Design Modification and Optimization of a Sand Wash Plant

Sand washing is a common application in South Africa’s quarry and mining industry. Quarry industries want to separate their fine particles from their coarser, larger particles. The aim of the study was to redesign and optimize the sand wash plant through resizing, equipment selection, simulation modelling and mass balancing. This was achieved by collecting a feed sample and retrieving the particle size distribution information. These data were used to conduct a mass balance and design the plant. Once the equipment was sized and installed, further test work was completed to compare results from the previous test work conducted. These results showed that the sand wash plant’s behaviour not only matched the simulated results but provided the required size particles which were less than 75 µm. An optimized design was tested on an existing wash plant, and the test work had reflected that the plant was not only efficient in providing the same grade of material but also saved a large amount of water. The innovative designs into the sand wash plant were estimated to be sustainable and cost-effective.