FRAC SAND MINING
compromise in performance or maintenance. “It
is the result of a number of years of
development work from CDE and aims to
address a number of the limitations of the
existing washing equipment offering in this
sector.”
A development of their existing modular
equipment range, FracLine integrates several
processes onto a single, compact chassis
offering a number of advantages for operators as
CDE Chairman, Tony Convery explains: “As the
requirements of each frac sand processing
project are unique, we sought to develop a
machine that had the flexibility to cope with this.
The specification of each machine is made up
of a selection of the appropriate processing
phases – slime removal, classification,
dewatering, attrition – in whatever combination
is needed to ensure the production of a
consistently graded product that is optimised for
use in downstream processes.”
According to CDE, the modular construction
allows for future changes to the plant set up on a
number of fronts – capacity increases, the
number of cut points and products, and
increased levels of attrition through the
introduction of additional ShearClean dynamic
attrition cell technology.
“The result of this for the customer is that
future changes in their requirements – whether
they be a requirement for additional capacity, a
change in market requirements, or the
characteristics of the feed material, can be easily
accommodated. This future proofs FracLine and
provides comfort that the investment is fit for
purpose for the long term” explains Tony Convery.
In combination with the reduced footprint that
FracLine offers, the machine has also significantly
reduced the height of the installation which
comes with a number of benefits. Glenn Sloan,
CDE Product Development Manager explains: “A
lot of frac sand processing operations face a loss
in production due to the very cold winters in
Wisconsin and surrounding areas. By reducing
the height and footprint of our system we are
able to accommodate the machine inside a
building which allows the machine to operate
365 days a year if the mining operation permits.
This has a huge impact on the return on
investment which is now considerably improved
by the increase in production volumes that
FracLine offers.”
The low profile of FracLine has additional
advantages such as a reduction in energy
consumption as a result of not having to pump
material to the same heights that were previously
considered the norm. It also allows for ease of
maintenance with all the main components close
to ground level. “This not only increases plant
accessibility, but reduces health & safety risks on
site, removes the need for specialist lifting
equipment and ultimately reduces maintenance
downtime” explains Sloan.
The integrated ShearClean dynamic attrition
cell technology also helps to reduce energy
consumption thanks to the introduction of a
patent-pending fluidisation system. “Typically
with attrition cell technology, the motors are
sized for start-up – at which point they require
significantly more energy than during operation.
Our patent-pending fluidisation system ensures
that the motor sizes are reduced by making the
material easier to handle on start-up, offering
The McCloskey Washing Systems (MWS)
SandStorm™ 620. This modular, mobile wash
plant is described as the world's most
innovative and efficient modular sand wash
plant
significant energy savings during the operation of
FracLine.”
McCloskey solutions for each
application
Producing spec frac sand is a challenge that
requires focus on yield and efficiency, with a clear
understanding of the feed material. Typically only
a small fraction ‘in the middle’ of the feed
gradation is product material (ie 20/40 mesh,
30/50 mesh, 40/70 mesh, 70/140 mesh), so
maximising recovery of particles in that range is
essential to maximise the downstream dry
screening efficiency.
Craig Rautiola, Manager – Technical Sales &
Applications, North America at McCloskey
Washing Systems (MWS) told IM: “Our plants are
designed with simple yet sophisticated process
flow specific to each application. Some frac sand
deposits require up to two stages of coarse
separation that require hindered settling
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66 International Mining | JUNE 2017