OCEAN PUMP uses sand suction dredger and conveyor belt dredger as a sand mining equipment for the most suitable solution in Malaysia sand extraction work. We have many customers in Malaysia and other southeast Asian countries. Through detailed investigation and years of industrial experience, we have a professional understanding and experiments for local sand mining works.
River sand mining equipment and technology
1.The Conveyor Belt Dredger’s Design Principle
The conveyor belt dredger has self-priming, self-washing, and self-unloading functions for sand. When working, the conveyor belt dredger could mine and wash the sand through its own equipment during the process of construction. When the dredger reaches full loaded, the sand will be transported to the designated position. When the dredger reaches the shore, the sand will be unloaded on the shore by the conveyor belt. After finishing unloading the sand, the dredger will drive back to the sand mining area to continue the work.
2.The Conveyor Belt Dredger’s Working Process
The construction process of Conveyor Belt Dredger is loading sand → full sand sailing → unloading sand → empty sailing.
3.The Conveyor Belt Dredger’s Construction technology
During sand mining, The Conveyor Belt Dredger completes sand extraction through two steps: transporting sand and unloading sand. During construction, The Conveyor Belt Dredger close to sand suction equipment in the sand mining area. When the dredger full loading, it will transport sand to the designated position. Then, the dredger arrives at the shore and begins to unload sand. After unloading sand, the dredger will sail back to the sand mining area and restart the next round of working.
1) Loading sand on empty dredger. The Conveyor Belt Dredger is close to the sand mining equipment for sand loading. The river sand is pumped to the belt cabin through the supporting sand mining equipment.
2) Sand unloading. The Conveyor Belt Dredger uses the belt conveyor that is laid from the bottom of the cabin to the bow of the ship to discharge sand. The method of discharging sand is similar to the belt conveyor used by bulk cargo carriers. Under the action of gravity, the sea sand in the tank continues to sink to the belt conveyor that is in the bottom, and then the belt conveyor will transport the sea sand to the bow of the ship for sand unloading. During construction, the bow of the belt conveyor reaches the shore, and then the sea sand will be unloaded to the shore.
4.Conditions of use
The Conveyor Belt Dredger can be self-propelled, self-discharging, and flexible. It could complete hydraulic screening during the overflow process. If the sand quality is good, it can directly ship to the shore. But the requirements of water depth are high. The dredger is suitable for places with less wind and waves. It is also useful for long-distance transportation when transferring from the shore to the working places. The dredger is especially suitable for construction in the estuary, deep water channels, and other waters.
II Design Principle and Technology of Jet Suction Dredger
- Design Principle of Jet Suction Dredger
The jet suction dredger’s working principle is to use junk siphon principles. The sand pump on the sand mining equipment could jet out the high-pressure water. When the high-pressure water passes the suction of the jet suction dredger, the unique design of the dredger makes high-pressure water flow accelerated, and it forms a negative pressure environment. The strong sediment adsorption and vacuum pressure will suck the sand, convey it through the suction pump and pipeline to the shore.
- Construction Process of Jet Suction Dredger
The construction process of jet suction dredger is as follows: dredging sand → full loading sailing → unloading sand → empty sailing
- Construction Technology of Jet Suction Dredger
(1) After the ship positioning, swinging, and anchoring operations are completed of the sand dredger. Start to connect the pipeline. After the pipeline is located and both ends of the pipeline are connected with the dredger pipe and the shore pipe, the starting and distribution of work is completed.
(2) Set one or more sets of sand suction pumps and high-pressure water pumps on the jet suction dredger. The high-pressure flushing pump washes the mud into the silt. The sand pump transports the silt to the sand booster pump, then blown into the operation area.
- Conditions of Use
The jet suction dredger has the advantages of simple structure, no rotating parts underwater, reliable operation, not limited by water depth, etc. It can be widely used in sand extraction and dredging in shallow rivers or reservoirs, but the sand mining equipment’s discharge distance is short.
III Construction principle and technology of sand suction pump dredger
- Construction Principle of Sand Suction Dredger
The sand suction dredger uses the sand suction pump to suck the sand from the bottom of the river, and then transported to the land through the pipeline to complete the sand suction. If need a certain range of particle size of sand, then use the screening equipment to filtrate the sand.
- The Construction Technology
Sand suction dredger works according to the principle of sand pumping. It is formed by one local sand suction pump with two simple pontoons based on the transformation of a simple ship. During the construction, a sand suction dredger works in the water near the shore point, the pipeline transfers the sand to the areas on the land.
- Conditions of use
The equipment has the characteristics of small volume, lightweight, easy to disassemble and install, low maintenance cost, especially suitable for water depth within 1.0 meters, good sand layer, fewer stones, and slow flow of sand field use. The sand suction pipe of the equipment is lifted by the hoist to achieve the lifting. The sand suction pipe is equipped with a special sand suction head, which can effectively coordinate the water pump with the sand suction pump for use. However, due to the long conveying distance and weak screening capacity of the sand mining equipment, it is necessary to have a reclamation area.
IV The Cutter Suction Dredger’s Principle and Process
- The Cutter Suction Dredger’s Principle
The small cutter suction dredger use its cutter to mix with cement into mud. The mud go into the suction pump and through pipeline to discharge to the drainage area. During the construction of the cutter suction dredger, the work of dredging, mud transport, and mud discharge are all completed by the dredger itself. Because of this, the production efficiency is higher.
- Technological Process of Small Cutter Suction Dredger
(1) At the inlet of the suction mouth, a rotary special reamer device is installed to cut and loosen the underwater mud and sand. The machines driven by mechanical power to make more mud and sand be sucked through the suction pipe with water.
(2) A certain vacuum could be generated by the action of the centrifugal mud pump on the ship. This process could indraft the sand through the suction pipe, and then discharge through the ship’s mud pipe.
(3) The positioning of the dredger, the transverse swing of the hull, and the longitudinal forward movement are carried out by the positioning steel pile and the steel pile lifting device that are installed on the ship.
- Characteristics and Conditions of The sand mining equipment
The requirement of a cutter suction dredger for the water depth is relatively high. The size of the dredger is large, and it is not flexible enough. However, the conveying distance of the dredger is far, and the amount of filling is huge. The dredger needs to have a filling area.
Restrictions on sand mining in the upstream reaches of the river
The article takes a project in Malaysia as a typical case to analyze the restriction conditions of sand mining in the upstream reaches of the river.
1) The upstream reaches of the river are blocked by leaping structures above the river surface
Both the upstream and downstream of the river are blocked by bridges and other cross-over buildings that are lower from the river surface. Belt suction ships and small cutter suction boats cannot pass through the cross-over buildings, and thus cannot reach the upstream sand extraction area.
(2) The river itself has shallow water depth and narrow river channels
The shallow water depth of the sand fetching area in the upstream reaches of the river is only 1.0m, and the river is narrow, and the overall water depth is shallow, which cannot meet the draught requirements of small ships. The narrow river is easy to cause construction in this area for belt sand suction boats and small cutter suction boats. The river is blocked.
(3) There is no reclamation area on the upstream bank of the river
According to on-site investigations, there are only small simple sand mining equipment on the land on the upstream reaches of the river, the site area is small, and there is no reclamation area required for the sand extraction process by the sand suction boat, and the land on the shore is privately used by local indigenous people, and the cost of expropriation is relatively high. This has caused certain difficulties for ships in the upstream reaches of the river to obtain sand.
Research on the technology to adapt to the restrictive conditions of the upstream reaches of the river
The water depth of the river is relatively shallow, the river course is narrow, and there are leaping buildings on the upstream reaches of the river to block ships. The sand extraction construction in the upstream reaches of the river, belt sand mining equipment and small cutter suction boats cannot be used in this area; jet boats and sand suction pump boats can meet the requirements The draught is relatively shallow, but the transport distance of the jet boat is short, and the screening ability of the sand suction pump boat is weak. It needs a dredging area and a screening device is required to screen the gravel. The belt sand suction boat can carry out sand washing and screening, but it cannot Sand washing and screening are carried out in the upstream sand source area. This results in insufficient adaptability of a single process, and it is impossible to simply use a certain process for sand extraction.
In this regard, according to the survey of existing sand extraction equipment in the upstream reaches of the river, there is a belt sand ship and a ready-made sand field in the downstream of a bridge in the upstream area of the river; there is sand mining equipment in the upstream section of a bridge in the river, and it is located in the river. There are also special gravel screening equipment and sites in the upstream area. Combining the characteristics of various equipment and engineering requirements for sand and gravel content, etc., there are conditions for adopting a combined construction method in the local area. The sand suction pump ship is used as the sand extraction equipment in the sand extraction area of the upstream of the river. The belt sand suction boat supplies sand, and then the river sand is transported and unloaded to the shore by the belt sand suction boat; when the sand source is close to the river landing point, the sand suction boat is used to transport the river sand through the pipeline to the screening equipment, and then pass The screening equipment screens the sand. When the sand-water mixed fluid in the pipeline flows from one sand trough to another under the action of gravity, river sand of different particle sizes is cleaned and sieved out. In this way, the strengths and weaknesses are avoided, and the demand for sand mining operations in shallow rivers is met. The construction process is mainly as follows: project start → construction preparation → sand suction pump boat to suck sand → far away from the landing point, the sand suction pump boat pumps the sand into the belt sand boat (closer to the landing point, suction Sand pump ship pumps sand to shore gravel screening equipment through pipelines) → belt sand ship transports and unloads sand to the shore stacking point (silt is screened by shore gravel screening equipment) → sand supply project is completed.
In summary, the combined construction process of sand suction pump ship and belt sand suction ship was successfully implemented in a sand supply project in Malaysia, which met the requirements of supply intensity, improved construction efficiency, and gave full play to the combined construction capabilities of local equipment. In addition, the supplied river sand has extremely low mud content, and the dredged-filled sand body can meet the needs after being piled ashore, and the application effect is good. A reasonable sand mining system design requires expert advice. The designer team of TAI’AN OCEAN Pumps has rich experience and is willing to provide assistance.
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