Turning 130 TPH of Dirty River PGS into High-Grade Sand and Aggregate

A recent client approached Baichy Machinery with a common but frustrating problem. Their quarry was rich in sand and gravel mix (PGS), but the material contained up to 20% sticky clay and淤泥. They were struggling to produce clean concrete sand, and their existing equipment kept clogging. They needed a solution that could handle 100–130 tons per hour of this dirty feed and output clean, sellable products.

The Solution: A Custom-Built, High-Scrubbing Workflow

Baichy’s engineers designed a fixed processing line focusing on high-intensity scrubbing and efficient gradation. The design philosophy was simple: remove the dirt early, crush the rock smartly, and recover every grain of sand.

The layout consisted of eight key stages:

1. Scalping: A GZD-1100x4200 Vibrating Grizzly Feeder removed the sticky sub-60mm material immediately, protecting the crushers downstream.

2. Primary Crushing: A rugged PE-600x900 Jaw Crusher reduced the large cobbles.

3. Shaping: A PF-1214 Impact Crusher crushed the material further, ensuring the final gravel had a high-value cubic shape.

4. Sand Making: A 2PG-1010 double roller crusher milled the small stones into 0-5mm sand, keeping dust levels low.

5. Screening: A 3YK-1860 Vibrating Screen sorted the material into 0-5mm, 5-20mm, and 20-40mm fractions.

6. Intensive Washing: The 0-5mm sand and slurry entered a Log Washer. Here, the clay was vigorously broken down in a high-friction environment.

7. Final Rinsing: A Spiral Sand Washer rinsed the sand, carrying away the dirty water.

8. Recovery: A Hydrocyclone system or fine sand recycling machine was added to "mine" the waste water for any remaining fine sand, boosting overall yields.

The Result: From Waste to Wealth

The installation of the Log Washer and Fine Sand Recovery system was the game-changer.

1. High-Quality Output: The plant now produces 50-60 tons per hour of clean washed sand (0-5mm) with a fineness modulus of 1.5–2.5, perfect for local ready-mix concrete companies.

2. Clean Aggregates: It also produces 30-40 tons of clean 5-20mm and 20-40mm gravel, free from clay coatings.

3. Zero Waste: The fine sand recovery system captures an additional 10-15 tons of material daily that was previously lost to the settling pond. This directly adds to the bottom line.

Client Feedback:

"We were skeptical about processing this dirty river material, but the Baichy team designed a system that handles it perfectly. The log washer makes all the difference. We are now the only supplier in the area with truly clean sand."

Is your site losing money to muddy waste? You don't have to leave profits in the settling pond. Baichy Machinery specializes in solving tough aggregate processing problems. Contact Baichy Machinery now to get a quote and turn your dirtiest material into your biggest profit center!