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DEC scaling Industrial Units |
Scaling Industrial Units: 10 to 20 Tons/Hour
The fundamental unit for processing production tailings operates at a capacity of either 10 or 20 tons per hour. Configured within a container fleet, it can also be situated on any flat surface adjacent to a shore or pond, without the need for a cement base. This module's design stems from insights gathered during three months of operation at a small industrial plant, handling up to 2.5 tons per hour. Adjustments consider technological variations to enhance productivity. Each installation is customized for specific raw materials (sometimes within the same category) and is not interchangeable for other sources while maintaining the same efficiency.
The responsibility for providing equipment for excavation and transportation to the industrial DEC units lies with the customer, covering associated expenses.
How it Operates on Red Mud (Example):
The material designated for processing, with a moisture content of up to 5%, is continuously fed into the loading unit's bunker feeder. Two consistent streams are directed from the loading team's bunker to the 2nd and 3rd modules—containers housing high-speed rotary mills.
In the mills, the loaded materials undergo combined processing, involving shock-mechanical action with the imposition of a centrifugal field, followed by air separation. This combined effect opens mineral grains and transforms the initially irregularly shaped metal phase particles into a spherical form.
The material, crushed from 1 mm to a fraction of 50 microns, undergoes complete mineral grain opening and activation through a self-grinding effect, concurrently removing a light dusty fraction with a coarse separator from the working area.
The material, crushed to a fraction of 50 microns, progresses to the 4th module container with a high-speed rotary mill. Here, self-grinding to a fraction of 5 microns occurs, selectively opening mineral aggregates of red mud components. The mill's grinding mode is configured to destroy inclusions, exposing the metals within, while the dusty light fraction is extracted into the cyclone.
Subjected to regrind in the mill to a fraction of 5 microns, the material enters the 5th container module through a screw conveyor into another high-speed rotary mill. This phase involves additional cleaning of impurities through self-grinding and selective disintegration to a fraction of 1 micron, with the remaining dust being removed by a coarse separator. The light pulverized fraction collects in the cyclone.
From the mill, where it is crushed to a fraction of 1 micron and cleared of any remaining dust, the material is transported, via a screw conveyor, to a specialized aero separator. In this separator, the falling material, in the form of particles with open mineral intergrowths and a fraction of 1 micron, undergoes separation based on density, sorting by weight, shape, and size. Subsequently, it enters the finishing unit module-container.
Within the finishing module container, red mud, now in the form of fine particles with a fraction of 1 micron, is subjected to further crushing in a rotary mill of unique design. The material is then separated on a magnetic separator into final products of processing: a magnetic fraction representing iron ore raw materials and non-magnetic fractions comprising aluminum oxide and dry, finely dispersed raw materials.
