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TWS introduce the AggreSand system

AggreSand system

Terex Washing Systems announce the latest addition to their extensive product portfolio

TEREX Washing Systems (TWS) are making final plans to unveil an innovative new washing system. The AggreSand system – the latest edition to the company’s already extensive product portfolio – is due to be officially launched during the second quarter of 2013.

The AggreSand system combines aggregate washing and screening with sand processing on a modular chassis, bringing together tried and trusted TWS components in an innovative modular design.

A gap in the market for such a system was identified following extensive research, part of which was conducted at TWS’s first-ever product development forums. This involved TWS engineers and sales technicians working with the global distributor network to formulate the concept.

Central to the development of the new plant was a modular design, pre-wired and pre-plumbed making it quick and easy to set-up and easy to maintain. The plant also includes a range of other innovative features and designs.

Sean Loughran, director of TWS, commented: ‘The AggreSand system will represent the epitome of washing in the marketplace and is a combination of significant enhancements and design changes to existing products as well as the introduction of new pioneering ideas.

‘In our ongoing efforts to meet and exceed customer expectations, the AggreSand system will enable TWS customers to wash a wide range of materials at a high specification and produce up to five products.’

Key features and benefits of the AggreSand system include:

H 12 Hopper – New TWS-designed 12 cubic metre capacity modular hopper feeder available with an automatic tipping grid and a 12ft two-deck vibrating grid complete with variable-speed belt feeder, all controlled from the main operator interface and radio-control unit.

Feed conveyor – Wide inclined feed conveyor with direct-drive electric motor and gearbox arrangement works at a 19° angle when feeding the AggreSand system. The conveyor features an innovative sealed wash box at the discharge point to give material a pre-rinse before screening. Its innovative design eliminates splashing and produces an even distribution of material across the full width of the rinsing screen.

165R-3 rinsing screen – Highly efficient 165R-3 (three-deck, two-bearing) rinsing screen of riveted construction. Screen designed to isolate spray bars from vibration by utilizing high-quality rubber gators on the mid and bottom decks, while rubber extensions prevent overspill or splashing from the top-deck screen. The 165R-3 offers a full 80 square foot (7.54 square metres) of screening area on all three decks, each of which has eight individually controlled spray bars fitted with polyurethane fan-type spray nozzles. An advanced rolling chute arrangement provides the ability to blend top- and mid-deck overflows as well as mid- and  bottom-deck overflows. Screen designed to receive standard polyurethane modular screens on all decks (woven-wire option also available).

Sump tank – Large-capacity split sump tank receives rinsed fines from the bottom-deck screen into either a coarse or fine compartment. The coarse side has a built-in float system to help equalize the levels in both tanks and prevent overflowing. Large inspection doors included in both tanks as well as butterfly valve drains on both sides. The tank is also fitted with anti-turbulence plates and a pump-protection system.

Centrifugal slurry pumps and hydrocylones – Two centrifugal slurry pumps (coarse and fine) pump material from both sides of the sump tank into two hydrocyclones. These remove silts and clays (–63 microns) which are sent to the water-treatment plant. Heavier material (+63micron) exits the bottom of the hydrocyclones into a rubber-lined box where blending can take place if required.

125 dewatering screen – Underflow from the hydrocyclones transfers on to a dewatering screen via a discharge box which evenly distributes the material across the screen. Both materials are dewatered over a 500 micron polyurethane screen to produce two instantly saleable grades of sand. The high-energy dewatering screen is fitted with two high-efficiency counter-rotating vibratory motors that remove capillary water to produce two dewatered sands. A rubber-lined catch box under the dewatering screen carries the underflow back to the tank for recirculation through the cyclones.

Integrated conveyors – The AggreSand system has the option of five 9.3m long x 650mm wide conveyors (three for aggregate and two for sand) powered by direct-drive electric motors and gearbox arrangements and angled to give up to 4m stockpile height. Two conveyors have an innovative automated radial wheel drive system that increases stockpiling capacity to 350 cubic metres. The conveyors are fitted with high-quality teardrop polyurethane scrapers. The aggregate oversize conveyor can be placed on either side of the machine in accordance with the customer’s site set-up/preference.

Accessible service areas – 600mm wide access platforms are fitted on both sides of the machine, allowing easy access to the rinsing and dewatering screens. All walkways and handrails are galvanized as standard with curved ends and expanded metal floors. The centrifugal slurry pumps are mounted on roll-in/roll-out tables, while the main feed conveyor section, which travels over the aggregate screen, is hinged to allow greater screen access. The rinsing screen has a roll-away chute to allow for easy access to all screen decks. The plant is also fitted with a high-pressure retractable wash-down hose. The pumps on the plant are fitted with drains to virtually eliminate downtime in frosty conditions. The AggreSand system is supplied with four integrated and pre-wired 500W metal-halide floodlights controlled via a photocell and mounted on winch-controlled hinged poles.

Cutting-edge control system – User-friendly PLC control system designed to give levels of automation and control not previously available on wash plants. The system provides full measurement and control of belt speed, water pressure, pump pressures etc, including radio control of all critical functions such as auto-start/stop, feeder start/stop and speed control. Full telemetry can be supplied as an option whereby all data is sent to the plant owner remotely, eg belt tonnages, alarm conditions, run times etc.

Easy set-up – Quick installation and deployment with one connecting power point and one water feed point for the entire plant. The system is economical in terms of water use and can be coupled to a TWS water-treatment plant to further reduce the overall water requirement. The plant also has a small footprint, thereby reducing the requirement for major ground preparation work.

Ease of transport – All components are designed so they can be easily dismantled and placed  into standard 40ft containers, resulting in fewer crane lifts and reducing the reassembly time on site.

For further information email Terex Washing Systems using the contact form below.

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