Artificial Sand Production Line
Intro
Artificial sand, also known as manufactured sand (M-sand), is a sustainable alternative to natural sand, widely used in construction, concrete, and infrastructure projects. The production of artificial sand involves a series of mechanical processes to transform raw materials such as rocks, granite, limestone, or industrial byproducts (e.g., mine tailings) into high-quality sand with controlled particle sizes and shapes. Below is a detailed overview of the artificial sand production line process.
Artificial Sand Production Line
The artificial sand production line is a technologically advanced process that transforms raw stone into high-performance sand tailored for modern construction needs. By integrating efficient crushing, grading, and washing technologies, manufacturers produce eco-friendly sand that matches or exceeds the quality of natural sand. As global demand for sustainable construction materials grows, artificial sand production lines play a pivotal role in supporting infrastructure development while preserving natural resources.
Case
450-500TPH River Pebble Crushing and Sand Making Plant in Malaysia
MATERIAL: River pebble
OUTPUT SIZE: 0-5mm, 5-10mm, 10-20mm, 20-31.5mm
MAX FEED SIZE: 630mm
CAPACITY: 450-500TPH
Necessary Equipments
Jaw Crusher
Cone Crusher
VSI Crusher
Process Description
1. Raw Material Preparation
The process begins with the selection and preparation of raw materials. Hard rocks (e.g., granite, basalt) or softer materials (e.g., limestone) are mined, blasted, or collected from quarries. These materials are transported to the production site and undergo pre-screening to remove impurities like soil, clay, or oversized debris. A vibrating feeder ensures uniform feeding into the crushing system.
2. Primary Crushing
Large rocks (typically 200–500 mm in size) are fed into a jaw crusher or hammer crusher for primary crushing. This stage reduces the material to smaller fragments (approximately 30–100 mm). The goal is to achieve a size suitable for the subsequent sand-making stage.
3. Secondary Crushing (Optional)
For harder materials or to refine particle size further, a cone crusher or impact crusher may be used. This stage produces aggregates of 10–40 mm, optimizing the feed size for the sand-making equipment.
4. Sand-Making Process
The core stage of artificial sand production involves sand-making machines, most commonly vertical shaft impact (VSI) crushers or high-pressure grinding rollers (HPGR).
VSI Crushers: These machines use a high-speed rotor to throw raw materials against anvils or rock-lined chambers. The "rock-on-rock" or "rock-on-iron" crushing mechanism generates cubical, well-graded sand particles. Adjusting the rotor speed and feed rate controls the final sand shape and fineness modulus.
HPGR Systems: These apply intense pressure to crush materials, producing sand with low flakiness and enhanced particle strength.
This stage converts coarse aggregates into sand-sized particles (0–5 mm), often producing a mix of fine sand and micro-dust.
5. Screening and Gradation Control
The crushed material is transferred to vibrating screens or air classifiers to separate sand into specific grades (e.g., coarse sand: 2.36–4.75 mm; medium sand: 0.6–2.36 mm; fine sand: <0.6 mm). Oversized particles are recirculated to the sand-making machine for reprocessing, forming a closed-loop system to maximize efficiency.
6. Dust Removal and Washing
To meet quality standards, artificial sand often requires dust removal and washing:
Dust Control: Dry production lines use bag filters or cyclone separators to remove excess stone powder (typically limiting powder content to 5–15%).
Washing Systems: Wet production lines employ sand washers or wheel bucket classifiers to rinse out clay, silt, and impurities. A dewatering screen or hydrocyclone then reduces moisture content, ensuring the sand meets moisture specifications (2–3%).
7. Tailings Management
Wastewater from washing is treated in settling ponds or filter presses to recover reusable water and separate sludge. Modern plants emphasize water recycling systems to minimize environmental impact and reduce freshwater consumption.
8. Storage and Packaging
The final sand is conveyed to storage silos or stockpiles. Depending on application requirements, it may be blended with additives (e.g., fly ash) to enhance properties or packaged in bulk for transportation. Automated loading systems ensure rapid dispatch to construction sites.
