New Hydro-Clean™ Removes Contamination with up to 75% Less Water than Standard Washing Equipment
Friday, May 14th, 2010
The new Hydro-Clean™ washing unit from St. Catharines, Ontario-based W.S. Tyler effectively cleans deleterious material from aggregate, industrial minerals and metals while reducing water consumption by up to 75 percent over traditional log washers. Taking a maximum feed material size of up to six inches (150 mm) into its vertical drum, the Hydro-Clean employs high-pressure nozzles, rotating at 90 rpm, to spray up to 90% recycled water on the material with pressures up to 2,900 psi (200 bars). The washing unit removes silt and clay particles as small as 63 microns from mineral mixtures and, with its short retention times, can process up to 400 TPH (400 tonnes), depending on model size and application. Due to its compact size and weight, overall operating and structural costs are considerably lower than with traditional washing systems—which also require more equipment and a greater footprint. A traditional washing system can require up to three screens along with a log washer or screw. With a Hydro-Clean unit, the producer only needs an additional wash screen for the Hydro-Clean’s discharged material.
The Hydro-Clean is ideal for use in clay-heavy material deposits. The dirty material is fed via hopper to a vertical washing drum, where high-pressure nozzles mounted at the top rotate and spray the material with water. The water streams spread and wash the material at pressures of up to 2,900 psi, effectively interacting with the material to break up agglomerates and clean the particles of stubborn material. The turbulence in the drum creates additional scrubbing and abrasive forces that enhance the cleaning process as the material travels down the drum cylinder. And because high-pressure streams of water are injected into areas of the rock (holes, cracks, etc.) that are difficult to reach with traditional cleaning methods like log washers or screws, the end result is a cleaner product that generates higher selling value. In addition, many producers use this unit to turn material that was once dirty waste into revenue.
During the cleaning process, the washed material works its way down the drum and exits onto a discharge conveyor that leads to a standard wash screen, which removes any remaining dirt or clay still on the stone as it fractionates the material. The resulting dirty water flows through polyurethane screen mesh installed in the sides of the washing drum and is collected by a waste water pipe, which sends the water to a treatment system for additional fine screening.
The Hydro-Clean consumes little water and power. Water consumption ranges from 27 to 211 gpm, depending on application and model size—compared to log washers that can require up to 800 gpm of water. Power requirements for the Hydro-Clean are no higher than 300 hp (225 kW) on its largest model. When compared to conventional systems, the Hydro-Clean experiences little wear with a maintenance-friendly design that allows for easy exchange of the few standard components that are subject to wear. The Hydro-Clean is available in four model sizes that produce 20 to 400 TPH, depending on the application.
The distance between the washing rotor and the material bed in the Hydro-Clean is variable and allows the system to adapt to various material types. Level sensors located at the material feed inlet provide exact data to the PLC control unit, ensuring a consistent material flow into the system.