Sand Processing System for Concrete Base Material
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Solution Overview
Problem
The existing methods for producing concrete starting material are inefficient, unsustainable, and environmentally harmful due to labor and energy-intensive sand extraction and processing, with unpredictable grain size distribution and reactivity issues, especially when using additives like concrete crusher sand with variable composition.
Innovation Solution
A sand processing system that supplies multiple sand fractions with known grain size ranges and measures the grain size distribution of the mixture to achieve a predetermined target composition, allowing for the controlled mixing of sand fractions, including additives with larger grain sizes and reactive components, to ensure consistent quality and reduce environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If sand is extracted from water bodies and processed using conventional methods, then sand is obtained for concrete production, but the process is labor-intensive, energy-consuming, and environmentally disruptive
Solution Approach 1:
The system uses automatic grain size measurement and feedback control to adjust sand fraction mixing ratios, eliminating the need for manual screening and processing operations. The automated system serves itself by continuously monitoring and adjusting the mixing process based on real-time grain size distribution data
Solution Approach 2:
The system changes the grain size distribution parameters of the final sand product by selectively mixing different sand fractions with known grain size ranges. By controlling the mixing ratios of various fractions, the system can produce sand with predetermined target grain size distributions suitable for different concrete applications
2Manufacturing precision
If sand is extracted and screened to achieve desired grain size distribution, then sand quality is improved, but labor and energy requirements increase
Solution Approach 1:
The sand fractions are pre-classified into distinct grain size ranges before mixing. By preparing the sand fractions in advance with known grain size characteristics, the system eliminates the need for final screening operations and achieves precise grain size distribution control through controlled mixing ratios
Solution Approach 2:
The system incorporates grain size measurement devices that continuously monitor the grain size distribution of the mixed sand and provide feedback to the control system. This feedback loop allows real-time adjustment of mixing ratios to maintain precise grain size distribution control without manual intervention
3Adaptability or versatility
If additives with variable composition and grain size are used in concrete production, then material versatility is improved, but consistency and reliability of the final product deteriorate
Solution Approach 1:
The system segments the sand material into multiple fractions with well-defined grain size ranges. By dividing the sand into distinct segments with known characteristics, the system can consistently reproduce target grain size distributions regardless of variations in the source material composition
Solution Approach 2:
The system creates composite sand mixtures by combining multiple sand fractions in controlled ratios. This composite approach allows the system to achieve consistent grain size distributions by compensating for variations in individual fraction compositions through balanced mixing
4Quantity of substance
If conventional sand processing methods are used, then sand is obtained for concrete, but environmental impact and costs increase
Solution Approach 1:
The automated measurement and control system eliminates the need for energy-intensive conventional screening and processing operations. The system serves itself by using real-time data to optimize the mixing process, reducing overall energy consumption and environmental impact
Solution Approach 2:
The system can utilize sand fractions that would otherwise be discarded or require extensive processing. By accepting sand fractions with a broad range of grain sizes and using feedback control to achieve target distributions, the system recovers value from materials that would normally be wasted or require energy-intensive processing
Data Source
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AI summary
A method and sand processing system (100) for obtaining a concrete starting material containing sand, wherein the concrete starting material has a predetermined target composition. The method comprises of supplying sand of a first composition (101A-101D), supplying sand of a second composition (102), mixing (108) the supplied sand of the first composition and the supplied sand of the second composition for the purpose of obtaining a sand mixture, performing at least one measurement (109) on at least one of the sand of the second composition and the sand mixture for the purpose of determining the sand grain size distribution of this sand, and determining on the basis of the measurement whether the sand mixture has said target composition.