Summary：Explore challenges in bauxite sand production and discover solutions using advanced equipment and intelligent systems for efficient, energy-saving operations.

Bauxite sand production faces three major challenges: clay agglomeration, high silica content, and difficulties in controlling fine powder. How can we achieve efficient and energy-saving production? Today, we will explore a complete solution for a 1 million ton per year bauxite sand production line. We will delve into the selection of core equipment, the intelligent control system, and revealing power consumption data!

1. Overcoming Three Major Challenges in Bauxite Sand Production

1.1 Severe Clay Blockage

PFW European Version Impact Crusher

  • Innovative 70m/s ultra-high-speed rotor instantly crushes clay blocks.
  • Dual hydraulic opening device for quick 20-minute maintenance.
  • Tested clay processing efficiency increased by 80%, downtime reduced by 65%.
pfw impact crusher

1.2 High Silicon Ore Leads to High Wear Costs

HPT Hydraulic Cone Crusher

  • Lamination crushing technology extends liner lifespan by 3 times.
  • Intelligent hydraulic system adjusts stroke in real-time, with power consumption as low as 0.85 kW·h per ton.
  • Paired with MC-300 laser particle size analyzer, automatically returns oversized materials.
hpt cone crusher

1.3 Difficulties in Controlling Fine Powder Content

VSI5X Vertical Shaft Impact Crusher

  • "Stone-on-stone" mode precisely controls 0-5mm fine powder to 92%.
  • Air screening system reduces alkali consumption to 1.8kg per ton of sand.
  • Dual-screw sand washer + fine sand recovery machine, with fine sand loss rate under 3%.
vsi5x sand making machine

2. Intelligent System Saving 2 Million Yuan in Annual Power Costs

2.1 Central Control Brain

Siemens S7-1500 PLC System enables:

  • 5G remote operation and maintenance, improving fault response speed by 70%.
  • Vibration monitoring devices provide 99% accuracy in bearing fault warnings.
  • Real-time laser particle size analysis adjusts material return rate (20%-25%).

2.2 AI Ore Sorting Technology

Hikvision Industrial Camera accurately identifies ore hardness (f=8-16):

  • Automatically adjusts cone crusher cavity pressure.
  • Digital twin platform shortens virtual debugging cycle by 40%.
  • Equipment automatically shuts down if temperature/vibration exceeds threshold.

3. Bauxite Sand Production Line Configuration

3.1 Primary Crushing

  • Equipment Model: PE1200×1500 Jaw Crusher
  • Key Technical Specifications: Direct feeding of large ore lumps (mm)
  • Energy-Saving Features: 15% power saving with hydraulic drive

3.2 Secondary Crushing

  • Equipment Model: HPT300 Cone Crusher
  • Key Technical Specifications: Output ≤20mm
  • Energy-Saving Features: 30% power saving with laminated crushing

3.3 Sand Making

  • Equipment Model: VS15X-1145 Impact Crusher
  • Key Technical Specifications: Fine powder rate 92%
  • Energy-Saving Features: 20% alkali reduction with air classification

3.4 Washing

  • Equipment Model: XSD3016 Sand Washer
  • Key Technical Specifications: Processing capacity 200t/h
  • Energy-Saving Features: 85% water saving with fines recovery system

3.5 Smart Control

  • Equipment Model: Siemens S7-1500 PLC
  • Key Technical Specifications: 5G remote diagnostics
  • Energy-Saving Features: Annual maintenance cost reduction: ¥500k+

In summary, the production of bauxite sand is not without its challenges, but with the right strategies and technologies, these obstacles can be effectively overcome. By addressing issues such as severe clay blockage, high silica content, and the management of fine powder, we can enhance both efficiency and cost-effectiveness in the production line.