Silica Sand - Fines Recovery System



Derrick Corporation's wet sizing Stack Sizer machines and a Fine Sand Recovery System were selected as key components by Separator Roberts & Schaefer for a sand processing plant near Jaworznow, Poland. This plant primarily produces sand products for the mining and construction industries as well as the foundary industry.


The sand processing system consists of three stages: 

Stage 1:
One (1) three-deck Stack Sizer equipped with 0.5 mm Derrick tensionable urethane screen panels is fed 50 MTPH of 2.0 mm x 0 sand to produce a 2.0 mm x 0.5 mm product fraction that discharges directly onto a conveyor belt for stockpiling. The required 2.0 mm x 0.5 mm fraction has an error of less than 5%. The undersize fraction (-0.5 mm) is pumped to the feed sump for Stage 2.

Stage 2:
One (1) three-deck Stack Sizer equipped with 0.3 mm Derrick tensionable urethane screen panels is fed 32 MTPH (25% solids) to produce a -0.5 mm x +0.3 mm product fraction that discharges directly onto a second conveyor belt for stockpiling. The customer's required -0.5 mm x +0.3 mm fraction has an error of less than 2%. The undersize fraction (-0.3 mm) material is pumped to a feed sump for Stage 3. 

Stage 3: 
Derrick's Fines Recovery System with its twenty (20) 4" hydrocyclone manifold prepares and dewaters the -0.3 mm undersize fraction from Stage 2. The 4" hydrocyclones make a separation of approximately 38 microns. One-half of the dilute hydrocyclone overflow is discharged as waste while the remainder is returned to the hydrocyclone feed sump to maintain fluid levels in the sump. The hydrocyclone underflow feeds the high g-force dewatering screen. Derrick tensionable 500 mesh and 180 micron urethane screen panels are used to dewater the -0.3 mm x +38 microns product. The dewatered product fraction is discharged onto a third conveyor for stockpiling. The undersize fraction from the dewatering screen is pumped back to the hydrocyclone feed sump and reintroduced into the system.
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