A sand optimizer and a method thereof

Abstract

A sand optimizer (100) is disclosed A vertical shaft impactor crusher (105) includes a crushing chamber (110) to process stone material. A rotor (105A) generates a hot airflow and directs an upward dust flow. An induced draft fan (125) extracts fine dust and circulates air stream. A cyclone assembly (130) collect fine dust and separate clean air. A second rotary air lock (135) prevents the air with dust emission and allow the fine dust to exit the cyclone assembly. An amibatic non-return air duct (140) prevents fine particles from entering a discharge air duct and direct the clean air into the vertical shaft impactor crusher. A third rotary air lock (145) allows a final product to exit. A bag filter (155) bypass excess air. A plurality of valves including a butterfly valve and pendulum valve. At least two hydraulic cylinders provide unidirectional force by converting hydraulic energy into mechanical energy.

Description

[0001] A SAND OPTIMIZER AND A METHOD THEREOF

[0002] EARLIEST PRIORITY DATE:

[0003] This Application claims priority from a Complete patent application filed in India having Patent Application No. 202421048442, filed on June 24, 2024, and titled “A SAND OPTIMIZER AND A METHOD THEREOF”.

[0004] FIELD OF INVENTION

[0005] Embodiments of the present disclosure relate to the field of sand manufacturing, and more particularly, a sand optimizer and a method thereof.

[0006] BACKGROUND

[0007] Sand manufacturing industry is essential due to the rising demand for sand. The sand manufacturing process involves sand washing plants which play a crucial role in the construction and mining industries by removing dirt from sand and producing clean, high-quality sand for various uses. The sand washing plants face a variety of challenges that can be categorized into environmental, technical, and economical aspects. One of the primary issues is securing a consistent water supply for sand washing throughout the year, which presents a significant obstacle. Further, operations often face opposition from local communities and conflicts with the public and environmental regulatory bodies are major challenges to the business. Other challenges include the increased costs for sludge settling chemicals, higher production loss due to sludge formation, ongoing maintenance issues, substantial investments in constructing water storage and settling tanks, as well as equipment for water and sludge transportation.

[0008] Additionally, air classifier systems are commonly employed as alternatives to sand washing plants. However, they come with their own set of challenges. A significant issue is that existing air classifiers follow the open-air theory and airbag filtration, which can't effectively clean sand during humid conditions because the moisture causes the feed material to obstruct the airbag filters. As a result, the sand becomes stiff and concreate and the micron filtration unfeasible. Further, maintaining the airbags is expensive, and even a simple crack in the airbag can halt the entire operation. The existing air classifiers also require technically skilled engineers to manage the solenoid valve pressure system. Moreover, the initial and maintenance costs of air classifiers are high for many small to medium-sized enterprises.

[0009] Hence, there is a need for a sand optimizer and a method thereof which addresses the aforementioned issue(s).

[0010] OBJECTIVES OF THE INVENTION

[0011] The primary objective of the invention is to use a vertical shaft impactor crusher for crushing and grinding of stone material optimizes the reduction of materials to the required sizes.

[0012] Another objective of the invention is to integrate a rotor to direct an upward dust flow for preventing the escape of oversized particles by diverting the oversized particles back into the vertical shaft impactor crusher.

[0013] Yet another objective of the invention is to incorporate components that enhance air and dust management. The components include a cyclone assembly to separates fine dust from the air, releasing clean air back into the vertical shaft impactor crusher, an amibatic non-return air duct to prevent fine particles from entering a discharge air duct and direct the clean air exiting the induced draft fan back into the vertical shaft impactor crusher, and a bag filter for managing and filtering out excess air.

[0014] Yet another objective of the invention is to include a plurality of valves for precise control over air flow and stone material handling. BRIEF DESCRIPTION

[0015] In accordance with an embodiment of the present disclosure, a sand optimizer is provided. The sand optimizer includes a vertical shaft impactor crusher. The vertical shaft impactor crusher includes a crushing chamber adapted to receive a predetermined quantity of stone material via a first rotary air lock. The first rotary air lock is adapted to regulate the intake of the stone material. The crushing chamber is adapted to process the stone material by crushing and grinding. The vertical shaft impactor crusher includes a rotor coupled to the crushing chamber. The rotor is adapted to generate a hot airflow through rapid rotation of the vertical shaft impactor crusher thereby contributing to hot air circulation within the crushing chamber. The rotor is adapted to direct an upward dust flow for preventing the escape of oversized particles by diverting the oversized particles back into the vertical shaft impactor crusher. The sand optimizer includes an induced draft fan operatively coupled to the vertical shaft impactor crusher. The induced draft fan is adapted to extract fine dust carried by the hot airflow. The induced draft fan is adapted to circulate air stream throughout the sand optimizer to maintain a fixed air quantity. The sand optimizer includes a cyclone assembly operatively coupled to the induced draft fan. The cyclone assembly is adapted to collect the fine dust from the air stream. The cyclone assembly is adapted to separate clean air from the dust. The clean air is released into the induced draft fan via an air inlet duct for recirculation. The sand optimizer includes a second rotary air lock positioned at a lower side of the cyclone assembly. The second rotary air lock is adapted to prevent the air with dust emission. The second rotary air lock is adapted to allow the fine dust to exit the cyclone assembly and enter into a fine dust conveyor. The sand optimizer includes an amibatic non-return air duct operatively coupled to the induced draft fan. The amibatic non-return air duct is adapted 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 into the vertical shaft impactor crusher, thereby completing an operational air circulation sequence. The sand optimizer includes a third rotary air lock positioned at a discharge point of the vertical shaft impactor crusher. The rotary air lock is adapted to allow a final product to exit the vertical shaft impactor crusher to a final conveyor after the processing. The sand optimizer includes a bag filter adapted to bypass excess air from the induced draft fan. The bag filter is equipped with electrical vibrating mechanisms. The sand optimizer includes a plurality of valves including a butterfly valve adapted to adjust air quantity passing through an air pipe from induced draft fan to bag filter. The plurality of valves includes a pendulum valve adapted to control discharge and air leakage from the bag filter. The bag filter with built-in pendulum and butterfly valves redirects the excess air. The sand optimizer includes at least two hydraulic cylinders. The at least two hydraulic cylinders are 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 and chamber of a top rotor of sand optimizer.

[0016] In accordance with another embodiment of the present disclosure, a method to operate a sand optimizer is provided. The method includes receiving, by a crushing chamber, a pre-determined quantity of stone material via a first rotary air lock. The first rotary air lock is adapted to regulate the intake of the stone material. The method includes processing by the crushing chamber, the stone material by crushing and grinding. The method includes generating, by a rotor, a hot airflow through rapid rotation of the vertical shaft impactor crusher thereby contributing to hot air circulation within the crushing chamber. The method includes directing, by the rotor, an upward dust flow for preventing the escape of oversized particles by diverting the oversized particles back into the vertical shaft impactor crusher. The method includes extracting, by an induced draft fan, fine dust carried by the hot airflow. The method includes circulating, by the induced draft fan, air stream throughout the sand optimizer to maintain a fixed air quantity. The method includes collecting, by a cyclone assembly, the fine dust from the air stream. The method includes separating, by the cyclone assembly, clean air from the dust. The clean air is released into the induced draft fan via an air inlet duct for recirculation. The method includes preventing the air with dust emission by a second rotary air lock. The method includes allowing, by the second rotary air lock, the fine dust to exit the cyclone assembly and enter into a fine dust conveyor. The method includes preventing, by an amibatic non-return air duct, fine particles from entering a discharge air duct. The method includes directing, by the amibatic non-return air duct, the clean air exiting the induced draft fan back into the vertical shaft impactor crusher, thereby completing an operational air circulation sequence. The method includes allowing, by a third rotary air lock, a final product to exit the vertical shaft impactor crusher to a final conveyor after the processing. The method includes bypassing, by a bag filter, excess air from the induced draft fan, wherein the bag filter is equipped with electrically vibrating mechanisms. The method includes adjusting, by a butterfly valve, air quantity passing through an air pipe from induced draft fan to bag filter. The method includes controlling, by a pendulum valve, discharge and air leakage from the bag filter. The bag filter with built-in pendulum and butterfly valves redirects the excess air. The method includes 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 a top rotor of sand optimizer.

[0017] To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.

[0018] BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which: FIG. 1 is a schematic representation of a sand optimizer in accordance with an embodiment of the present disclosure;

[0020] FIG. 2 is a schematic representation of a hydraulic cylinder in action position shown in FIG. 1 in accordance with an embodiment of the present disclosure;

[0021] FIG. 3(a) illustrates a flow chart representing the steps involved in a method to operate a sand optimizer in accordance with an embodiment of the present disclosure;

[0022] FIG. 3(b) illustrates continued steps of the method of FIG. 3 (a) in accordance with an embodiment of the present disclosure; and

[0023] FIG. 3(c) illustrates continued steps of the method of FIG. 3(b) in accordance with an embodiment of the present disclosure.

[0024] Further, those skilled in the art will appreciate that elements in the figures are 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 the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

[0025] DETAILED DESCRIPTION

[0026] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.

[0027] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or subsystems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

[0028] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

[0029] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

[0030] Embodiment of the present disclosure relates to a sand optimizer. The sand optimizer includes a vertical shaft impactor crusher. The vertical shaft impactor crusher includes a crushing chamber adapted to receive a pre-determined quantity of stone material via a first rotary air lock. The first rotary air lock is adapted to regulate the intake of the stone material. The crushing chamber is adapted to process the stone material by crushing and grinding. The vertical shaft impactor crusher includes a rotor coupled to the crushing chamber. The rotor is adapted to generate a hot airflow through rapid rotation of the vertical shaft impactor crusher thereby contributing to hot air circulation within the crushing chamber. The rotor is adapted to direct an upward dust flow for preventing the escape of oversized particles by diverting the oversized particles back into the vertical shaft impactor crusher. The sand optimizer includes an induced draft fan operatively coupled to the vertical shaft impactor crusher. The induced draft fan is adapted to extract fine dust carried by the hot airflow. The induced draft fan is adapted to circulate air stream throughout the sand optimizer to maintain a fixed air quantity. The sand optimizer includes a cyclone assembly operatively coupled to the induced draft fan. The cyclone assembly is adapted to collect the fine dust from the air stream. The cyclone assembly is adapted to separate clean air from the dust. The clean air is released into the induced draft fan via an air inlet duct for recirculation. The sand optimizer includes a second rotary air lock positioned at a lower side of the cyclone assembly. The second rotary air lock is adapted to prevent the air with dust emission. The second rotary air lock is adapted to allow the fine dust to exit the cyclone assembly and enter into a fine dust conveyor. The sand optimizer includes an amibatic non-return air duct operatively coupled to the induced draft fan. The amibatic non-return air duct is adapted 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 into the vertical shaft impactor crusher, thereby completing an operational air circulation sequence. The sand optimizer includes a third rotary air lock positioned at a discharge point of the vertical shaft impactor crusher. The rotary air lock is adapted to allow a final product to exit the vertical shaft impactor crusher to a final conveyor after the processing. The sand optimizer includes a bag filter adapted to bypass excess air from the induced draft fan. The bag filter is equipped with electrical vibrating mechanisms. The sand optimizer includes a plurality of valves including a butterfly valve adapted to adjust air quantity passing through an air pipe from induced draft fan to bag filter. The plurality of valves includes a pendulum valve adapted to control discharge and air leakage from the bag filter. The bag filter with built-in pendulum and butterfly valves redirects the excess air. The sand optimizer includes at least two hydraulic cylinders. The at least two hydraulic cylinders are 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 and chamber of a top rotor of sand optimizer.

[0031] FIG. 1 is a schematic representation of a sand optimizer (100) in accordance with an embodiment of the present disclosure. The sand optimizer (100) includes a vertical shaft impactor crusher (105). The vertical shaft impactor crusher (105) includes a crushing chamber (110) adapted to receive a pre-determined quantity of stone material via a first rotary air lock (115). The first rotary air lock (115) is adapted to regulate the intake of the stone material. The crushing chamber (110) is adapted to process the stone material by crushing and grinding.

[0032] The vertical shaft impactor crusher (105) is a type of a mill that reduces particles of material into smaller, finer particles by propelling them against a hard surface within the mill, known as the wear plate. It is effective for grinding both hard and friable materials with minimal metallic waste.

[0033] In an embodiment, the stone material is fed to the crushing chamber (110) via the first rotary air lock (115), sourced directly from an input feeding conveyor. The stone material sized up to -45mm, is introduced into the crushing chamber (110). Below provided the operating characteristics of the vertical shaft impactor crusher (105):

[0034] 1. Strength of Material: Can handle up to 200 MPa.

[0035] 2. Mohs Hardness: Suitable for materials with a hardness of up to 7

[0036] 3. Absolute Humidity: Operates effectively under conditions with up to 5% humidity.

[0037] 4. Feed Size: Accepts material up to 40 mm in size.

[0038] 5. Product Size: Produces particles smaller than 4.75 mm. 6. Capacity: Can process up to 25,50,75, 100, 150 tons per hour as per the model of Sand Optimizer

[0039] In one embodiment, the vertical shaft impactor crusher (105) body shell is employed as an air classifier body shell chamber. The body shell of the vertical shaft impactor crusher (105) is also utilized as the body shell chamber for the Air Classifier, sharing identical dimensions and design.

[0040] The sand optimizer (100) combines the functionalities of the air classifier and the vertical shaft impactor into a single unit. This integration necessitates specific modifications to accommodate the combined processes effectively. The result is a dualfunction machine, the "SAND OPTIMIZER," which simplifies operations by housing both mechanisms within a common shell.

[0041] Additionally, the sand optimizer (100) features a top-loading inlet and operates using a single electric motor that drives both the vertical shaft impactor and the air classifier. The rotor is specially adapted to perform multiple operations including crushing, grinding, classifying, and impacting, enhancing the efficiency and functionality of the unit.

[0042] The vertical shaft impactor crusher (105) includes a rotor (105-A) coupled to the crushing chamber (110). The rotor (105-A) accelerates the stone material using centrifugal force towards the crushing chamber (110). As the rotor (105-A) spins, the centrifugal force accelerates the stone material outward toward the walls of the crushing chamber (110). Subsequently, the material is flung with great energy against hard surfaces, thereby being crushed and broken down into smaller particles. Further, the rotor (105-A) generates a hot airflow through rapid rotation of the vertical shaft impactor crusher (105) thereby contributing to air circulation within the crushing chamber (110). The rotor (105-A) is adapted to direct an upward dust flow for preventing the escape of oversized particles by diverting the oversized particles back into the vertical shaft impactor crusher (105). The dust flow propelled upward is smaller than -150 microns.

[0043] It must be noted that the rotor (105 -A) of the vertical shaft impactor operates at a high rotational speed, typically between 1400 and 1500 RPM. A top rotor (120) is strategically positioned to maintain a speed approximately 600 to 800 RPM lower than that of the vertical shaft impactor crusher (105).

[0044] The sand optimizer (100) includes an induced draft fan (125) operatively coupled to the vertical shaft impactor crusher (105). The induced draft fan (125) is adapted to extract fine dust carried by the hot airflow. The induced draft fan (125) is adapted to circulate air stream throughout the sand optimizer (100) to maintain a fixed air quantity.

[0045] In one embodiment, the induced draft fan (125) operates at a speed ranging from 800 to 960 revolutions per minute.

[0046] The sand optimizer (100) includes a cyclone assembly (130) operatively coupled to the induced draft fan (125). The cyclone assembly (130) is adapted to collect the fine dust from the air stream. The cyclone assembly (130) is adapted to separate clean air from the dust. The clean air is released into the induced draft fan (125) via an air inlet duct for recirculation.

[0047] The sand optimizer (100) includes a second rotary air lock (135) positioned at a lower side of the cyclone assembly (130). The second rotary air lock is adapted to prevent the air with dust emission. The second rotary air lock is adapted to allow the fine dust to exit the cyclone assembly (130) and enter into a fine dust conveyor (169).

[0048] The sand optimizer (100) includes an amibatic non -return air duct (140) operatively coupled 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. The amibatic nonreturn air duct (140) is adapted to direct the clean air exiting the induced draft fan (125) back into the vertical shaft impactor crusher (105), thereby completing an operational air circulation sequence.

[0049] The sand optimizer (100) includes a third rotary air lock (145) positioned at a discharge point of the vertical shaft impactor crusher (105). The third rotary air lock (145) is adapted to allow a final product to exit the vertical shaft impactor crusher (105) to a final conveyor (150) after the processing.

[0050] The sand optimizer (100) includes a bag filter (155) adapted to bypass excess air from the induced draft fan (125). The bag filter (155) is equipped with electrically vibrating mechanisms. The bag filter (155) functions as an additional safety measure.

[0051] The sand optimizer (100) includes a plurality of valves including a butterfly valve adapted to adjust air quantity passing through an air pipe from induced draft fan (125) to bag filter (155). The plurality of valves includes a pendulum valve adapted to control discharge and air leakage from the bag filter (155). The butterfly valves redirect the excess air produced by the induced draft fan (125).

[0052] The sand optimizer (100) includes at least two hydraulic cylinders. The at least two hydraulic cylinders (170, 175) (electrically operated) 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 top rotor (120) of sand optimizer (100).

[0053] The sand optimizer (100) includes a plurality of ducts. The plurality of ducts includes a cyclonic and extraction duct (180), a centrifugal force duct (185), a induced draft air duct (190) and an air safety duct (195). The plurality of ducts is adapted to facilitate movement of the air and stone materials within the sand optimizer (100). The cyclonic and extraction duct ( 180) carries fine dust and hot air from the top outlet of the vertical shaft impactor crusher (105) to the dust collecting cyclone separator. The process involves the fusion and extraction of dust through the top rotor (120).

[0054] The centrifugal force duct (185) is a half-radius shaped duct carrying fresh and hot air from the air outlet of the dust collecting cyclone separator to the inlet of the induced draft fan (125).

[0055] The induced draft air duct (190) carries fresh and hot air from the air delivery point of the induced draft fan (125) to the bottom discharge of the Vertical Shaft Impactor crusher (105) which connects through an amibatic system (140) linked to the Air Classifier.

[0056] The air safety duct (195) carries excess fresh and hot air forming inside the induced draft air duct (190) to the bag filter (155), bypassing it to the atmosphere. This process balances air quantity and pressure inside the sand optimizer (100).

[0057] It must be noted that the plurality of ducts is constructed from Hardox 500 material for preventing air leakage. The Hardox 500 material is a bendable and weldable abrasionresistant steel with a nominal hardness of 500 HBW. Suitable for applications that demand higher wear resistance.

[0058] The sand optimizer (100) includes a supporting structure adapted to encompass all components of the sand optimizer (100) comprising vertical shaft impactor crusher (105), induced draft fan (125), cyclone assembly (130), amibatic non-return air duct (140), bag filter (155), a plurality of valves (165, 160), a plurality of ducts, arotor (105- A), a plurality of rotary air lock (115,135, 145) , at least two hydraulic cylinders (170, 175). The supporting structure is mounted on a mild steel support framework with appropriate civil foundation. Consider an example where stone material, with a size of up to -40mm, is fed into the sand optimizer via the first rotary air lock (115), that regulates the intake, ensuring a consistent and controlled feed into the vertical shaft impactor crusher (105). Once inside, the stone material is rapidly crushed and ground by the crusher’s rotor which spins at high speeds, generating a hot airflow that enhances circulation within the crushing chamber. The rotor (105-A) also directs upward dust flow to capture and redirect oversized particles back into the crusher for further processing. The fine dust generated is extracted by the induced draft fan (125) and passed through the cyclone assembly (130) where it is separated from clean air. The clean air is recirculated back into the crusher, while the fine dust is collected and moved out via a second rotary air lock. The final processed material exits through the third rotary air lock to the fine conveyor (150), ready for use, all while ensuring minimal environmental impact and maximizing efficiency.

[0059] FIG. 2 is a schematic representation of a hydraulic cylinder in action position shown in FIG. 1 in accordance with an embodiment of the present disclosure. The hydraulic cylinder is depicted lifting a top rotor (120) assembly and the VSI (110) chamber. The respective hydraulic cylinders (170, 175) are utilized to provide the necessary unidirectional force through a unidirectional stroke, converting hydraulic energy into mechanical energy to facilitate the lifting and precise positioning of both the top rotor (120) and the VSI chamber. This mechanism ensures efficient operation and maintenance of the sand optimizer (100) by allowing easy access to critical components.

[0060] FIG. 3(a) illustrates a flow chart representing the steps involved in a method (200) to operate a sand optimizer in accordance with an embodiment of the present disclosure. FIG. 3(b) illustrates continued steps of the method (200) of FIG. 3 (a) in accordance with an embodiment of the present disclosure. FIG. 3(c) illustrates continued steps of the method (200) of FIG. 3(b) in accordance with an embodiment of the present disclosure. The method (200) includes receiving, by a crushing chamber, a predetermined quantity of stone material via a first rotary air lock. The first rotary air lock is adapted to regulate the intake of the stone material in step 205.

[0061] The method (200) includes processing by the crushing chamber, the stone material by crushing and grinding in step 210.

[0062] The vertical shaft impactor crusher is a type of a mill that reduces particles of material into smaller, finer particles by propelling them against a hard surface within the mill, known as the wear plate. It is effective for grinding both hard and friable materials with minimal metallic waste.

[0063] In an embodiment, the stone material is fed to the crushing chamber via the first rotary air lock, sourced directly from an input feeding conveyor. The stone material sized up to -45mm, is introduced into the crushing chamber.

[0064] The method (200) includes generating, by a rotor, a hot airflow through rapid rotation of the vertical shaft impactor crusher thereby contributing to hot air circulation within the crushing chamber in step 215. The rotor accelerates the stone material using centrifugal force towards the crushing chamber. As the rotor spins, the centrifugal force accelerates the stone material outward toward the walls of the crushing chamber. In doing so, the material is flung with great energy against hard surfaces, thereby being crushed and broken down into smaller particles.

[0065] The method (200) includes directing, by the rotor, an upward dust flow for preventing the escape of oversized particles by diverting the oversized particles back into the vertical shaft impactor crusher in step 220. The dust flow propelled upward is smaller than -150 microns.

[0066] It must be noted that the rotor of the vertical shaft impactor operates at a high rotational speed, typically between 1400 and 1500 RPM. The rotor is strategically positioned to maintain a speed approximately 600 to 800 RPM lower than that of the vertical shaft impactor crusher.

[0067] The method (200) includes extracting, by an induced draft fan, fine dust carried by the hot airflow in step 225.

[0068] In one embodiment, the induced draft fan operates at a speed ranging from 800 to 960 revolutions per minute.

[0069] The method (200) includes circulating, by the induced draft fan, air stream throughout the sand optimizer to maintain a fixed air quantity in step 230.

[0070] In one embodiment, the induced draft fan operates at a speed ranging from 800 to 960 revolutions per minute.

[0071] The method (200) includes collecting, by a cyclone assembly, the fine dust from the air stream in step 235.

[0072] The method (200) includes separating, by the cyclone assembly, clean air from the dust. The clean air is released into the induced draft fan via an air inlet duct for recirculation in step 240.

[0073] The method (200) includes preventing, by a second rotary air lock, the air with dust emission in step 245.

[0074] The method (200) includes allowing, by the second rotary air lock, the fine dust to exit the cyclone assembly and enter into a fine dust conveyor in step 250.

[0075] The method (200) includes preventing, by an amibatic non-return air duct, fine particles from entering a discharge air duct in step 255. The method (200) includes directing, by the amibatic non-return air duct, the clean air exiting the induced draft fan back into the vertical shaft impactor crusher, thereby completing an operational air circulation sequence in step 260.

[0076] The method (200) includes allowing, by a third rotary air lock, a final product to exit the vertical shaft impactor crusher to a final conveyor after the processing in step 265.

[0077] The method (200) includes bypassing, by a bag filter, excess air from the induced draft fan, wherein the bag filter is equipped with electrically vibrating mechanisms in step 270. The bag filter functions as an additional safety measure.

[0078] The method (200) includes adjusting, by a butterfly valve, air quantity passing through an air pipe from induced draft fan to bag filter in step 275.

[0079] The method (200) includes controlling, by a pendulum valve, discharge and air leakage from the bag filter. The bag filter with built-in pendulum and butterfly valves redirects the excess air in step 280.

[0080] The method (200) includes 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 a top rotor of sand optimizer in step 285.

[0081] Additionally, facilitating, by a plurality of ducts movement of the air and stone materials within the sand optimizer. The plurality of ducts includes a cyclonic and extraction duct, a centrifugal force duct, a induced draft air duct and an air safety duct..

[0082] It must be noted that the plurality of ducts is constructed from Hardox 500 material for preventing air leakage. The Hardox 500 material is a bendable and weldable abrasionresistant steel with a nominal hardness of 500 HBW. Suitable for applications that demand higher wear resistance. The sand optimizer includes a supporting structure adapted to encompass all components of the sand optimizer comprising vertical shaft impactor crusher, induced draft fan, cyclone, amibatic non-return air duct, bag filter, a plurality of valves and a plurality of ducts. The supporting structure is mounted on a mild steel support framework with appropriate civil foundation.

[0083] V arious embodiments of the sand optimizer and the method thereof as described above reduces the dependency on large quantities of fresh water, enhancing plant cleanliness and mitigating pollution-related issues that often arise from public and government scrutiny. The sand optimizer reduces product loss by 15-20% and eliminates the extra costs associated with water treatment chemicals. The sand optimizer provides a controlled environment for sand processing by using a vertical shaft impactor crusher, cyclone assembly and bag filter and the like. Further, the sand optimizer achieves consistent production under all weather conditions and adapts seamlessly to varying moisture content in the stone material, which allows for production even with moist inputs. Maintenance costs are lowered due to fewer mechanical and water-related issues. Notably, the sand produced meets 100% of the Zone II grade ISO383 standards, ensuring high-quality output. Furthermore, the sand optimizer establishes an eco- friendly operation that not only minimizes environmental impact but also allows for the successful sale of the dry fine dust byproduct of sand production. Additionally, the sand optimizer operates using sequential rules as a unified method, achieved by integrating the vertical shaft impactor and air classifier.

[0084] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof. While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. 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 may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.

Claims

CLAIM:

1. A sand optimizer (100) comprising: characterized in that, a vertical shaft impactor crusher (105) comprising: a crushing chamber (110) adapted to: receive a pre-determined quantity of stone material via a first rotary air lock (115) wherein the first rotary air lock (115) is adapted to regulate the intake of the stone material; and process the stone material by crushing and grinding; a rotor (105 -A) coupled to the crushing chamber (110) wherein the rotor (105 -A) is adapted to: generate a hot airflow through rapid rotation of the vertical shaft impactor crusher (105) thereby contributing to hot air circulation within the crushing chamber (110); and direct an upward dust flow for preventing the escape of oversized particles by diverting the oversized particles back into the vertical shaft impactor crusher (105); an induced draft fan (125) operatively coupled to the vertical shaft impactor crusher (105), wherein the induced draft fan (125) is adapted to: extract fine dust carried by the hot airflow; and circulate air stream throughout the sand optimizer (100) to maintain a fixed air quantity;a cyclone assembly (130) operatively coupled to the induced draft fan (125) (125), wherein the cyclone assembly (130) is adapted to: collect the fine dust from the air stream; and separate clean air from the dust, wherein the clean air is released into the induced draft fan (125) via an air inlet duct for recirculation; a second rotary air lock (135) positioned at a lower side of the cyclone assembly (130), wherein the second rotary air lock (135) is adapted to: prevent the air with dust emission; and allow the fine dust to exit the cyclone assembly ( 130) and enter into a fine dust conveyor (169); an amibatic non-return air duct (140) operatively coupled 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; direct the clean air exiting the induced draft fan (125) back into the vertical shaft impactor crusher (105), thereby completing an operational air circulation sequence; a third rotary air lock (145) positioned at a discharge point of the vertical shaft impactor crusher (105), wherein the rotary air lock is adapted to allow a final product to exit the vertical shaft impactor crusher (105) to a final conveyor (150) after the processing; a bag filter (155) 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 adjust air quantity passing through an air pipe from induced draft fan (125) to 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 valves 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 a top rotor (120) of sand optimizer (100).

2. The sand optimizer (100) as claimed on claim 1, comprising a plurality of ducts, wherein the plurality of ducts comprises a cyclonic and extraction duct (180), a centrifugal force duct (185), a 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 sand optimizer (100).

3. The sand optimizer (100) as claimed in claim 1, wherein the stone material sized up to minus 45mm, is introduced into the crushing chamber (110) of the vertical shaft impactor crusher (105).

4. The sand optimizer (100) as claimed in claim 1, wherein the dust flow propelled upward is smaller than 150 microns in size.

5. The sand optimizer (100) as claimed in claim 1, wherein the final product conforms to IS 383 Zone II grade specification.

6. The sand optimizer (100) as claimed in claim 1, wherein the induced draft fan (125) operates at a speed ranging from 800 to 960 revolutions per minute.

7. The sand optimizer (100) as claimed in claim 1, comprises a supporting structure adapted to encompass all components of the sand optimizer (100) comprising vertical shaft impactor crusher (105), induced draft fan (125), cyclone assembly (130), amibatic non-return air duct (140), bag filter (155), a plurality of valves (165, 160) a plurality of ducts, a top rotor (120), a plurality of rotary air lock (115,135, 145) , and at least two hydraulic cylinder (170,175), wherein the supporting structure is mounted on a mild steel support framework with appropriate civil foundation with walkway adapted with handrail and staircase.

8. The sand optimizer (100) as claimed in claim 1, wherein the rotor (105-A) accelerates the stone material using centrifugal force towards the crushing chamber (HO).

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

10. A method (200) to operate a sand optimizer comprising: characterized in that, receiving, by a crushing chamber, a pre-determined quantity of stone material via a first rotary air lock wherein the first rotary air lock is adapted to regulate the intake of the stone material; (205) processing, by the crushing chamber, the stone material by crushing and grinding; (210)generating, by a rotor, a hot airflow through rapid rotation of a vertical shaft impactor crusher thereby contributing to air circulation within the crushing chamber; (215) directing, by the rotor, an upward dust flow for preventing the escape of oversized particles by diverting the oversized particles back into the vertical shaft impactor crusher; (220) extracting, by an induced draft fan, fine dust carried by the hot airflow; (225) circulating, by the induced draft fan, air stream throughout the sand optimizer to maintain a fixed air quantity; (230) collecting, by a cyclone assembly, the fine dust from the air stream; (235) separating, by the cyclone assembly, clean air from the dust, wherein the clean air is released into the induced draft fan via an air inlet duct for recirculation; (240) preventing, by a second rotary air lock, the air with dust emission; (245) allowing, by the second rotary air lock, the fine dust to exit the cyclone assembly and enter into a 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 vertical shaft impactor crusher, thereby completing an operational air circulation sequence; (260) allowing, by a third rotary air lock, a final product to exit the vertical shaft impactor crusher to a final 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) adjusting, by a butterfly valve, air quantity passing through an air pipe from induced draft fan to bag filter; (275) controlling, by a pendulum valve, 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 a top rotor of the sand optimizer.(285)

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