A system and a method for processing stone material to produce manufactured sand

Abstract

A system (100) for processing stone material to produce manufactured sand is disclosed. The system includes a horizontal shaft impactor (105) coupled to a horizontal rotating shaft, adapted to crush and grind stone material. A crushing chamber (110) receives material through a first rotary air lock (115) that regulates feed rate and prevents air leakage. A rotor (120), driven by a motor, generates a hot airflow for air circulation and creates an upward dust flow to retain oversized particles. An induced draft fan (125) extracts fine dust and circulates air, while a cyclone assembly (130) separates and stores the dust. A second rotary air lock (135) discharges fine dust, and an amibatic non-return air duct (140) prevents particle entry into the discharge air duct. The system includes a bag filter (155), at least two hydraulic cylinders (170, 175), and a plurality of valves to regulate airflow, ensuring efficient sand production. FIG. 1

Description

FIELD OF INVENTION

[0001] Embodiments of the present disclosure relate to the field of sandmanufacturing, and more particularly, a system and a method for processing stonematerial to produce manufactured sand.BACKGROUND

[0002] A sand processing industry involves crushing hard rocks or stones into small,angular particles, followed by washing, screening, drying, refining, and grading toproduce high-quality manufactured sand for industrial and construction use. To achievethis, sand washing plants and air classifier systems play a crucial role in ensuring thefinal product meets required standards.

[0003] A sand washing plant in the sand processing industry is a facility used toclean and remove impurities such as silt, clay, dust, and other unwanted particles fromraw sand. However, operating these plants comes with numerous environmental,technical, and economic challenges. One of the primary concerns is securing aconsistent water supply for sand cleaning throughout the year, which poses a majorhurdle. Additionally, these plants often face resistance from environmental regulatorybodies and the public due to the ecological impact of water usage and waste disposal.The need for sludge settling chemicals adds to operational costs, while the washingprocess itself leads to a substantial 10-20% loss in production due to sludge formation.Maintaining cleanliness within the plant further complicates operations, requiringadditional resources. Moreover, high capital investments are necessary for waterstorage facilities, settling tanks, and transportation equipment such as JCB excavators,tanker lorries, and tipper lorries, adding to the overall financial burden.

[0004] In addition to sand washing plants, air classifier systems are also widely usedin the sand processing industry. An air classifier is a machine that separates particlesof different sizes in a medium, such as air. It's used in the sand processing industry toseparate fine, ultrafine, and coarse materials. However, these systems also come withtheir own set of challenges. Cleaning sand during humid weather proves to beproblematic. Additionally, wet material feed may disrupt air bag filtration, leading tosystem malfunctions. Even a single crack in the filtration bag may cause significantoperational disruptions, necessitating frequent maintenance. The system also requiresthe continuous presence of a qualified engineer to ensure smooth operation. Moreover,high installation and maintenance costs contribute to financial losses, and the airclassifier system itself results in substantial production losses.

[0005] Hence, there is a need for a system and a method for processing stonematerial to produce manufactured sand which addresses the aforementioned issue(s).OBJECTIVES OF THE INVENTION

[0006] The primary objective of the invention is to use a horizontal shaftimpactor for crushing and grinding stone material to produce manufactured sand withcontrolled gradation and shaping.

[0007] Another objective of the invention is to adapt a body shell of thehorizontal shaft impactor as an air classification chamber, enabling efficient separationof fine dust particles and improving overall sand quality.

[0008] Yet another objective of the invention is to incorporate the horizontalshaft impactor connected to an induced draft fan for creating a controlled airflow thatfacilitates fine dust extraction, air circulation, and operational efficiency.

[0009] Yet another objective of the invention is to retrofit the horizontal shaftimpactor into a system with an existing impactor to enhance sand productioncapabilities and achieve the desired gradation for various applications.BRIEF DESCRIPTION

[0010] In accordance with an embodiment of the present disclosure, a system forprocessing stone material to produce manufactured sand is provided. The systemincludes a horizontal shaft impactor coupled to a horizontal rotating shaft. Thehorizontal shaft impactor is adapted to crush and grind the stone material. Thehorizontal shaft impactor is retrofitted with an existing impactor. The horizontal shaftimpactor includes a crushing chamber adapted to receive a pre-determined quantity ofstone material through a first rotary air lock to regulate feed rate while preventing airleakage. The horizontal shaft impactor includes a rotor connected to the crushingchamber. The rotor is adapted to generate a hot airflow through rapid horizontalrotation driven by a motor, facilitating an air circulation within the crushing chamber.The rotor is adapted to create an upward dust flow for preventing the escape ofoversized particles by redirecting the oversized particles into the crushing chamber.The system includes an induced draft fan operatively connected to the horizontal shaftimpactor. The induced draft fan is adapted to extract fine dust carried by the hot airflowfrom the crushing chamber. The induced draft fan is adapted to circulate an air streamthroughout the system to maintain a fixed air quantity. The system includes a cycloneassembly operatively connected to the induced draft fan. The cyclone assembly isadapted to separate and store the fine dust from the air stream. The cyclone assemblyis adapted to release clean air back to the induced draft fan through an air inlet duct forrecirculation. The system includes a second rotary air lock positioned at a lower end ofthe cyclone assembly. The second rotary air lock is adapted to prevent the air with dustemission. The second rotary air lock is adapted to discharge the fine dust collected intoa first fine dust conveyor. The system includes an amibatic non-return air ductoperatively connected to the induced draft fan. The amibatic non-return air duct isadapted to prevent fine particles from entering a discharge air duct. The amibatic non-return air duct is adapted to direct the clean air exiting the induced draft fan back intothe horizontal shaft impactor, thereby completing an operational air circulationsequence. The system includes a third rotary air lock positioned at a discharge point ofthe horizontal shaft impactor. The third rotary air lock is adapted to allow a finalproduct processed to exit the horizontal shaft impactor to a second fine dust conveyorafter the processing. The system includes a bag filter operatively connected to theinduced draft fan. The bag filter is adapted to bypass excess air from the induced draftfan. The bag filter is equipped with electrically vibrating mechanisms. The systemincludes a plurality of valves includes a butterfly valve adapted to regulate air quantitypassing through the air pipe from the induced draft fan to the bag filter. The pluralityof valves includes a pendulum valve adapted to control discharge and air leakage fromthe bag filter. The bag filter with built-in pendulum and butterfly valves redirects theexcess air. The system includes at least two hydraulic cylinders is adapted to provideunidirectional force through a unidirectional stroke by converting hydraulic energy intomechanical energy to lift up and close-down of crushing chamber and chamber of therotor.

[0011] In accordance with another embodiment of the present disclosure, amethod for processing stone material to produce manufactured sand is provided. Themethod includes crushing and grinding, by a horizontal shaft impactor, the stonematerial. The horizontal shaft impactor is retrofitted with an existing impactor. Themethod includes receiving, by a crushing chamber, a pre-determined quantity of stonematerial through a first rotary air lock to regulate feed rate while preventing air leakage.The method includes generating, by a rotor, a hot airflow through rapid horizontalrotation driven by a motor, facilitating an air circulation within the crushing chamber.The method includes creating, by the rotor, an upward dust flow for preventing theescape of oversized particles by redirecting the oversized particles into the crushingchamber. The method includes extracting, by an induced draft fan, fine dust carried bythe hot airflow from the crushing chamber. The method includes circulating, by theinduced draft fan, an air stream throughout the system to maintain a fixed air quantity.The method includes separating and storing, by a cyclone assembly, the fine dust fromthe air stream. The method includes releasing, by the cyclone assembly, clean air backto the induced draft fan through an air inlet duct for recirculation. The method includespreventing, by a second rotary air lock, the air with dust emission. The method includesdischarging by the second rotary air lock. the fine dust collected into a first fine dustconveyor. The method includes preventing, by an amibatic non-return air duct, fineparticles from entering a discharge air duct. The method includes directing, by theamibatic non-return air duct, the clean air exiting the induced draft fan back into thehorizontal shaft impactor, thereby completing an operational air circulation sequence.The method includes allowing, by a third rotary air lock, a final product processed toexit the horizontal shaft impactor to a second fine dust conveyor after the processing.The method includes bypassing, by a bag filter, excess air from the induced draft fan.The bag filter is equipped with electrically vibrating mechanisms. The method includesregulating, by a butterfly valve of a plurality of valves, air quantity passing through theair pipe from the induced draft fan to the bag filter. The method includes controlling,by a pendulum valve of the plurality of valves discharge and air leakage from the bagfilter. The bag filter with built-in pendulum and butterfly valves redirects the excessair. The method includes providing, by at least two hydraulic cylinders, unidirectionalforce through a unidirectional stroke by converting hydraulic energy into mechanicalenergy to lift up and close-down of crushing chamber and chamber of the rotor.

[0012] To further clarify the advantages and features of the present disclosure, amore particular description of the disclosure will follow by reference to specificembodiments thereof, which are illustrated in the appended figures. It is to beappreciated that these figures depict only typical embodiments of the disclosure andare therefore not to be considered limiting in scope. The disclosure will be describedand explained with additional specificity and detail with the appended figures.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The disclosure will be described and explained with additional specificityand detail with the accompanying figures in which:

[0014] FIG. 1 is a schematic representation of a system for processing stonematerial to produce manufactured sand in accordance with an embodiment of thepresent disclosure;

[0015] FIG. 2(a) illustrates a flow chart representing the steps involved in amethod for processing stone material to produce manufactured sand in accordance withan embodiment of the present disclosure;

[0016] FIG. 2(b) illustrates continued steps of the method of FIG. 2 (a) inaccordance with an embodiment of the present disclosure; and

[0017] FIG. 2(c) illustrates continued steps of the method of FIG. 2 (b) inaccordance with an embodiment of the present disclosure.

[0018] Further, those skilled in the art will appreciate that elements in the figuresare illustrated for simplicity and may not have necessarily been drawn to scale.Furthermore, in terms of the construction of the device, one or more components of thedevice may have been represented in the figures by conventional symbols, and thefigures may show only those specific details that are pertinent to understanding theembodiments of the present disclosure so as not to obscure the figures with details thatwill be readily apparent to those skilled in the art having the benefit of the descriptionherein.DETAILED DESCRIPTION

[0019] For the purpose of promoting an understanding of the principles of thedisclosure, reference will now be made to the embodiment illustrated in the figures andspecific language will be used to describe them. It will nevertheless be understood thatno limitation of the scope of the disclosure is thereby intended. Such alterations andfurther modifications in the illustrated system, and such further applications of theprinciples of the disclosure as would normally occur to those skilled in the art are to beconstrued as being within the scope of the present disclosure.

[0020] The terms "comprises", "comprising", or any other variations thereof, areintended to cover a non-exclusive inclusion, such that a process or method thatcomprises a list of steps does not include only those steps but may include other stepsnot expressly listed or inherent to such a process or method. Similarly, one or moredevices or subsystems or elements or structures or components preceded by"comprises... a" does not, without more constraints, preclude the existence of otherdevices, sub-systems, elements, structures, components, additional devices, additionalsub-systems, additional elements, additional structures or additional components.Appearances of the phrase "in an embodiment", "in another embodiment" and similarlanguage throughout this specification may, but not necessarily do, all refer to the sameembodiment.

[0021] Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by those skilled in the art to whichthis disclosure belongs. The system, methods, and examples provided herein are onlyillustrative and not intended to be limiting.

[0022] In the following specification and the claims, reference will be made to anumber of terms, which shall be defined to have the following meanings. The singularforms "a", "an", and "the" include plural references unless the context clearly dictatesotherwise.

[0023] Embodiment of the present disclosure relates to a system for processingstone material to produce manufactured sand. The system includes a horizontal shaftimpactor coupled to a horizontal rotating shaft. The horizontal shaft impactor is adaptedto crush and grind the stone material. The horizontal shaft impactor is retrofitted withan existing impactor. The horizontal shaft impactor includes a crushing chamberadapted to receive a pre-determined quantity of stone material through a first rotary airlock to regulate feed rate while preventing air leakage. The horizontal shaft impactorincludes a rotor connected to the crushing chamber. The rotor is adapted to generate ahot airflow through rapid horizontal rotation driven by a motor, facilitating an aircirculation within the crushing chamber. The rotor is adapted to create an upward dustflow for preventing the escape of oversized particles by redirecting the oversizedparticles into the crushing chamber. The system includes an induced draft fanoperatively connected to the horizontal shaft impactor. The induced draft fan is adaptedto extract fine dust carried by the hot airflow from the crushing chamber. The induceddraft fan is adapted to circulate an air stream throughout the system to maintain a fixedair quantity. The system includes a cyclone assembly operatively connected to theinduced draft fan. The cyclone assembly is adapted to separate and store the fine dustfrom the air stream. The cyclone assembly is adapted to release clean air back to theinduced draft fan through an air inlet duct for recirculation. The system includes asecond rotary air lock positioned at a lower end of the cyclone assembly. The secondrotary air lock is adapted to prevent the air with dust emission. The second rotary airlock is adapted to discharge the fine dust collected into a first fine dust conveyor. Thesystem includes an amibatic non-return air duct operatively connected to the induceddraft fan. The amibatic non-return air duct is adapted to prevent fine particles fromentering a discharge air duct. The amibatic non-return air duct is adapted to direct theclean air exiting the induced draft fan back into the horizontal shaft impactor, therebycompleting an operational air circulation sequence. The system includes a third rotaryair lock positioned at a discharge point of the horizontal shaft impactor. The third rotaryair lock is adapted to allow a final product processed to exit the horizontal shaftimpactor to a second fine dust conveyor after the processing. The system includes abag filter operatively connected to the induced draft fan. The bag filter is adapted tobypass excess air from the induced draft fan. The bag filter is equipped with electricallyvibrating mechanisms. The system includes a plurality of valves includes a butterflyvalve adapted to regulate air quantity passing through the air pipe from the induceddraft fan to the bag filter. The plurality of valves includes a pendulum valve adapted tocontrol discharge and air leakage from the bag filter. The bag filter with built-inpendulum and butterfly valves redirects the excess air. The system includes at least twohydraulic cylinders is adapted to provide unidirectional force through a unidirectionalstroke by converting hydraulic energy into mechanical energy to lift up and close-downof crushing chamber and chamber of the rotor.

[0024] FIG. 1 is a schematic representation of a system (100) for processing stonematerial to produce manufactured sand in accordance with an embodiment of thepresent disclosure. The system (100) includes a horizontal shaft impactor (HSI) (105)coupled to a horizontal rotating shaft. The horizontal rotating shaft operates parallel tothe ground. The horizontal shaft impactor (105) is adapted to crush and grind the stonematerial, using impact force, breaking down larger particles into finer aggregatessuitable for manufactured sand production, as it ensures controlled gradation, improvedparticle shape, and minimal fines. The horizontal shaft impactor (105) is retrofittedwith an existing impactor to achieve the desired sand gradation and shaping forconcrete and plastering sand production, meeting IS 383 ZONE II specifications.Example for the existing impactor includes a vertical shaft impactor (VSI), and the like.

[0025] The horizontal shaft impactor (105) includes a crushing chamber (110)adapted to receive a pre-determined quantity of stone material through a first rotary airlock (115) to regulate feed rate while preventing air leakage.

[0026] In an embodiment, the stone material is fed into the crushing chamber(110) from an input feeding conveyor via the first rotary air lock. The system (100)processes stone material with a maximum feed size of 20 mm. Below are the operatingcharacteristics of the horizontal shaft impactor (105):1. Strength of Material: Handles materials up to 200 MPa2. Mohs Hardness: Suitable for materials with a hardness of up to 73. Absolute Humidity: Operates effectively under conditions with upto 5% humidity4. Feed Size: Accepts material up to 20 mm in size5. Product Size: Produces particles smaller than 4.75 mm6. Capacity: Processes 25, 50, 75, 100, or 150 tons per hour,depending on the model

[0027] The horizontal shaft impactor (105) includes a rotor (120) connected tothe crushing chamber (110). The rotor (120) is adapted to generate a hot airflowthrough rapid horizontal rotation driven by a motor, facilitating an air circulation withinthe crushing chamber (110). More specifically, as stone material enters through theinput conveyor, the high-speed rotor motion creates impact and grinding forces,effectively breaking down the particles. The motor, such as an electric motor, providesthe necessary power to drive the rotor (120), enabling impact plates or blow bars of thehorizontal shaft impactor (105) to efficiently crush and grind the stone material.

[0028] Further, the rotor (120) creates an upward dust flow for preventing theescape of oversized particles by redirecting the oversized particles into the crushingchamber (110). The fine dust particles propelled upward from the horizontal shaftimpactor (105) is smaller than 150 microns in size, ensuring a refined final productwith minimal impurities.

[0029] In one embodiment, a body shell of the horizontal shaft impactor (105)serves a dual purpose by functioning as an air classifier's body shell chamber. Thedesign and dimensions of the horizontal shaft impactor (105)'s body shell are identicalto those of the air classifier chamber, allowing for seamless integration and efficientutilization.

[0030] It must be noted that the rotor (120) of the horizontal shaft impactor (105)operates at a high rotational speed, typically between 1000 to 1200 RPM. The rotor(120) is strategically positioned to maintain a speed that is approximately 600 RPM to800 RPM lower than that of the horizontal shaft impactor (105).

[0031] The system (100) includes an induced draft fan (125) operativelyconnected to the horizontal shaft impactor (105). The induced draft fan (125) is adaptedto extract fine dust carried by the hot airflow from the crushing chamber (110). Theinduced draft fan (125) is adapted to circulate an air stream throughout the system (100)to maintain a fixed air quantity.

[0032] In an embodiment, the induced draft fan (125) operates at a speed rangingfrom 800 to 960 revolutions per minute.

[0033] The system (100) includes a cyclone assembly (130) operativelyconnected to the induced draft fan (125). The cyclone assembly (130) is adapted toseparate and store the fine dust from the air stream. The cyclone assembly (130) isadapted to release clean air back to the induced draft fan (125) through an air inlet ductfor recirculation.

[0034] The system (100) includes a second rotary air lock (135) positioned at alower end of the cyclone assembly (130). The second rotary air lock (135) is adaptedto prevent the air with dust emission. The second rotary air lock (135) is adapted todischarge the fine dust collected into a first fine dust conveyor (138).

[0035] The system (100) includes an amibatic non-return air duct (140)operatively connected to the induced draft fan (125). The amibatic non-return air duct(140) is adapted to prevent fine particles from entering a discharge air duct. Theamibatic non-return air duct (140) is adapted to direct the clean air exiting the induceddraft fan (125) back into the horizontal shaft impactor (105), thereby completing anoperational air circulation sequence.

[0036] The system (100) includes a third rotary air lock (145) positioned at adischarge point of the horizontal shaft impactor (105). The third rotary air lock (145)is adapted to allow a final product processed to exit the horizontal shaft impactor (105)to a second fine dust conveyor (150) after the processing.

[0037] The system (100) includes a bag filter (155) operatively connected to theinduced draft fan (125). The bag filter (155) is adapted to bypass excess air from theinduced draft fan (125). The bag filter (155) is equipped with electrically vibratingmechanisms.

[0038] The system (100) includes a plurality of valves, includes a butterfly valve(160) adapted to regulate air quantity passing through the air pipe from the induceddraft fan (125) to the bag filter (155). The plurality of valves includes a pendulum valve(165) adapted to control discharge and air leakage from the bag filter (155). The bagfilter (155) with built-in pendulum and butterfly valve (160) redirects the excess air.

[0039] The system (100) includes at least two hydraulic cylinders (170, 175) isadapted to provide unidirectional force through a unidirectional stroke by convertinghydraulic energy into mechanical energy to lift up and close-down of crushing chamber(110) and chamber of the rotor (120).

[0040] Additionally, the system (100) includes a plurality of ducts. The pluralityof ducts includes a cyclonic and extraction duct (180), a centrifugal force duct (185),an induced draft air duct (190) and an air safety duct (195). The plurality of ducts isadapted to facilitate movement of the air and stone materials within the system (100).

[0041] The cyclonic and extraction duct (180) carries fine dust and hot air fromthe top outlet of the horizontal shaft impactor (105) to the dust collecting cycloneseparator. The process involves the fusion and extraction of dust through the top rotor.

[0042] The centrifugal force duct (185) is a half-radius shaped duct carrying freshand hot air from the air outlet of the dust collecting cyclone separator to the inlet of theinduced draft fan (125).

[0043] The induced draft air duct (190) carries fresh and hot air from the airdelivery point of the induced draft fan (125) to the bottom discharge of the horizontalshaft impactor (105) which connects through an amibatic system linked to the airclassifier.

[0044] The air safety duct (195) carries excess fresh and hot air forming insidethe induced draft air duct (190) to the bag filter (155), by passing it to the atmosphere.This process balances air quantity and pressure inside the system (100).

[0045] It must be noted that the plurality of ducts is constructed from Hardox 500material for preventing air leakage. The Hardox 500 material is a bendable andweldable abrasion-resistant steel with a nominal hardness of 500 HBW. Suitable forapplications that demand higher wear resistance.

[0046] The system (100) includes a supporting structure adapted to encompassall components of the system (100) including the horizontal shaft impactor (105), theinduced draft fan (125), the cyclone assembly (130), the amibatic non-return air duct(140), the bag filter (155), the plurality of valves, the plurality of ducts, the rotor (120),the plurality of rotary air lock, the at least two hydraulic cylinders (170, 175). Thesupporting structure is mounted on a mild steel support framework with appropriatecivil foundation.

[0047] Let's consider an example, a sand manufacturing company, "X",specializes in producing high-quality manufactured sand for the construction industry.To enhance efficiency and meet IS 383 ZONE II specifications for concrete andplastering applications, the company "X" implements the system for processing stonematerial. In operation, raw stone material (≤20mm) is fed into the crushing chamber ofthe horizontal shaft impactor (105) via the first rotary air lock (115), ensuring aregulated feed rate while preventing air leakage. The rotor (120), driven by the motor,generates high-speed impact forces, breaking down the material into finer aggregatessuitable for concrete and plastering applications. Simultaneously, the rotor's rapidhorizontal rotation creates a hot airflow, facilitating an upward dust flow that preventsoversized particles from escaping and recirculates them for further processing. Theinduced draft fan (125) extracts fine dust and maintains controlled airflow. The cycloneassembly (130) separates and stores the fine dust while recirculating clean air back intothe system through the amibatic non-return air duct (140). Finally, the processedmanufactured sand exits the system through the third rotary air lock (145) onto thesecond fine conveyor (150), ensuring compliance with IS 383 ZONE II specifications.Any excess air is managed through a bag filter (155), reducing dust emissions andensuring a clean working environment.

[0048] FIG. 2(a) illustrates a flow chart representing the steps involved in amethod (200) for processing stone material to produce manufactured sand inaccordance with an embodiment of the present disclosure. FIG. 2(b) illustratescontinued steps of the method (200) of FIG. 2 (a) in accordance with an embodimentof the present disclosure. FIG. 2(c) illustrates continued steps of the method (200) ofFIG. 2 (b) in accordance with an embodiment of the present disclosure. The method(200) includes crushing and grinding, by a horizontal shaft impactor, the stone material.The horizontal shaft impactor is retrofitted with an existing impactor in step 205. Thehorizontal rotating shaft operates parallel to the ground. More specifically, thehorizontal shaft impactor crush and grind the stone material, using impact force,breaking down larger particles into finer aggregates suitable for manufactured sandproduction, as it ensures controlled gradation, improved particle shape, and minimalfines. Further, the horizontal shaft impactor is retrofitted with the existing impactor toachieve the desired sand gradation and shaping for concrete and plastering sandproduction, meeting IS 383 ZONE II specifications. Example for the existing impactorincludes a vertical shaft impactor (VSI), and the like.

[0049] The method (200) includes receiving, by a crushing chamber, a pre-determined quantity of stone material through a first rotary air lock to regulate feed ratewhile preventing air leakage in step 210.

[0050] In an embodiment, the stone material is fed into the crushing chamberfrom an input feeding conveyor via the first rotary air lock. The system processes stonematerial with a maximum feed size of 20 mm.

[0051] The method (200) includes generating, by a rotor, a hot airflow throughrapid horizontal rotation driven by a motor, facilitating an air circulation within thecrushing chamber in step 215. More specifically, as stone material enters through theinput conveyor, the high-speed rotor motion creates impact and grinding forces,effectively breaking down the particles. The motor, such as an electric motor, providesthe necessary power to drive the rotor, enabling impact plates or blow bars of thehorizontal shaft impactor to efficiently crush and grind the stone material.

[0052] The method (200) includes creating, by the rotor, an upward dust flow forpreventing the escape of oversized particles by redirecting the oversized particles intothe crushing chamber in step 220. The fine dust particles propelled upward from thehorizontal shaft impactor is smaller than 150 microns in size, ensuring a refined finalproduct with minimal impurities.

[0053] It must be noted that the rotor of the horizontal shaft impactor operates ata high rotational speed, typically between 1000 to 1200 RPM. The rotor is strategicallypositioned to maintain a speed that is approximately 600 RPM to 800 RPM lower thanthat of the horizontal shaft impactor.

[0054] The method (200) includes extracting, by an induced draft fan, fine dustcarried by the hot airflow from the crushing chamber in step 225.

[0055] In an embodiment, the induced draft fan operates at a speed ranging from800 to 960 revolutions per minute.

[0056] The method (200) includes circulating, by the induced draft fan, an airstream throughout the system to maintain a fixed air quantity in step 230.

[0057] The method (200) includes separating and storing, by a cyclone assembly,the fine dust from the air stream in step 235.

[0058] The method (200) includes releasing, by the cyclone assembly, clean airback to the induced draft fan through an air inlet duct for recirculation in step 240.

[0059] The method (200) includes preventing, by a second rotary air lock, the airwith dust emission in step 245.

[0060] The method (200) includes discharging by the second rotary air lock. Thefine dust collected into a first fine dust conveyor in step 250.

[0061] The method (200) includes preventing, by an amibatic non-return air duct,fine particles from entering a discharge air duct in step 255.

[0062] The method (200) includes directing, by the amibatic non-return air duct,the clean air exiting the induced draft fan back into the horizontal shaft impactor,thereby completing an operational air circulation sequence in step 260.

[0063] The method (200) includes allowing, by a third rotary air lock, a finalproduct processed to exit the horizontal shaft impactor to a second fine dust conveyorafter the processing in step 265.

[0064] The method (200) includes bypassing, by a bag filter, excess air from theinduced draft fan. The bag filter is equipped with electrically vibrating mechanisms instep 270.

[0065] The method (200) includes regulating, by a butterfly valve of a pluralityof valves, air quantity passing through the air pipe from the induced draft fan to the bagfilter in step 275.

[0066] The method (200) includes controlling, by a pendulum valve of theplurality of valves discharge and air leakage from the bag filter. The bag filter withbuilt-in pendulum and butterfly valves redirects the excess air in step 280.

[0067] The method (200) includes providing, by at least two hydraulic cylinders,unidirectional force through a unidirectional stroke by converting hydraulic energy intomechanical energy to lift up and close-down of crushing chamber and chamber of therotor in step 285.

[0068] Additionally, the system includes a plurality of ducts. The plurality ofducts includes a cyclonic and extraction duct, a centrifugal force duct, an induced draftair duct and an air safety duct. The plurality of ducts is adapted to facilitate movementof the air and stone materials within the system.

[0069] The cyclonic and extraction duct carries fine dust and hot air from the topoutlet of the horizontal shaft impactor to the dust collecting cyclone separator. Theprocess involves the fusion and extraction of dust through the top rotor.

[0070] The centrifugal force duct is a half-radius shaped duct carrying fresh andhot air from the air outlet of the dust collecting cyclone separator to the inlet of theinduced draft fan.

[0071] The induced draft air duct carries fresh and hot air from the air deliverypoint of the induced draft fan to the bottom discharge of the horizontal shaft impactorwhich connects through an amibatic system linked to the air classifier.

[0072] The air safety duct carries excess fresh and hot air forming inside theinduced draft air duct to the bag filter, bypassing it to the atmosphere. This processbalances air quantity and pressure inside the system.

[0073] The system includes a supporting structure adapted to encompass allcomponents of the system including the horizontal shaft impactor, the induced draftfan, the cyclone assembly, the amibatic non-return air duct, the bag filter, the pluralityof valves, the plurality of ducts, the rotor, the rotary air lock, the at least two hydrauliccylinders. The supporting structure is mounted on a mild steel support framework withappropriate civil foundation.

[0074] Various embodiments of the system (100) and the method for processingstone material to produce manufactured sand as described above offer a completelysustainable innovation, ensuring consistent production of sand under all weatherconditions. The horizontal shaft impactor (105) 's body shell functions as an airclassification chamber, enabling effective separation of fine dust particles, whichenhances sand quality. The integration of the horizontal shaft impactor (105) with theinduced draft fan (125) creates a controlled airflow that facilitates fine dust extraction,air circulation, and overall system efficiency. Additionally, the retrofit of the horizontalshaft impactor (105) into a system with an existing impactor enhances sand productioncapabilities, achieving the required gradation for various applications such as concreteand plastering. The horizontal shaft impactor, along with the induced draft fan (125),cyclone assembly (130), and bag filter (155), enables operational adaptability tovarying moisture content in feed material, eliminating the need for fresh water andreducing dependence on water treatment chemicals. The system maintains lowermaintenance costs, prevents product loss by 15-20%, and produces 100% Zone II gradesand (ISO 383 standards). The system helps maintain plant cleanliness and reduceenvironmental impact, mitigating concerns from pollution control departments.Additionally, the system facilitates the sale of dry fine dust byproducts, ensuring aneco-friendly operation while enhancing profitability.

[0075] It will be understood by those skilled in the art that the foregoing generaldescription and the following detailed description are exemplary and explanatory ofthe disclosure and are not intended to be restrictive thereof.

[0076] While specific language has been used to describe the disclosure, anylimitations arising on account of the same are not intended. As would be apparent to aperson skilled in the art, various working modifications may be made to the method inorder to implement the inventive concept as taught herein.

[0077] The figures and the foregoing description give examples of embodiments.Those skilled in the art will appreciate that one or more of the described elements maywell be combined into a single functional element. Alternatively, certain elements maybe split into multiple functional elements. Elements from one embodiment may beadded to another embodiment. For example, the order of processes described hereinmay be changed and are not limited to the manner described herein. Moreover, theactions of any flow diagram need not be implemented in the order shown; nor do all ofthe acts need to be necessarily performed. Also, those acts that are not dependent onother acts may be performed in parallel with the other acts. The scope of embodimentsis by no means limited by these specific examples.

Claims

1. A system (100) for processing stone material to produce manufactured sand, comprising: characterized in that, a horizontal shaft impactor (105) coupled to a horizontal rotating shaft, wherein the horizontal shaft impactor (105) is adapted to crush and grind the stone material, wherein the horizontal shaft impactor (105) is retrofitted with an existing impactor, wherein the horizontal shaft impactor (105) comprising: a crushing chamber (110) adapted to receive a pre-determined quantity of stone material through a first rotary air lock (115) to regulate feed rate while preventing air leakage; a rotor (120) connected to the crushing chamber (110) wherein the rotor (120) is adapted to: generate a hot airflow through rapid horizontal rotation driven by a motor, facilitating an air circulation within the crushing chamber (110); and create an upward dust flow for preventing the escape of oversized particles by redirecting the oversized particles into the crushing chamber (110); an induced draft fan (125) operatively connected to the horizontal shaft impactor (105), wherein the induced draft fan (125) is adapted to: extract fine dust carried by the hot airflow from the crushing chamber (110); and circulate an air stream throughout the system (100) to maintain a fixed air quantity; a cyclone assembly (130) operatively connected to the induced draft fan (125), wherein the cyclone assembly (130) is adapted to: separate and store the fine dust from the air stream; and release clean air back to the induced draft fan (125) through an air inlet duct for recirculation; a second rotary air lock (135) positioned at a lower end of the cyclone assembly (130), wherein the second rotary air lock (135) is adapted to: prevent the air with dust emission; and discharge the fine dust collected into a first fine dust conveyor (138); an amibatic non-return air duct (140) operatively connected to the induced draft fan (125), wherein the amibatic non-return air duct (140) is adapted to: prevent fine particles from entering a discharge air duct; and direct the clean air exiting the induced draft fan (125) back into the horizontal shaft impactor (105), thereby completing an operational air circulation sequence; a third rotary air lock (145) positioned at a discharge point of the horizontal shaft impactor (105), wherein the third rotary air lock (145) is adapted to allow a final product processed to exit the horizontal shaft impactor (105) to a second fine dust conveyor (150) after the processing; a bag filter (155) operatively connected to the induced draft fan (125), wherein the bag filter (155) is adapted to bypass excess air from the induced draft fan (125), wherein the bag filter (155) is equipped with electrically vibrating mechanisms; a plurality of valves, comprising: a butterfly valve (160) adapted to regulate air quantity passing through the air pipe from the induced draft fan (125) to the bag filter (155); and a pendulum valve (165) adapted to control discharge and air leakage from the bag filter (155), wherein the bag filter (155) with built-in pendulum and butterfly valve (160) redirects the excess air; and at least two hydraulic cylinders (170, 175) is adapted to provide unidirectional force through a unidirectional stroke by converting hydraulic energy into mechanical energy to lift up and close-down of crushing chamber (110) and chamber of the rotor (120).

2. The system (100) as claimed in claim 1, comprising a plurality of ducts, wherein the plurality of ducts comprises a cyclonic and extraction duct (180), a centrifugal force duct (185), an induced draft air duct (190) and an air safety duct (195), wherein the plurality of ducts is adapted to facilitate movement of the air and stone materials within the system (100).

3. The system (100) as claimed in claim 1, wherein the feed size of the stone material processed in the horizontal shaft impactor (105) is up to 20 mm.

4. The system (100) as claimed in claim 1, wherein the horizontal shaft impactor (105) has a processing capacity ranging from 25 to 150 tons per hour.

5. The system (100) as claimed in claim 1, wherein the fine dust particles propelled upward from the horizontal shaft impactor (105) is smaller than 150 microns in size.

6. The system (100) as claimed in claim 1, wherein the plurality of ducts is constructed from Hardox 500 material for preventing air leakage.

7. The system (100) as claimed in claim 1, comprising a supporting structure adapted to encompass all components of the system (100) comprising the horizontal shaft impactor (105), the induced draft fan (125), the cyclone assembly (130), the amibatic non-return air duct (140), the bag filter (155), the plurality of valves, the plurality of ducts, the rotor (120), the plurality of rotary air lock, the at least two hydraulic cylinders (170, 175).

8. A method (200) for processing stone material to produce manufactured sand, comprising: characterized in that, crushing and grinding, by a horizontal shaft impactor, the stone material, wherein the horizontal shaft impactor is retrofitted with an existing impactor; (205) receiving, by a crushing chamber, a pre-determined quantity of stone material through a first rotary air lock to regulate feed rate while preventing air leakage; (210) generating, by a rotor, a hot airflow through rapid horizontal rotation driven by a motor, facilitating an air circulation within the crushing chamber; (215) creating, by the rotor, an upward dust flow for preventing the escape of oversized particles by redirecting the oversized particles into the crushing chamber; (220) extracting, by an induced draft fan, fine dust carried by the hot airflow from the crushing chamber; (225) circulating, by the induced draft fan, an air stream throughout the system to maintain a fixed air quantity; (230) separating and storing, by a cyclone assembly, the fine dust from the air stream; (235) releasing, by the cyclone assembly, clean air back to the induced draft fan through an air inlet duct for recirculation; (240) preventing, by a second rotary air lock, the air with dust emission; (245) discharging, by the second rotary air lock, the fine dust collected into a first fine dust conveyor; (250) preventing, by an amibatic non-return air duct, fine particles from entering a discharge air duct; (255) directing, by the amibatic non-return air duct, the clean air exiting the induced draft fan back into the horizontal shaft impactor, thereby completing an operational air circulation sequence; (260) allowing, by a third rotary air lock, a final product processed to exit the horizontal shaft impactor to a second fine dust conveyor after the processing; (265) bypassing, by a bag filter, excess air from the induced draft fan, wherein the bag filter is equipped with electrically vibrating mechanisms; (270) regulating, by a butterfly valve of a plurality of valves, air quantity passing through the air pipe from the induced draft fan to the bag filter; (275) controlling, by a pendulum valve of the plurality of valves, discharge and air leakage from the bag filter, wherein the bag filter with built-in pendulum and butterfly valves redirects the excess air; and (280) providing, by at least two hydraulic cylinders, unidirectional force through a unidirectional stroke by converting hydraulic energy into mechanical energy to lift up and close-down of crushing chamber and chamber of the rotor. (285).