Artificial Sand Production

Research on Artificial Sand Production
Objective of the Research: The increasing demand for sand in construction, coupled with the depletion of natural sand resources, has necessitated the production of artificial sand as a viable solution for the construction industry. Artificial sand offers several advantages over natural sand, including the ability to adjust size modulus and particle composition proportion to meet specific requirements of different types of concrete. Artificial crushed sand also exhibits stable particle composition, higher angularity compared to natural sand, lower content of flat particles compared to sandstone, and better control over impurities that may be harmful to the environment, such as mud and clay.
Motivation for the Research: Recognizing the potential to recover and recycle soil and rock waste from the dump at Tan Thinh Mineral Joint Stock Company for use in construction materials and leveling materials, I, as the Director, initiated the idea of producing artificial crushed sand from available sources within the company. After conducting a thorough review of relevant literature and documents, I devised a comprehensive plan to implement the project for artificial sand production. Since January 2019, the project has been underway, aiming to utilize the company's resources to produce high-quality artificial sand for the construction industry.  The total investment in research and project implementation amounts to 30 billion Vietnamese dong.
Phase 1: Ideation and Design of Artificial Sand Production from Available Materials
  • During the initial phase of the project, I identified a potential source of "material" that could be utilized for the production of artificial sand. In the stone crushing process, small particles (0 - 5mm) are often discarded or mixed into the aggregate rock (0 - 40mm) with low value. Through my research, I discovered that up to 42% of the sandstone from the Company's soil and rock waste dump can be reused. This inspired me to develop the idea of using this "material" to produce artificial sand.
  • To implement this production model, I collaborated with the Engineers from the Company's Technical Department to design and construct an artificial sand production line from waste rock. The overall equipment composition of the production line includes a vibrating feeder, primary crusher for processing large particles (usually a jaw crusher or counter-attack crusher), secondary crusher for medium-sized particles (usually a medium jaw crusher, cone crusher, or hammer mill for rocks with low hardness), a sand mill (vertical shaft centrifugal impact crusher due to its advantages for handling high-hardness input materials), and a vibrating floor machine for sieving and classification of the crushed stone into different sizes.
  • The design and construction of this production line took place over a period of 6 months from January 2019 to June 2020, in collaboration with the Engineers from the Company's Technical Department. The total investment for the crushing and screening line, including product classification, during this phase amounted to nearly 24 billion Vietnamese dong, with a production capacity of 250 tons per hour for each line. This marked the successful completion of Stage 1 of the project.
Phase 2: Research and Production Line Adjustment
  • The initial artificial crushed sand product produced by the company did not meet the required standards, as the installed production line was only capable of handling sandstone, while the waste soil at the Tan Thinh Company disposal site contained a significant amount of clay. In order to address this issue, I conducted research and worked closely with engineers from the Technical Department of the Company to make adjustments to the production line. Notably, I introduced the following additions to the production line to improve the quality of the artificial sand product:
  • Sand Washing Machine (Rotary Sieve): A rotary sand washing machine was added to the production line to dissolve and separate dirt and impurities, resulting in the production of standard artificial sand products.
  • Sand Recovery Machine: A sand recovery machine was incorporated into the production line to recover fine sand grains after the sand washing process.
  • These additions were successfully implemented in the production line. The resulting product is coarse sand particles of 0-4mm mixed with minimal impurities, which are then fed into the sand washing tank for impurity removal. The clay mud mixed in the waste rock is effectively washed out, resulting in a clay content of only 0.96%, well below the regulatory standards, ensuring the cleanliness of the finished sand.
  • After 3 months of dedicated efforts in designing and adjusting the production line, I proactively conducted quality assessments on the crushed sand products. The quality of the crushed sand for concrete and mortar produced by Tan Thinh Company has been assessed by the Institute of Materials (Ministry of Construction) to meet TCVN 9025-2012 standards and has been certified by the Vinacontrol certification organization with Product QRCM0546 dated 4/7/2020 and Certificate of Quality Management System ISO 9001:2015 QSV0722 dated 4/7/2020.
Through independent testing, it has been confirmed that the company's crushed sand products meet the requirements for construction, including sand for concrete, mortar, and pavement. According to construction experts, artificial sand has special properties such as more uniform sand grains, adjustable modulus and proportion of particles to meet specific mixing requirements for different types of concrete. The use of artificial sand also allows for savings in cement and asphalt, shortens construction time, and increases the longevity of the structures.
Results and Achievements:
The production of artificial crushed sand from the recovered "material" of stone and sandstone at the Tan Thinh quarry waste dump has yielded significant benefits in various aspects. Firstly, the artificial sand product, which now has a value three times higher than small particles discarded or mixed into aggregate rock during the stone crushing process, has proven to be a profitable venture. Based on a monthly production capacity of 48,000 tons, assuming 80% machine operating capacity, the selling value of waste soil (if sold, as customers typically do not buy this type) amounts to 1,536,000,000 VND, while the selling value of artificial sand totals 5,760,000,000 VND per month. As a result, the Company is projected to recover its capital investment in the new production lines within approximately 6 months. Furthermore, the Company's annual revenue is expected to increase by nearly 70 billion VND as a result of utilizing waste rock to produce artificial sand.
In addition to the financial benefits, the Company's investment in producing artificial sand from sandstone also holds positive environmental significance. By utilizing rock from the landfill, the Company has contributed to reducing the pressure of dumped soil and rock, mitigating the risk of landslides in the dumpsite during abnormal weather conditions. Moreover, the production of artificial sand has helped meet the demand for construction sand, gradually reducing the exploitation of natural sand resources from river beds and mitigating the occurrence of landslides. This sustainable approach aligns with the planning for exploration, exploitation, and use of minerals as common building materials and minerals in the Binh Duong province area, in line with the provincial plan for 2020 with a vision to 2030

NGO THANH TUNG
 
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