often equipped with sophisticated control systems to monitor and regulate the various processes, ensuring efficient operation and consistent product quality.

9. Environmental Compliance: Due to environmental regulations and concerns, silica sand washing plants must adhere to relevant environmental standards, including wastewater treatment and dust control measures.

Silica sand washing plants play a crucial role in producing high-quality silica sand that meets the requirements of different industries. They are essential for improving the purity and quality of silica sand, making it suitable for a wide range of applications.

This setup is for the silica sand process, the size range of the silica sand is 0-10mm, the main machines are as below.

Hopper + electromagnetic feeder > belt conveyor > rotary trommel screen > +0.5mm to ball mill, 0-0.5mm to spiral sand wash machine > spiral chute > slurry pump > wet plate magnetic separator > dewatering screen

Process Explanation The hopper+electromagnetic feeder for feeding materials to the rotary trommel screen automatically, you only need to load the materials to the hopper by truck or excavator or else as you want.

The rotary trommel screen is for washing the silica sand and separating the size 0-0.5mm to the spiral sand wash machine, and +0.5mm to the ball mill.

The ball mill is for grinding the +0.5mm size to 0-0.5mm, then to the spiral sand wash machine.

The spiral sand wash machine is for washing and getting rid of the sticky clay in the silica sand, then to the spiral chute.

The slurry pump transports the clean materials to the spiral chute to separate the silica sand from other heavy materials.

The wet plate magnetic separator is for separating the magnetic minerals in the silica sand, making the silica sand purer.

The dewatering screen is for drying the silica sand and recycling the water for the machines.

The capacity for this washing plant can be customized as per request such as 10tph, 50tph,100tph, etc

Notes: If the materials are not much sticky, will not need the spiral sand wash machine, and the quantity of the machines just for your reference, will depend on your capacity.

The spiral chute will normally make two stages, the middle concentrate from the first stage spiral chute will to the second stage to concentrate again, which will make sure a higher grade and also release the workload of the magnetic separator.

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Silica sand?

Common specifications of quartz sand are: 0.5-1mm, 1-2mm, 2-4mm, 4-8mm, 8-16mm, 16-32mm, 10-20 mesh, 20-40 mesh, 40-80 mesh, 80-120 mesh, 100-200 mesh, 200 mesh, 325 mesh. After years of development, at present, quartz sand is often divided into: ordinary quartz sand, refined quartz sand, high-purity quartz sand, fused silica sand and silicon powder.

?Ordinary quartz sand

Generally, it is a water treatment filter material made of natural quartz ore, which is crushed, washed, dried and screened twice; SiO2≥90—99%, Fe2O3≤0.06—0.02%, the filter material has: , High density, high mechanical strength, and long service life of the dirt-carrying capacity line, it is a material for chemical water treatment. It can be used in metallurgy, ink silicon carbide, glass and glass products, enamel, cast steel, caustic soda, chemical industry, spray noise and other industries.

? Refined quartz sand

SiO2≥99—99.5%, Fe2O3≤0.005%, using high-quality natural quartz sand, carefully selected and finely processed. The main use is in the manufacture of glass, refractory materials, smelting ferrosilicon, metallurgical fluxes, ceramics, abrasive materials, casting quartz sand, etc., and in the construction of using its strong anti-acid medium corrosion ability to prepare acid-resistant concrete and Acid-resistant mortar. Refined quartz sand is sometimes called acid-washed quartz sand in the industry.

?High-purity quartz sand

High-purity quartz sand is made of high-grade quartz stone through a series of processes. At present, the industry has not established a unified industry standard for high-purity quartz sand, and its definition is not very clear. Quartz sand with Al2O3 content below 0.01%. High-purity quartz sand is widely used in electric light sources, optical fiber communications, solar cells, semiconductor integrated circuits, precision optical instruments, medical utensils, aerospace and other high-tech industries.

?Silica powder

Silicon micropowder is a kind of non-toxic, odorless and non-polluting silica powder which is processed by grinding, precision classification, impurity removal and high temperature spheroidization using crystalline quartz and fused quartz as raw materials. Inorganic non-metallic materials with excellent properties such as heat, high insulation, low linear expansion coefficient and good thermal conductivity.

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