Rock to Road

Equipment Pits & Quarries
Terex introduces the Aggresand system


March 27, 2013
By Aggregates and Roadbuilding

Topics

aggresandMarch 26,
2013, Dungannon, Northern Ireland 
Terex Washing Systems (TWS) is making final plans to unveil a new innovative
washing system – The AggreSand system. Terex AggreSand system combines
aggregate washing and screening with sand processing on a modular chassis.

aggresandMarch 26,
2013, Dungannon, Northern Ireland 
Terex Washing Systems (TWS) is making final plans to unveil a new innovative
washing system – The AggreSand system. Terex AggreSand system combines
aggregate washing and screening with sand processing on a modular chassis. It
brings together Terex Washing Systems quality components in an innovative
modular design, setting itself apart from other washing systems in the
marketplace.

 

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Central
to the development of the new plant is 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.”

 

AggreSand System Key Features
& Benefits

 

H 12 Hopper 
– TWS designed a new modular hopper feeder with 12m cubed 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
degree angle when feeding the AggreSand system. The inclined feed conveyor
features an innovative sealed wash box at the discharge point to give material
a pre-rinse 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 80 square foot (7.54 square metres) 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 course
or fine compartment. The course 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 (Course & Fine) are used to pump material from
both sides of the sump tank into two hydrocyclones. The hydrocyclones remove
silts and clay (material below 63micron), which are sent to the water treatment
plant. The heavier material (above 63micron) exits the bottom of the
hydrocyclones into a rubber-lined 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 stockpiling capacity to an amazing 350 cubic metres. 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 customers’ site set-up/preference. The 4m
stockpile 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 the 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 40ft containers,
limiting the reassembly time on site with fewer crane lifts required.