May 22, 2013 - 5 years ago
By Supply Post

Terex Washing Systems
(TWS) is making final
plans to unveil a new innovative
washing system, one
which is sure to become a
global market leader – The
AggreSand system. This
is the latest edition to an
already extensive product
portfolio and is due to
be officially launched in
Quarter 2, 2013. Terex AggreSand
system combines
aggregate washing and
screening with sand processing
on a modular chassis.
It brings together tried
and trusted Terex Washing
Systems components in an
innovative modular design,
setting itself apart from
other washing systems in
the marketplace.
A gap in the market for
such a washing evolution
was identified following
extensive research, part
of which was conducted
at the Terex Washing Systems
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 preplumbed
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 5 products.”
AggreSand System Key
Features & Benefits H 12
Hopper
TWS designed a new
modular hopper feeder
with 12m3 capacity in
keeping with ever increasing
loading shovel sizes in
today’s modern quarries
and sand pits. The H 12
is available with an automatic
tipping grid and
a 12’ two deck vibrating
grid complete with variable
speed belt feeder, all controlled
from the main operator
interface and radio
control unit.
Feed Conveyor
The wide feed conveyor
has a direct drive electric
motor and gearbox arrangement
and will work at
a 19° angle when feeding
the AggreSand system. The
inclined feed conveyor features
an innovative sealed
wash box at the discharge
point to give material a prerinse
to pre-condition for
screening. The innovative
design eliminates splashing
at this point and produces
an even distribution
of material to the full width
of the rinsing screen thus
utilizing the full screening
area.
165R-3 Rinsing Screen
TWS opted for the highly
efficient 165R-3 (three
deck, two bearing) rinsing
screen. The screen’s riveted
construction reduces
the stress associated with
welded construction methods.
TWS engineers designed
this in such a way
to isolate the spray bars
from all vibration, utilizing
high quality rubber
gators on the mid and bottom
decks. Top deck rubber
extensions also prevent
overspill or splashing from
the top deck screen. The
165R-3 gives a true 80ft2
(7.54m2) of screening area
on all three decks. Each
deck has eight individually
controlled spray bars
fitted with polyurethane
fan-type spray nozzles. An
advanced rolling chute arrangement
gives the ability
to blend top deck and mid
deck overflows as well as
mid deck & bottom deck
overflows which will prove
very useful in construction
and demolition recycling
applications. The screen is
designed to receive standard
polyurethane modular
screens (woven wire
screens option also available)
on all decks.
Sump Tank
The large capacity split
sump tank receives the
rinsed fines from the bottom
deck screen into either
a coarse or fine compartment.
The coarse side
of the tank has a built-in
float system to help equalize
the levels in both tanks
and prevent overflowing.
Large inspection doors
are 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
& Hydrocylones
Two centrifugal slurry
pumps (Coarse & Fine)
are used to pump material
from both sides of the
sump tank into two hydrocyclones.
The hydrocyclones
remove silts and
clay (material below 63 micron)
which are sent to the
water treatment plant. The
heavier material (above 63
micron) exits the bottom
of the hydrocyclones into
a rubberlined box where
blending can take place if
required.
125 Dewatering Screen
The underflow from the
hydrocyclones transfers
onto a dewatering screen
via a discharge box which
equally distributes the material
across the screen to
increase the dewatering
screen area. Both materials
are dewatered over a
500 micron polyurethane
screen to produce two instantly
salable grades of
sand. The high energy
dewatering screen is fitted
with two high efficiency
counter rotating vibratory
motors which remove capillary
water to produce two
dewatered sands. The rubber
lined catchbox 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
conveyors, three aggregate
and two sand. The 650mm
wide conveyors are powered
by direct drive electric
motors and gearbox arrangements.
The 9.3m long
conveyors are angled at optimum
height for excellent
production. The two conveyors
have an innovative
automated radial wheel
drive system that increases
stock piling capacity to an
amazing 350m3. The conveyors
are fitted with high
quality teardrop polyurethane
scrapers. The aggregate
oversize conveyor has
a novel feature whereby
it can be placed on either
side of the machine in accordance
with the customer’s
site set-up/preference.
The 4m stock pile height
of these conveyors make
them ideal for producing
generous stock piles or
feeding other equipment
within the Terex product
range.
Accessible Service Areas
Maintenance and access
was of critical importance
during the design
process of the AggreSand
system, and this has been
achieved through a number
of advanced features.
There are 600mm wide
access platforms on both
sides of the machine. This
allows easy access to both
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 for
ease of access and maintenance.
The main feed conveyor
section which travels
over the aggregate screen
is hinged so that it can
be raised to allow greater
screen access. The rinsing
screen has a roll away
chute to also allow for easy
access to all screen decks.
The plant is also fitted with
a high pressure retractable
wash down hose. If
required, the spraybars
can be easily removed for
maintenance purposes.
The pumps on the plant are
fitted with drains for drainage
in frosty conditions to
virtually eliminate downtime.
The AggreSand system
is supplied with integrated
prewired 4x500watt
metal halide flood lights
controlled via photocell
and mounted on winch
controlled hinged poles for
ease of maintenance.
Cutting Edge Control
System
TWS has developed
an advanced and cutting
edge user-friendly control
system. The AggreSand
system will give operators
levels of automation
and control not previously
available on wash plants.
TWS has utilized PLC technology
which has already
been field proven within
the wider Terex crushing
and screening plants. The
control system will provide
measurement and control
in terms of belt speed, water
pressure, pump pressures,
etc. This will include
full radio control of
all critical functions such
as auto start/stop, feeder
start/stop and speed control.
Full telemetry is supplied
as an option where
all data is sent to the plant
owner remotely, such as
belt tonnages, alarm conditions,
run times, etc.
Easy Set-Up
The AggreSand system
encompasses tried and
trusted Terex components
in an innovative modular
set up. The AggreSand
system is designed specifically
to provide quick installation
and deployment
with one connecting power
point and one water feed
point for the entire plant.
Set up time will typically be
one day, making the plant
ideal for long or short term
contracts. The AggreSand
system has an economic
water requirement and is
ideal for coupling to a TWS water treatment plant to
recycle this water, thus reducing
the overall water requirement.
The plant was
designed to have a small
footprint, also 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 40 ft containers,
limiting the reassembly
time on site with fewer
crane lifts required.
TWS will officially
launch the AggreSand system
in Quarter 2, 2013. To
find out more or to discuss
specific washing requirements,
contact TWS.
[email protected], or visit
www.terex.com/washing
for an overview of the full
product offering.