Dewatering Screen & Hydrocyclone About Information
Modern aggregate production demands efficient water management and material processing systems that deliver clean, market-ready products. Dewatering screens combined with hydrocyclones represent a crucial technology in washing operations, particularly when handling fine materials like sand and gravel. These integrated systems tackle one of the industry's most persistent challenges: removing excess moisture from washed aggregates while recovering valuable fines that would otherwise be lost in wastewater streams.
At Constmach, we've engineered our dewatering screen and hydrocyclone combinations to maximize material recovery and minimize water consumption. Our systems function as sophisticated sand washing machines that go beyond simple cleaning. They separate, classify, and dewater materials in a continuous process, ensuring your final product meets specifications while reducing operational costs. Whether you're processing manufactured sand, natural aggregates, or recycled materials, proper dewatering equipment determines both product quality and profit margins.
The hydrocyclone acts as the first stage in material processing. When slurry enters the cyclone under pressure, centrifugal force separates particles based on size and density. Coarser materials spiral downward and discharge through the apex, while finer particles and water overflow through the top outlet. This classification step removes silt and clay particles that could contaminate your finished product.
After hydrocyclone classification, materials move to the dewatering screen where high-frequency vibration and specialized screen media work together. The screen deck angles typically between 15 and 25 degrees, allowing gravity to assist material movement while vibration breaks the water's surface tension. Multiple layers of polyurethane or woven wire mesh capture even fine particles while allowing water to drain through. This dual-action process achieves moisture content as low as 12-14%, making materials immediately suitable for stockpiling or further processing.
Our CDS-2040 system handles 150-200 tons per hour, making it ideal for large-scale operations. The 2040 designation refers to the screen deck dimensions of 2000mm width and 4000mm length, providing substantial surface area for material processing. This capacity suits operations running multiple washing lines or producing high volumes of manufactured sand for ready-mix concrete and asphalt applications.
The system incorporates two hydrocyclones working in parallel to handle the incoming slurry volume. Each cyclone measures 250mm in diameter and operates at 10-12 meters of water head pressure. The twin configuration ensures consistent processing even when feed rates fluctuate. The dewatering screen itself uses a two-deck arrangement with different mesh sizes, allowing operators to control final product gradation while maximizing water removal.
Installation flexibility stands out with the CDS-2040. The modular design allows mounting on a steel structure frame or concrete foundation depending on site conditions. Feed pump requirements typically range from 15kW to 22kW depending on material characteristics and required head pressure. The entire system operates on 380V three-phase power, standard in industrial facilities worldwide.
Processing 100-150 tons per hour, the CDS-1635 represents our most versatile configuration. This gravel washer suits medium-sized operations or serves as a secondary washing line in larger facilities. The 1600mm by 3500mm screen provides adequate area for thorough dewatering without excessive footprint requirements.
A single 200mm diameter hydrocyclone handles the feed capacity efficiently at this production level. The cyclone operates at similar pressure parameters as larger models but requires less pump power, typically 11kW to 15kW. This translates to lower energy consumption per ton of processed material, making the CDS-1635 particularly economical for operations where electricity costs significantly impact profitability.
Screen deck configuration on this model offers options for single or dual-deck arrangements. Operators processing primarily coarse sand might opt for a single deck to maximize throughput, while those handling materials with wider size distributions benefit from the dual-deck classification capability. Polyurethane screen panels come standard, offering excellent wear resistance and opening retention compared to traditional woven wire.
The CDS-1225 delivers 60-80 tons per hour in a compact package. This sand washer fits operations with space constraints or those starting with smaller production volumes but planning future expansion. The 1200mm by 2500mm screen deck maintains the same high-frequency vibration characteristics as larger models, ensuring effective dewatering despite reduced surface area.
Feed requirements for this system remain modest. A 7.5kW to 11kW pump typically provides sufficient pressure for the 150mm hydrocyclone. The compact size allows installation on existing platforms or integration into mobile washing plants. Transport dimensions make the CDS-1225 particularly attractive for contractors who move equipment between project sites.
Despite its smaller capacity, this model incorporates the same design principles and component quality as our larger systems. The screen frame uses heavy-duty structural steel with reinforced mounting points. Vibration motors come from European manufacturers, ensuring smooth operation and long service intervals. The hydrocyclone body fabricates from high-grade polyurethane or rubber-lined steel, resisting the abrasive action of sand particles in the slurry stream.
Dewatering screens and hydrocyclones don't operate in isolation. They integrate with upstream washing equipment like screw washers, log washers, or sand washing machines. At Constmach, we design complete washing circuits where each component complements the others. Feed preparation matters considerably. Materials entering the hydrocyclone should already be scrubbed and delumped to prevent blockages and ensure accurate classification.
Water quality affects performance directly. High-density slurries require more powerful pumps and may need dilution before hydrocyclone entry. Conversely, overly dilute feeds waste pump energy and reduce cyclone efficiency. Most operations target 25-35% solids content by weight in the feed slurry. This concentration balances pump requirements against classification effectiveness.
Climate considerations influence system specification. Cold weather operations may require insulated hydrocyclone bodies to prevent freezing. Hot, dry environments benefit from spray bars that keep screen media wet, preventing material buildup. Constmach engineers account for these factors during system design, ensuring reliable year-round operation regardless of location.
When investing in a dewatering screen and hydrocyclone system, you're making a decision that affects production capacity, product quality, and operating costs for years to come. Constmach builds equipment that performs reliably under demanding conditions while maintaining low lifecycle costs. Our engineering team draws on decades of aggregate production experience, incorporating lessons learned from installations across six continents.
We manufacture components in-house using CNC machinery and modern welding techniques that ensure dimensional accuracy and structural integrity. Quality control extends beyond fabrication. Every system undergoes factory testing before shipment, verifying vibration characteristics, structural soundness, and component function. This testing protocol prevents costly startup delays and ensures your equipment arrives ready for immediate installation.
Technical support distinguishes Constmach from competitors offering similar sand washing machines. Our engineers assist with site planning, foundation design, and integration with existing equipment. After installation, remote monitoring capabilities allow our team to troubleshoot issues quickly, often resolving problems without site visits. Spare parts stock at regional warehouses means critical components ship within 24-48 hours, minimizing downtime.
Choosing Constmach means partnering with a manufacturer committed to your operational success. Our dewatering screens and hydrocyclones deliver the performance metrics that matter: high recovery rates, low moisture content, and consistent product quality shift after shift. Request detailed specifications and arrange a consultation with our application engineers to discover how our washing solutions can enhance your aggregate production operation.
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