5 Processos de produção de areia manufacturada

Manufactured sand (M-Sand) is artificial sand processed through specialized machinery(sand making machine and other ancillary equipment) to create precisely sized and shaped particles for construction applications. This guide examines 5 proven sand manufacturing processes with detailed flowcharts for optimal production.

What Is a Manufactured Sand Machine?
Manufactured sand machines are industrial equipment that transform raw materials into high-quality artificial sand through crushing, grinding, and shaping processes. These systems range from simple hammer crushers to advanced multi-stage vertical shaft impactors.

How to Design a Sand Manufacturing Process?
The ideal sand production process depends on:

• Raw material characteristics
• Required production capacity
• Finished product specifications
• Environmental considerations
• Budget constraints

Below, we compare 5 established manufacturing methods with their advantages and limitations.

 

Visão geral
The artificial sand-making process has developed from the single-crushing sand-making process (such as hammer crushing, rod grinding, vertical shaft impact crusher sand making) to the combined crushing process (vertical shaft crusher & rod grinder, two-stage vertical shaft crusher). The dry, wet, and semi-dry processes have also been put into production.
Clique para saber que trituradores de pedra fornecemos.

 

1. Hammer Crusher Sand Manufacturing

Fluxo do processo ( foto abaixo )
Using a feeder and a belt conveyor to transfer the stone material from the bin to the triturador de martelos. All the crushed stones are screened by a sieve screen, in which those larger than 5mm are returned to the crusher, and those smaller than 5mm enter the finished sand bin.

Key Features

• Production Method: Dry process
• Scale: Small production systems
• Vantagens: Low initial investment; Quick setup; Immediate results
• Limitations: High wear rate; Significant dust generation; Limited to small-scale operations

 

2. Rod Mill Sand Manufacturing

Rod mill sand manufacturing generally adopts a wet making method, suitable for some difficult-to-crush rocks. It has the vantagens of simple structure, convenient operation, reliable equipment, good grain shape, uniform particle size distribution, adjustable fineness modulus, and stable quality.

 

Limitações
High energy and steel rods consumption, noise, difficult to dewater, a small feed particle size (≤25mm), high operating cost, etc., are not used as the main sand making equipment; more commonly used in combination with a vertical shaft impact crusher.
Besides, the wet sand making process has a long sand dewatering cycle, requires a large sand silo, and will affect the output of finished sand. The wet process brings environmental pollution caused by production wastewater. High water consumption, but low recycling rate. The moisture content of the finished sand is not easy to control below 6%.

 

3. VSI Crusher Sand Manufacturing

Vertical shaft impact crusher sand manufacturing process operational details:
Ideal For: Limestone processing
Vantagens: Low unit energy consumption; Excellent particle shaping; Low wearing costs
Shortages:

• The stone of 5~2.5mm is repeatedly squeezed and broken, has a poor crushing effect, and higher power consumption.
• The finished sand has a large range of particle diameters and more in fine diameter, and the intermediate particle diameter (2.5 to 1.25 mm, 1.25 to 0.63 mm particle diameter) has a small content.
• The control of the particle size modulus of the finished sand is difficult (controlled by humans).
• Low finished sand rate. The semi-dry production process generally refers to the pre-wet and post-dry production process. That is, the pre-screening adopts the wet process to produce and control the moisture content of the discharge, and some of the particles of 5 to 40 mm are dehydrated and used as the sand-making raw material, and the sand-crushing machine discharges the material. The water content is controlled between 2% and 5%, and the screening is no longer sprayed with water.

 

The VSI crusher sand manufacturing is mainly suitable for sites where the mud content of the raw material is not too high, and the sand requires a high powder content. However, the disadvantage is that the sand-making raw materials are washed by water, and must be reliably dehydrated before entering the vertical shaft to ensure that the moisture content of the raw materials broken into the vertical shaft is not more than 3%, otherwise the sand-making effect of the vertical shaft breaking and the screening efficiency of the screening are seriously affected.

 

4. Vertical Shaft Impact Crusher + Rod Mill Combination

The stone material is sent to the vertical shaft and rod mill by the feeding bin and the belt conveyor, respectively. After being crushed, it is sent to the screening machine for classification. All the stones larger than 5mm are returned to the converting bin for the next crushing circuit. Ground material enters the máquina de lavar areia e o ecrã de desidratação.

 

 

• This combination process possesses the advantages of a vertical shaft breaker and a rod grinder, and overcomes their respective shortcomings, such as the problem of medium diameter content and excessive loss of stone powder, which improves the sanding rate.
• “vertical shaft impact crusher + rod mill”, which can flexibly adjust the fineness and stone powder content of the finished product according to the change of raw materials, ensure the quality of finished sand, and effectively control the cost of sand making.
• More complicated and need higher equipment costs.

 

5. Two-stage VSI Crushers

A combination of high-speed and normal-speed vertical shaft impact crushers.
O material de pedra é alimentado no triturador de eixo vertical com velocidade normal (baixa) (v = 50 ～ 70m / s) pela caixa de alimentação e pelo transportador de correia. Após a trituração, ele entra na máquina de peneiramento. O material de pedra com mais de 5mm é devolvido à caixa de transferência. 5- 2.5mm de areia entra no silo de areia acabado, e outra parte da pedra é enviada para o eixo vertical de alta velocidade (v>75m/s). A pedra re-quebrada é misturada com a pedra com menos de 2,5mm e depois entra no armazém acabado.

(1) Adequado para a produção seca e semi-seca, é necessária mais investigação para a produção completamente húmida.
(2) Os trituradores de impacto de eixo vertical de duas velocidades podem aumentar ainda mais o teor de pó de pedra e reduzir o módulo de finura da areia acabada.

O excelente processo de produção de areia mecânica e a seleção razoável do equipamento são a garantia da qualidade da areia mecânica. Ao selecionar o processo de produção de areia mecânica, este deve ser combinado com os materiais específicos e os requisitos de produção, e a produção deve ser garantida de acordo com as condições locais.

 

Process Selection Guide

Processo	Best For	Capacidade	Humidade	Custo
Triturador de martelo	Small ops	Baixa	Dry	+
Moinho de barras	Tough materials	Médio	Wet	++
VSI Crusher	Calcário	Alto	Semi-dry	+++
VSI+Rod Mill	Quality sand	Alto	Ajustável	++++
Two-Stage VSI	Premium sand	Very High	Dry/Semi-dry	+++++

 

Pro Tip: Always conduct material testing and pilot trials before full-scale implementation.