Patent Publication Number: US-2022212200-A1

Title: Aggregate washing systems, methods, and apparatus

Description:
BACKGROUND 
     Aggregate washing equipment is used to wash, dewater, and/or otherwise process aggregate material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an embodiment of an aggregate washing system. 
         FIG. 2  is another perspective view of the aggregate washing system of  FIG. 1 . 
         FIG. 3  is a perspective view of another embodiment of an aggregate washing system. 
         FIG. 4  is a side elevation view of the aggregate washing system of  FIG. 3 . 
         FIG. 5  is a rear elevation view of the aggregate washing system of  FIG. 3 . 
         FIG. 6  is a sectional cutaway view along the section  5 - 5  of  FIG. 5  in a first configuration. 
         FIG. 7  is a sectional cutaway view along the section  5 - 5  of  FIG. 5  in a second configuration. 
         FIG. 8  is an expanded view of a portion of  FIG. 6 . 
         FIG. 9  is a perspective view of another embodiment of an aggregate washing system. 
         FIG. 10  is a top view of the aggregate washing system of  FIG. 9 . 
         FIG. 11  is a side elevation view of the aggregate washing system of  FIG. 9 . 
         FIG. 12  is a front elevation view of the aggregate washing system of  FIG. 9 . 
         FIG. 13  is a sectional view of the aggregate washing system of  FIG. 9  along section A-A of  FIG. 12 . 
         FIG. 14  schematically illustrates an embodiment of an aggregate washing system. 
         FIG. 15  schematically illustrates another embodiment of an aggregate washing system. 
     
    
    
     DESCRIPTION 
     Referring to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views,  FIG. 1  illustrates an embodiment of an aggregate washing system  100  that optionally includes a slurrying mechanism  200  (which may be described as a slurry-forming mechanism, an agitator, agitating mechanism, mixer, mixing mechanism, stirring mechanism, slurrifier, slurrifying mechanism, slurry mixer, slurry mixing mechanism, etc. according to some embodiments) and that optionally includes a dewatering mechanism  300  (e.g., a classifying mechanism such as a vibrating screen), which may be arranged in series as illustrated such that material (e.g., slurry) processed by the slurrying mechanism  200  is transferred to the dewatering mechanism  300 . The slurrying mechanism  200  and dewatering mechanism  300  are optionally supported by frames  20 ,  30 , respectively which are described elsewhere herein. The frames  20 ,  30  may comprise sections of a single rigidly and/or releasably interconnected frame or may be two independent and/or relatively movable frames. The frames  20 ,  30  may be mounted (e.g., by welding) to other structure or may be movably supported by skids, wheels or other mobile structure. Thus, the aggregate washing system  100  may be deployed as a single mobile plant, as a plurality of separate mobile plants, or in a stationary plant setting. 
     The slurrying mechanism  200  optionally generates a slurry comprising water and aggregate materials. The slurrying mechanism  200  optionally passes the slurry (e.g., all or substantially all of the slurry exiting the slurrying mechanism) to the dewatering mechanism. The dewatering mechanism optionally removes water (and/or fines or other undersize material) from the slurry and optionally passes at least partially washed (e.g., substantially washed, saleable, etc.) product (e.g., sand). 
     Water or other fluid (e.g., from a pond, tank or other water source) is optionally provided (in some embodiments exclusively provided) to the interior of the slurrying mechanism  200  via an inlet  270 . The inlet  270  is optionally formed in and/or extends through a sidewall (e.g., optionally at a lower end thereof and optionally at a rearward end thereof) and optionally in fluid communication with a water source, e.g. by fitting to a hose or pipe (not shown). 
     The slurrying mechanism  200  optionally includes a propulsion assembly  400  driven by an electric motor or other motor. The propulsion assembly may have one or more functions which may include agitating the aggregate material and water to form a slurry (e.g., agitating, mixing, slurrifying, slurrying, etc.) and/or propelling the raw material, water and/or aggregate material generally forwardly to an opening through which material is deposited onto the dewatering mechanism  300 . 
     Referring to  FIGS. 3-5 , another embodiment of an aggregate washing system  500  is illustrated including a slurrying mechanism  600  and a dewatering mechanism  700  (e.g., dewatering screen). The aggregate washing system  500  is optionally supported on a frame  580  (e.g., mobile or stationary frame) which optionally comprises a first frame  582  (e.g., optionally at least partially disposed beneath slurrying mechanism  600 ) and a second frame  584  (e.g., optionally at least partially disposed beneath dewatering mechanism  700 ). In some embodiments the frame  580  comprises a single unitary frame; in other embodiments the frame  580  comprises separate and/or separable frame portions for separately supporting the slurrying mechanism and dewatering mechanism. In some embodiments the frame  580  (and/or individual frames or frame portions) supports one or more platforms  520  for accessing the slurrying mechanism  600  and/or the dewatering mechanism  700 . Each platform  520  optionally includes a ladder  522  for accessing the platform  520 . 
     The slurrying mechanism  600  optionally comprises a tank  630  for containing aggregate material and water. One or more screens  632  (e.g., grates, mesh screens, etc.) are optionally positioned above at least a portion of the tank  630 . An inlet  610  (which may also comprise one or more screens) is optionally disposed above the tank  630  for introducing a feed (e.g., aggregate material, etc.) into the tank  630 . 
     Referring to  FIG. 6 , the slurrying mechanism  600  optionally includes a propulsion assembly  400  driven by an electric motor or other motor. The propulsion assembly  400  may include one or more common features or functionality of the propulsion assembly of the slurrying mechanism  200 . The propulsion assembly  400  may have one or more functions which may include agitating the aggregate material and water to form a slurry (e.g., agitating, mixing, slurrifying, slurrying, etc.) and/or propelling the raw material, water and/or aggregate material generally forwardly and/or upwardly to an opening  638  through which material (e.g., agitated material, mixed material, slurrified material, slurry, aggregate slurry, etc.) exits the tank. In the illustrated embodiment the material exiting opening  638  falls by gravity into the dewatering mechanism  700 ; in other embodiments, the material may instead by conveyed by one or more mechanisms (e.g., one or more conveyors, chutes, etc.) to the dewatering mechanism  700 . The propulsion assembly  400  is optionally rotatably supported on bearings  642 ,  644 . The propulsion assembly  400  is optionally driven for rotation by a motor  650  such as an electric motor (e.g., directly or via a belt  655  or other mechanism). In one embodiment, the propulsion assembly includes a shaft and a plurality of paddles are mounted to the shaft. The plurality of paddles can be arranged in a generally spiral arrangement. 
     Referring to  FIGS. 6 and 7 , a water inlet  662  optionally couples an interior volume of tank  630  to a water supply line  660  (see  FIG. 4 ) which is optionally in communication with a water source (e.g., via one or more valves, manifolds, etc). A restriction plate  664  is optionally positioned above the water inlet  662 . In some embodiments, the tank  630  retains water (e.g., all water, substantially all water, 90% of water by volume, etc.) supplied via the water inlet  662  except for water exiting the tank  630  via opening  638 . In some embodiments, the upper edge of the rear wall of tank  630  is higher than the opening  638 . 
     Comparing  FIG. 6  to  FIG. 7 , an angle A of the tank  630  (e.g., a bottom surface thereof) with respect to a horizontal plane P H  is optionally adjustable between a first angle A 1  and a second angle A 2 . In various embodiments, the value of A 2  less A 1  (e.g., the difference between A 1  and A 2 ) is 0.5 degrees, 1 degree, about 1 degree, 2 degrees, about 2 degrees, 3 degrees, about 3 degrees, between 0 and 3 degrees, between 0 and 4 degrees, between 1 and 3 degrees, between 1 and 4 degrees, between 0 and 5 degrees, between 1 and 5 degrees, etc. In some embodiments, the tank  630  is at least partially pivotally supported at one or more pivots  684  (e.g., left and right pivots) provided on one or more supports  680  (e.g., risers, frames, beams, etc. mounted to or supported on the frame  580 ). In some embodiments, the tank  630  is at least partially pivotally supported on one or more pivotal links  670 . Each link  670  is optionally pivotally coupled at a lower pivot  672  to the frame  580 . Each link is optionally pivotally coupled at an upper pivot  674  to the tank  630 . The link  670  is optionally length-adjustable (e.g., telescoping) between first and second configurations such as the configurations  670 A and  670 B. 
     Referring to  FIGS. 4 and 8 , the dewatering mechanism  700  optionally comprises a screen arrangement  780  supported between sidewalls  710 - 1 ,  710 - 2 . Each sidewall  710  is optionally supported on one or more sets of resilient supports  750   a ,  750   b . The dewatering mechanism  700  optionally includes a vibratory motor  720  supported on sidewalls  710  and configured to vibrate the dewatering mechanism. 
     The screen arrangement  780  optionally comprises a plurality of screen media (e.g., urethane or other screen media, mesh screens, etc.). In some embodiments the screen arrangement  780  comprises a “stepped” arrangement having a first level of screen media  784  disposed at an offset (e.g., vertical offset) from a second level of screen media  788  (e.g., a second level disposed lower than the first level). In some embodiments one or more transitional screen media  786  (e.g., angularly disposed screen media) are disposed between the first and second levels of screen media. In some embodiments one or more transitional screen media  782  (e.g., angularly disposed screen media) are disposed upstream of the first level of screen media. In some embodiments a plurality of screen media  783 ,  785  are disposed on one or more of the sidewalls  710 . 
     In some embodiments, an operating angle of the dewatering mechanism is adjustable. In some embodiments the operating angle of the dewatering mechanism is adjustable by adding or removing shims (e.g., under one or more resilient supports  750 ). In some embodiments, the operating angle of the dewatering mechanism and/or the slurrying mechanism is adjustable using an actuator (e.g., hydraulic actuator, etc.) or other mechanism. 
     In some embodiments, the dewatering mechanism  700  is provided with one or more washing elements (e.g., spray elements such as spray bars  762 ,  764 ,  766 ) in fluid communication with the water supply line  660  or another water source. The spray bars are optionally supported by one or more of the sidewalls  710  and optionally include one or more outlets oriented to direct water (e.g., a spray or stream of water) toward the screen arrangement  780 . In some examples, one or more washing elements (e.g., spray bar  762 ) is disposed and oriented to apply water (e.g., a spray or stream of water) toward a location disposed between the first and second levels of screen media. In some embodiments, the spray bar  762  is disposed to apply water to material dropping from the first level of screen media to the second level of screen media. Referring to  FIG. 9 , in some embodiments a spray bar or spray bars  690  are supported on the slurrying mechanism  600  and/or on the dewatering mechanism  700  and disposed to direct water onto material dropping onto and/or deposited on the screen media  782  and/or  784 . 
     Referring to  FIGS. 9-13 , another embodiment of an aggregate washing system  1000  is illustrated. The system  1000  optionally comprises a slurrying mechanism  800  and a dewatering screen  900 . Slurrying mechanism  800  optionally comprises a water inlet  810 , a material inlet  820  (e.g., optionally including a grate), and a propulsion assembly  850  configured to propel material to an outlet  890 . In some embodiments, the system  1000  includes a recirculation circuit  1100  comprising a hydrocyclone  1110 . The hydrocyclone  1110  is optionally supported above the dewatering screen  900  and optionally is not supported by the dewatering screen  900 , e.g., the hydrocyclone  1110  is optionally supported on a frame  1020  such that the hydrocyclone is at least partially isolated from vibration of the dewatering screen. One or more frames  1010  support the slurrying mechanism  800  and dewatering screen  900 ; the slurrying mechanism and dewatering screen  900  are optionally independent and/or mobile next to one another, or in some embodiments supported on a common frame  1010 . The frame  1020  is optionally supported on frame  1010  or in some embodiments is supported independently from frame  1010 . 
     In operation of the system  1000 , feed material (e.g., aggregate material and water) is fed into the slurrying mechanism  800 . The slurrying mechanism forms a slurry (e.g., wet aggregate slurry) which is propelled (e.g., by a screw  850 ) onto the dewatering screen  900 . The dewatering screen is vibrated (e.g., on resilient supports  920  such as springs) by a vibratory mechanism  950 . As material moves across the dewatering screen, one or more spray bars  980  or other washing elements optionally apply water to the material. Undersize material (e.g., comprising undersize aggregate material and water) optionally passes through a deck  910  into an underflume  1010 . A pump  1130  optionally returns undersize material via feed conduit  1140  to the feed inlet of the hydrocyclone  1110 . The underflow  1115  (which may be referred to as an underflow outlet) of the hydrocyclone  1110  optionally deposits a first subset (e.g., higher density subset) of the returned undersize material onto the deck  910 . The overflow (which may be referred to as an overflow outlet) of the hydrocyclone  1110  optionally transfers a second subset (e.g., lower density subset) of the returned undersize material away from the system  1000 , e.g., via conduit  1150 . 
     In some embodiments, a valve  1155  is operable to increase, decrease or cut off supplemental air flow into the overflow conduit  1150  (e.g., via an inlet  1154  and/or conduit  1152  in fluid communication with the conduit  1150 ). It should be appreciated that increased supplemental airflow into the overflow conduit  1150  increases the fraction of material passing into the underflow of the hydrocyclone (e.g., back onto the dewatering screen). 
     Referring to  FIG. 14 , an embodiment of system  1000  is illustrated schematically. The oversize material passing over dewatering screen  900  is optionally transferred (e.g., by a conveyor C) to a stockpile S 1 . Fine overflow material from the hydrocyclone  1110  is optionally transferred (e.g., via conduit  1150  and/or one or more conveyance devices) to a settling pond W 1  at which settlement stockpile S 2  is formed. Fine material from settling pond W 1  is optionally transferred to settling pond W 2 . Water and aggregate material from settling pond W 2  is optionally pumped via pump P to one or more locations in system  100  (e.g., the inlet end of slurrying mechanism  800 , the outlet end of slurrying mechanism  800 , and/or the dewatering screen  900 . 
     Referring to  FIG. 15 , an alternative embodiment of a system  1000 ′ is illustrated. The system  1000 ′ optionally does not have a recirculating circuit. In the system  1000 ′, undersize material passing through dewatering screen  900  is optionally transferred directly to settling pond W 1 . 
     Referring to  FIG. 13 , in some embodiments the dewatering screen  900  includes an angled deck portion  912  upstream of the deck  910 . In some embodiments, the deck  910  is approximately 6 feet long, greater than 5 feet wide, between 5 and 7 feet wide, between 5.5 and 6.5 feet wide, etc. In some embodiments, the deck  910  comprises a plurality of vertical elements that extend into the flow of material above the deck  910 . In some embodiments, the aperture size of apertures in deck  910  is greater than 0.3 mm, greater than 0.4 mm, about 0.5 mm, between 0.4 and 0.5 mm, etc. In some embodiments, the dewatering screen  900  is vibrated at a stroke amplitude of about 3/16 inch, greater than 2/16 inch, between 2/16 inch and ¼ inch, etc. In some embodiments, the dewatering screen  900  is operated at a frequency of about 1200 rpm, between 1100 and 1300 rpm, less than 1300 rpm, etc. In some embodiments, the dewatering screen  900  is vibrated to a g force of between 2 g and 3 g, greater than 2 g, greater than 1.5 g, etc. 
     The aggregate washing system embodiments described herein may be incorporated in mobile or stationary plants either alone or in combination with other equipment such as one or more conveyors (e.g., belt conveyors), one or more crushers (e.g., cone crushers, jaw crushers, gyratory crushers, impact crushers, etc.), and/or one or more classifiers (e.g., vibratory screens, grizzly feeders, hydraulic classifiers, hydrocyclones, etc.). 
     Ranges recited herein are intended to inclusively recite all values and sub-ranges within the range provided in addition to the maximum and minimum range values. Headings used herein are simply for convenience of the reader and are not intended to be understood as limiting or used for any other purpose. 
     Although various embodiments have been described above, the details and features of the disclosed embodiments are not intended to be limiting, as many variations and modifications will be readily apparent to those of skill in the art. Accordingly, the scope of the present disclosure is intended to be interpreted broadly and to include all variations and modifications within the scope and spirit of the appended claims and their equivalents. For example, any feature described for one embodiment may be used in any other embodiment.