果冻传媒

Mansfield Sand Company Limited has been quarrying sand in North Nottinghamshire, England for more than 170 years. They are known countrywide as a supplier of materials for top class sports and sporting venues across the United Kingdom and Ireland. They supply sand material to 16 Premier League Clubs, 16 Championship Clubs and 120 other football league and non-league clubs for use in their stadiums and training ground facilities.

Besides sand for football stadiums, Mansfield Sand also produces a wide range of products for landscaping and equestrian uses, including championship golf and world-class show jumping arenas, as well as asphalt sand, foundry sand, and sand for concrete and brick products.

CHALLENGE

In 2014, Mansfield Sand wanted to upgrade their plant and control system to process a new deposit. They required a plant that would process 300 metric tons per hour of -65mm sand to manufacture their various products, including golf sand that meets United States Golf Association standards, block pavior sand and asphalt sand.

In addition to this requirement, the local planning commission also set a noise restriction in place so the new plant would not disturb some rare birds nesting near the boundaries of the site.

It was at this time that Neill Rowland, 果冻传媒 Applications Engineer, knocked on their door. He explained that 果冻传媒 could offer them a Hydrosizer庐 sand plant that would produce five different products in one pass.

鈥淥ne of the things that sold the plant was 果冻传媒鈥檚 technical ability to offer this,鈥� said Rowland, noting that experience and confidence also played a role in Mansfield Sand鈥檚 decision to work with 果冻传媒.

Mansfield Sand was familiar with Hydrosizer庐 systems from an existing plant they had been operating for several decades, so they had already realized the benefits of Hydrosizer庐 for what they were trying to achieve.

鈥淲hen you start getting down to really fine sizing, Hydrosizer庐 classification is really more efficient and more cost-effective,鈥� explained Rowland. 鈥淭he Hydrosizer庐 is the only piece of equipment suitable for the application to achieve the tight tolerances.鈥�

SOLUTION

果冻传媒 installed a Hydrosizer庐 plant incorporating 果冻传媒 Pumps, Sumps, Hydrocyclones, Separator鈩�, Dewatering Screens and Blending System with the ability of blending to 1% accuracy to help Mansfield Sand meet the strict specifications required of their final products. The final products are discharged at less than 15% moisture, which creates stockpiling efficiency and allows for further drying processes.

To meet the requirements set forth by the planning commission, the entire plant is housed within a galvanized structure, clad and insulated to reduce the noise level. The plant鈥檚 components are also lined with rubber to protect them from the abrasiveness of the sand.

After some calculations from Mansfield Sand鈥檚 laboratory technicians, the company discovered the waste from the wash plant would fill their lagoon within 18 months, so they turned to 果冻传媒 for help with their water management.

果冻传媒 provided an Ultra Fines Recovery System to recover fines down to 40 microns to extend the life of Mansfield Sand鈥檚 lagoon system.

鈥淎nything bigger than 40 microns is recovered,鈥� Rowland said. 鈥淎nything less is going to the lagoon.鈥�

RESULTS

Since commissioning the Hydrosizer庐 plant, Mansfield Sand Company has not received a single customer complaint due to the performance of the equipment. The plant鈥檚 modern control system gives Mansfield Sand the ability to adjust the product to meet consumer demands.

鈥淭he plant does have quite a bit of functionality for them to develop product and potentially react to market changes,鈥� explained Rowland.

In four years of operation, the Hydrosizer庐 plant has proven to be both stable and reliable. It produces a consistent 280 mtph, and to date, the plant has produced 2 million tons of sand for Mansfield Sand Company. Furthermore, the Ultra Fines Recovery system has doubled the life of their lagoon by allowing Mansfield Sand to capture the fine material.

鈥淚t鈥檚 a low-value product, but it鈥檚 a product they can sell, and it鈥檚 a product that isn鈥檛 filling their lagoon, which is the real benefit to them,鈥� Rowland said.

Overall, Mansfield Sand is pleased with the Hydrosizer庐 plant and Ultra Fines Recovery System.

鈥淎 good team effort by both parties and a professional working relationship providing a technologically advanced plant gives Mansfield Sand flexibility, controllability and future-proofing for the estimated 30-year life of the site,鈥� said Richard Abraham, Managing Director of Mansfield Sand. 鈥淣ow, four years on, we continue to have a fantastic working relationship together. Our process plant continues to manufacture our premium quality sands to Mansfield Sand鈥檚 exacting standards. The partnership between Mansfield Sand and 果冻传媒 has rested on the 果冻传媒 team鈥檚 awareness of the importance we place on the reputation of our products and our respect for their experience. The partnership had a lot to prove, and it proved to be a great success.鈥�