SBM Mining requests quotation for crushing and grinding plant at Sangdong

In the late-1990’s it started to wash crushed fines produced in the quarry, transforming them into concrete sand by using vibratory screens, screw washers, hydrocyclones and dewatering screens.

Manufactured sand was already accepted in the market, especially by concrete producers. The main favourable characteristic of the manufactured sand is the consistency in its quality, both in gradation and lack of contaminants.

The manufactured sand also meets the concrete producers requirements in guaranteeing an alternative source of this important material, in both the medium and long term. In view of the increased restrictions in natural sand production this factor is considered of extreme importance.

With the success of this operation TCL decided to invest in a plant dedicated to the production of manufactured sand, not only to satisfy the increasing demand, but also to provide a superior quality product, particularly in particle cubicity that was still not satisfied simply by washing the fine aggregate.

Another reason that TCL invested in this plant for manufactured sand was the stagnation of the traditional aggregate market. Excellent growth potential for the business was forecast for the manufactured sand market coupled with the increasing value of the product. antimony crusher

In their search for a technology to produce high quality manufactured sand TCL found in SBM Minerals not only an excellent equipment supplier, but also a company that displayed superior technology in manufactured sand production, offering the total exploitation of rock by avoiding the generation of waste products.

Initial Installation

During the second half of 2002, TCL commissioned their first manufactured sand circuit with a cone crusher and two SBM B6100′s (150HP each) producing sand passing the 4.5mm mesh, with a combined hourly capacity of 120 tons.

For quality sand production, TCL adopted a combination of two technologies, that of cone and autogenous VSI crushers ( vertical shaft impact crusher ). SBM is a leader in both technologies. These machines complement each other to produce manufactured sand of excellent quality.

The combination of the two technologies is superior to traditional plants using only cone or VSI crushers, particularly in the feed conditions found in the TCL quarry. For screening, normally a critical process in sand production, two screens were placed in series with a sieve area of 5m x 2m each.

The feed of this plant consists of 5 products generated in the crushing of conventional aggregates with top size of 32mm and majority of the feed (about 50%) consisting of fraction 11-22mm.

A portion of the feed consists of the 7mm – 4.5mm fraction originating from the washing plant, increasing the level of moisture in the feed. The feed varies in accordance with the market demand for coarse aggregates.

The great advantage of the concept adopted in the sand plant is its acceptance of the coarse aggregate surplus, which prevents excessive supplies of products that have little demand in the market.

The use of the cone for first reduction, to below 11mm, makes it possible to better use the high reduction characteristic of this type of crusher. The two SBMs are used in the final reduction phase, generating particles with ideal gradation and particle shape for concrete production.

With this combination a plant with high production, low circulating load, tolerance to load variation in the feed grading, high tolerance to moisture, excellent shape and control over the generation of micro fines was obtained.

Plant Extension

As a result of an increasing demand for premium quality manufactured sand, TCL decided to extend their capacity and to diversify their product.

They invested in another crushing circuit, consisting of two further SBM B7100 VSI crushers (250HP each), for producing mortar sand with a top size of 2.4mm. This line, with an hourly production rate of 70 tons, has been operating since early 2003.

TCL still keeps a washing plant in operation to cater for their traditional customers. However, about 25% of the manufactured sand for concrete is currently sold unwashed, with high levels of micro fines, a percentage that is still growing.

The concepts revealed by the ICAR 102 Project* (for concrete production with manufactured sand containing high levels of micro fines) are being confirmed as desirable in the construction industry.

Manufactured sand with high levels of micro fines improves some important concrete properties such as compressive strength, workability, shrinkage, permeability and resistance to abrasion. In many cases it can allow a reduction in cement content.

Evidence of the importance of micro fines is the fact that some customers who consume washed manufactured sand add about 10% of filler to the concrete mix. This is exactly the percentage of micro fines removed in the washing process.

Beyond normal aggregates, TCL sees their future as being in the production of manufactured sand because of its qualities and the increased restrictions on natural sand production. The company, through its two dry sand production lines, is the biggest manufactured sand producer in Brazil.

VSI crushers manufactured sand plant of producing high quality in Brazil
VSI crushers manufactured sand

In the late-1990’s it started to wash crushed fines produced in the quarry, transforming them into concrete sand by using vibratory screens, screw washers, hydrocyclones and dewatering screens.

Manufactured sand was already accepted in the market, especially by concrete producers. The main favourable characteristic of the manufactured sand is the consistency in its quality, both in gradation and lack of contaminants.

The manufactured sand also meets the concrete producers requirements in guaranteeing an alternative source of this important material, in both the medium and long term. In view of the increased restrictions in natural sand production this factor is considered of extreme importance.

With the success of this operation TCL decided to invest in a plant dedicated to the production of manufactured sand, not only to satisfy the increasing demand, but also to provide a superior quality product, particularly in particle cubicity that was still not satisfied simply by washing the fine aggregate.

Another reason that TCL invested in this plant for manufactured sand was the stagnation of the traditional aggregate market. Excellent growth potential for the business was forecast for the manufactured sand market coupled with the increasing value of the product.

In their search for a technology to produce high quality manufactured sand TCL found in SBM Minerals not only an excellent equipment supplier, but also a company that displayed superior technology in manufactured sand production, offering the total exploitation of rock by avoiding the generation of waste products.

Initial Installation

During the second half of 2002, TCL commissioned their first manufactured sand circuit with a cone crusher and two SBM B6100′s (150HP each) producing sand passing the 4.5mm mesh, with a combined hourly capacity of 120 tons.

For quality sand production, TCL adopted a combination of two technologies, that of cone and autogenous VSI crushers ( vertical shaft impact crusher ). SBM is a leader in both technologies. These machines complement each other to produce manufactured sand of excellent quality.

The combination of the two technologies is superior to traditional plants using only cone or VSI crushers, particularly in the feed conditions found in the TCL quarry. For screening, normally a critical process in sand production, two screens were placed in series with a sieve area of 5m x 2m each.

The feed of this plant consists of 5 products generated in the crushing of conventional aggregates with top size of 32mm and majority of the feed (about 50%) consisting of fraction 11-22mm.

A portion of the feed consists of the 7mm – 4.5mm fraction originating from the washing plant, increasing the level of moisture in the feed. The feed varies in accordance with the market demand for coarse aggregates.

The great advantage of the concept adopted in the sand plant is its acceptance of the coarse aggregate surplus, which prevents excessive supplies of products that have little demand in the market.

The use of the cone for first reduction, to below 11mm, makes it possible to better use the high reduction characteristic of this type of crusher. The two SBMs are used in the final reduction phase, generating particles with ideal gradation and particle shape for concrete production.

With this combination a plant with high production, low circulating load, tolerance to load variation in the feed grading, high tolerance to moisture, excellent shape and control over the generation of micro fines was obtained.

Plant Extension

As a result of an increasing demand for premium quality manufactured sand, TCL decided to extend their capacity and to diversify their product.

They invested in another crushing circuit, consisting of two further SBM B7100 VSI crushers (250HP each), for producing mortar sand with a top size of 2.4mm. This line, with an hourly production rate of 70 tons, has been operating since early 2003.

TCL still keeps a washing plant in operation to cater for their traditional customers. However, about 25% of the manufactured sand for concrete is currently sold unwashed, with high levels of micro fines, a percentage that is still growing.

The concepts revealed by the ICAR 102 Project* (for concrete production with manufactured sand containing high levels of micro fines) are being confirmed as desirable in the construction industry.

Manufactured sand with high levels of micro fines improves some important concrete properties such as compressive strength, workability, shrinkage, permeability and resistance to abrasion. In many cases it can allow a reduction in cement content.

Evidence of the importance of micro fines is the fact that some customers who consume washed manufactured sand add about 10% of filler to the concrete mix. This is exactly the percentage of micro fines removed in the washing process.

Beyond normal aggregates, TCL sees their future as being in the production of manufactured sand because of its qualities and the increased restrictions on natural sand production. The company, through its two dry sand production lines, is the biggest manufactured sand producer in Brazil.

VSI crushers manufactured sand plant of producing high quality in Brazil
VSI crushers manufactured sand

In the late-1990’s it started to wash crushed fines produced in the quarry, transforming them into concrete sand by using vibratory screens, screw washers, hydrocyclones and dewatering screens.

Manufactured sand was already accepted in the market, especially by concrete producers. The main favourable characteristic of the manufactured sand is the consistency in its quality, both in gradation and lack of contaminants.

The manufactured sand also meets the concrete producers requirements in guaranteeing an alternative source of this important material, in both the medium and long term. In view of the increased restrictions in natural sand production this factor is considered of extreme importance.

With the success of this operation TCL decided to invest in a plant dedicated to the production of manufactured sand, not only to satisfy the increasing demand, but also to provide a superior quality product, particularly in particle cubicity that was still not satisfied simply by washing the fine aggregate.

Another reason that TCL invested in this plant for manufactured sand was the stagnation of the traditional aggregate market. Excellent growth potential for the business was forecast for the manufactured sand market coupled with the increasing value of the product.

In their search for a technology to produce high quality manufactured sand TCL found in SBM Minerals not only an excellent equipment supplier, but also a company that displayed superior technology in manufactured sand production, offering the total exploitation of rock by avoiding the generation of waste products.

Initial Installation

During the second half of 2002, TCL commissioned their first manufactured sand circuit with a cone crusher and two SBM B6100′s (150HP each) producing sand passing the 4.5mm mesh, with a combined hourly capacity of 120 tons. barite crusher

For quality sand production, TCL adopted a combination of two technologies, that of cone and autogenous VSI crushers ( vertical shaft impact crusher ). SBM is a leader in both technologies. These machines complement each other to produce manufactured sand of excellent quality.

The combination of the two technologies is superior to traditional plants using only cone or VSI crushers, particularly in the feed conditions found in the TCL quarry. For screening, normally a critical process in sand production, two screens were placed in series with a sieve area of 5m x 2m each.

The feed of this plant consists of 5 products generated in the crushing of conventional aggregates with top size of 32mm and majority of the feed (about 50%) consisting of fraction 11-22mm.

A portion of the feed consists of the 7mm – 4.5mm fraction originating from the washing plant, increasing the level of moisture in the feed. The feed varies in accordance with the market demand for coarse aggregates.

The great advantage of the concept adopted in the sand plant is its acceptance of the coarse aggregate surplus, which prevents excessive supplies of products that have little demand in the market.

The use of the cone for first reduction, to below 11mm, makes it possible to better use the high reduction characteristic of this type of crusher. The two SBMs are used in the final reduction phase, generating particles with ideal gradation and particle shape for concrete production.

With this combination a plant with high production, low circulating load, tolerance to load variation in the feed grading, high tolerance to moisture, excellent shape and control over the generation of micro fines was obtained.

Plant Extension

As a result of an increasing demand for premium quality manufactured sand, TCL decided to extend their capacity and to diversify their product.

They invested in another crushing circuit, consisting of two further SBM B7100 VSI crushers (250HP each), for producing mortar sand with a top size of 2.4mm. This line, with an hourly production rate of 70 tons, has been operating since early 2003.

TCL still keeps a washing plant in operation to cater for their traditional customers. However, about 25% of the manufactured sand for concrete is currently sold unwashed, with high levels of micro fines, a percentage that is still growing.

The concepts revealed by the ICAR 102 Project* (for concrete production with manufactured sand containing high levels of micro fines) are being confirmed as desirable in the construction industry.

Manufactured sand with high levels of micro fines improves some important concrete properties such as compressive strength, workability, shrinkage, permeability and resistance to abrasion. In many cases it can allow a reduction in cement content. phosphorite ball mill

Evidence of the importance of micro fines is the fact that some customers who consume washed manufactured sand add about 10% of filler to the concrete mix. This is exactly the percentage of micro fines removed in the washing process.

Beyond normal aggregates, TCL sees their future as being in the production of manufactured sand because of its qualities and the increased restrictions on natural sand production. The company, through its two dry sand production lines, is the biggest manufactured sand producer in Brazil.