Production of ultra-fine sands

AKA-SILT Ultra-Fine Sand Processing Plant

Economic Recovery of Ultra-Fine Sand

Rising raw material costs and increasingly stringent environmental regulations are driving the need for more efficient resource utilization in sand processing operations. With the AKA-SILT system, AKW Equipment and Process Design offers an innovative solution for the recovery of ultra-fine sand from process water. The system reduces product losses, lowers the load on sedimentation ponds and creates additional value from previously unused fine fractions. The technology also contributes to more sustainable water management and improved resource efficiency within existing processing plants.

Many existing sand processing plants are not designed to recover valuable material in the 0-150 μm size range. As a result, significant quantities of fine sand are lost to tailings and sedimentation ponds together with the process water. Besides the loss of valuable product, this increases the solids load within the water circuit and makes water management more challenging

Tailor-Made Fine Sand Recovery Technology

he AKA-SILT system combines ultra-fine hydrocyclone classification with highly efficient dewatering technology for the recovered fine sand fraction. This minimizes product losses in the 0-150 μm range, maximizes fine sand recovery and significantly reduces the load on sludge and sedimentation ponds.

Prior to system design, comprehensive test work is carried out in the AKW test center to determine particle size distribution, solids concentration and the optimum cut size for each application. Based on these results, the system is individually engineered to meet the process requirements. Depending on the material characteristics, separation cut sizes down to 8-10 μm can be achieved.

Proven Hydrocyclone Technology

The process water containing solids is first collected in a sump and subsequently screened via AKA-STRAINER before entering the classification circuit. At the heart of the system are AKA-SPIDER annular distributors equipped with small AKA-VORTEX polyurethane hydrocyclones. In the first hydrocyclone stage, the material is separated into a clay fraction (0-10 μm) and a valuable fine sand fraction (10-150 μm).

The hydrocyclone underflow containing the fine sand fraction is then transferred to a second hydrocyclone stage for further thickening. The overflow from this stage is returned to the primary classification stage, ensuring maximum recovery efficiency. The final dewatering step is performed on a specially developed dewatering screen. Recovered process water is returned directly to the plant water circuit.

Through the combination of AKA-SPIDER distributors, AKA-VORTEX hydrocyclones and advanced dewatering technology, AKA-SILT enables the economic recovery of ultra-fine sand while generating additional value from material that would otherwise be lost to tailings.

Creating Value from Fine Fractions

The AKA-SILT system produces two valuable secondary products. The recovered ultra-fine sand (10-150 μm) can be used in concrete, mortar and other mineral-based construction materials. The separated clay fraction (0-10 μm) can be utilized in sealing materials, the brick industry and various ceramic applications.

By transforming waste streams into marketable products, the system reduces raw material losses while creating additional revenue opportunities.

Key Benefits

  • Recovery of valuable ultra-fine sand fractions
  • Reduced raw material losses
  • Lower sludge volumes and disposal costs
  • Reduced load on sedimentation ponds
  • Improved process water quality
  • Reduced flocculant consumption
  • Chemical-free process
  • Sustainable utilization of natural resources
  • Sustainable utilization of natural resources

Patented Technology

The innovative AKA-SILT technology is protected by patent and highlights the long-standing expertise of AKW Equipment and Process Design in the development of sustainable mineral processing solutions. The patent is registered under the title“Method for Removing Fine Particles from Wastewater Streams” (DE 10 2020 109 403).

Conclusion

The AKA-SILT system enhances existing sand processing plants with an efficient and sustainable technology for ultra-fine sand recovery. Plant operators benefit from reduced product losses, improved water management and additional revenue potential through the utilization of previously discarded fine fractions. Thanks to its modular design, the system can be easily retrofitted into existing process plants and integrated into established production circuits.

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