McLanahan Modular Washing Solutions – UltraWASH & UltraSAND Plants

The cost of a permanent plant is normally offset by higher throughput and a long life span of the deposit. When higher throughput is not needed or possible, a modular wash plant can be put in place at a lower capital investment and deliver the level of production needed. The advantage of shipping a plant in containers does have an impact on the size of the equipment, so throughput is lower than with permanent plants.
June 15, 2022
Coarse Material Screw Washer
Coarse Material Screw Washer

McLanahan Corporation produces several types of modular wash plants that offer the same benefits as the company’s large-scale, permanent wash plant, but feature all the advantages that also come with modularity. Fully designed and ready to go out of the box, they are able to have you up and running in a much shorter time frame than customized plants. They also come in standard sizes, meaning that if they aren’t already in stock, they can be quickly sized, selected and manufactured.

Two of these modular solutions include the UltraWASH Modular Wash Plant and the UltraSAND Modular Wash Plant. These modular wash systems are ideal for producers facing criteria such as planning permits, multiple locations, short-term deployment, or an unknown/variable feed stock (e.g. C&D waste streams applications) that make implementing a customized, fixed processing solution difficult.

UltraWASH Modular Wash Plants

All equipment that is part of the UltraWASH plants, including the vibratory screen, hydrocyclones, dewatering screen, sump and pump, is based on the McLanahan’s well-known, field-proven designs. UltraWASH plants provide a quick, easy-to-install processing system.

McLanahan currently offers 9 different sizes and configurations for its UltraWASH, which is capable of producing up to three aggregate products and two sand products at one time. There is a single process water feed point, as well as a single effluent discharge point.

Dewatering ScreenMcLanahan UltraWASH offers three different wash options, as well – each with their own benefits to the end user.

Single Wash
The single wash model can create up to three aggregate products and one sand product. The feed is divided by the sizing screen, and the clean aggregate is separated and stockpiled with conveyors. The sand fraction is mixed with water in the sump and pumped to a pair of Hydrocyclones, which remove the silts and clays before excess water is removed from the sand by the Dewatering Screen ahead of stockpiling.

Double Wash
The double wash model is ideal for sand that is extra dirty and requires additional contaminant removal. The difference between the double wash and single wash model is the addition of a divided sump and secondary pump. Sand mixes with water in one side of the sump and is pumped to a large Hydrocyclone, where the first pass removal of silts and clays is affected. The product of this process is a partially cleaned sand that is discharged back to the other side of the divided sand sump, from where it is picked up again and pumped to the smaller, secondary Hydrocyclone for removal of the remaining silts and clays before being discharged onto a Dewatering Screen for excess water removal.

Twin Sand
The twin sand variant allows the creation of separate coarse and fine sand products. This model also includes a divided sump and two Hydrocyclones circuits and adds a split deck dewatering screen. In the twin sand model, the bottom deck of the sizing screen is divided, allowing the coarse sand fraction to fall into one side of the sump and the fine sand fraction to fall into the other side. The coarse and fine sands are then pumped separately to the Hydrocyclones for single pass removal of silts and clays, and the sand is discharged onto separate sides of the Dewatering Screen for excess water removal, primary product blending and separate stockpiling.  

UltraSAND Modular Plants

When you are looking for all the benefits of a modular plant, but looking to only produce a sand product, the UltraSAND Modular Plant is an alternative to a complete wash system.

UltraWASH side viewWith the greater separation efficiency of Hydrocyclones/Separators™, UltraSAND Plants are proven to provide a higher product yield, along with a much lower moisture content from the Dewatering Screen, depending on the characteristics of the sand. The end result is almost immediate use of the product, steeper stacker angles for more stockpile capacity, reduced water loss, and better housekeeping.

The UltraSAND Plant is well-suited for a wide variety of applications from simple dewatering of sand to multistage wash systems. When a system is screen fed, it has the flexibility of receiving coarse material and making multiple products on a single screen. The most common use is to wash and dewater concrete, asphalt, and/or masonry sand, but can also be applied to different materials and industries. UltraSAND Plants are the industry standard to wash and dewater industrial sands (i.e. frac sand, foundry sand, glass sand, etc.) after classification of mid-size fractions.

UltraWASH with cloudsHelping Customers Across The Globe

James Nolan, who owns Tri-Parish Sand and Gravel with his wife, Gail, has always been concerned about the cleanliness of the products they use in their ready mix facility. They strive to deliver quality products on the concrete side of their business, which starts with the material used to make those products. Tri-Parish Sand and Gravel is a dry mining operation located in Louisiana, USA. They produce C-33 concrete sand, pea gravel and #57 concrete gravel for use in their ready mix operation, Parish Ready Mix.

To better control the quality of their concrete products as well as lower their production costs so they could pass those savings onto their customers, the Nolans purchased land for dry mining their own sand and gravel. They looked at a few wash plants in different parts of the country for processing the feed and separating it into the various products needed at their ready mix facility.

UltraWASH with sand pilesIn 2020, Tri-Parish purchased the McLanahan UltraWASH 6206 Modular Wash Plant that debuted at CONEXPO/CON-AGG in Las Vegas. Availability was a key factor in the purchasing decision. Tri-Parish needed a wash plant quickly, and the McLanahan UltraWASH offered an entire wet processing plant in one compact, modular unit that was ready to run.

“We bought the plant, and we’re very, very pleased with it,” James Nolan said. “It definitely does way more than they said it would do.”

McLanahan UltraSAND Plant Provides Flexibility to South Vietnamese Man-Sand Plant

A customer in South Vietnam was looking to make a high-quality basalt crushed sand as a replacement for river sand. Manufacturing sand creates a large amount of fines from the crushing process, and the customer needed to remove these undersized particles to meet their required product specifications, which in this case was a fineness modulus of 2.2. Fines are typically removed with washing and classification equipment, so the customer needed a wash plant that would get the job done.

The customer reached out to Thanh Long JSC, McLanahan’s dealer in Vietnam, for a solution. Thanh Long JSC recommended a McLanahan UltraSAND Plant for producing their required product specification.

McLanahan UltraSAND Plants are modular sand washing and dewatering systems that are pre-designed and pre-engineered for rapid deployment. The fully designed UltraSAND Plant, with its quick setup time and small footprint, was more attractive to the customer than a stationary plant.

“As deposits are fully utilized, the fact that modular plants can be moved accordingly is very important,” said McLanahan Regional Sales Manager Neil Treseder. “They can be added to various modular options to suit ever-changing deposits. They don’t need a lot of infrastructure. In the Vietnamese market, the plants need to be versatile, quick to deploy and cost effective; the McLanahan modular Ultra line fits this bill.”

Treseder continued, “McLanahan modular plants are fully designed with a small footprint. Some customers have multiple sites, and if required, the plant can be moved to suit. The plants are shipped by containers, which makes them very cost effective.”

With the UltraSAND Plant, the customer’s crushed sand enters the sump, where it mixes with water and is pumped to a distributor box that splits the slurry between the two Hydrocyclones. The cyclones separate the fine particles from the product-sized sand and discharge them along with a majority of the water out the top of the cyclones. This waste stream is then sent to a settling pond.

The product-sized sand is discharged out the bottom of the Hydrocyclones and onto the Dewatering Screen. The Dewatering Screen removes excess water from the sand and discharges a drip-free product onto a stacking conveyor for stockpiling. The Dewatering Screen throughs — the water removed from the sand and any additional fine material that pass through the Dewatering Screen media — flow into the sump to mix with the slurry feed to the Hydrocyclones.

When the UltraSAND Plant arrived in South Vietnam, it was simply a matter of placing the equipment, attaching all the connecting pipes and hoses, and providing power to the Pump and Dewatering Screen before the plant was up and running.

Thanh Long JSC said the McLanahan UltraSAND Plant is working very well for the customer. The plant is providing a clean sand at the customer’s required tonnage and specifications, and it is also dewatering the finished product to 8% moisture. The lower moisture content reduces stockpile drying time, allowing the product to be sold sooner. It also reduces housekeeping requirements, as less water being transported in the final product allows for a cleaner site under conveyors and around stockpiles.

When a customer works with McLanahan, they get more than just industry-leading equipment with a long, reliable service life. They get the knowledge that comes with decades of process experience, along with the support of a global dealer network that provides unmatched local service all over the world. In addition to field-proven equipment, McLanahan also provides installation, startup, commissioning, training and after-sales support for all of its products.

Content produced in association with McLanahan

For more information on companies in this article