The portable frac sand plant from McLanahan Corp. and CEMCO produces a frac sand stockpile used in oil and natural gas drilling, as well as a stockpile of material outside the size range requirements for frac sand. The plant is easily transported from one deposit site to the next for frac and sand mining at multiple locations.
Two operators can set up and disassemble the plant in less than eight hours. Built for continuous duty, the plant has an average output of 150 tons per hour (depending on the separation point chosen) and meets all DOT requirements for transport. Plant design is based on McLanahan's Hydrosizer separation technology mounted on a CEMCO chassis. The standard plant design features two units on separate chassis, enabling it to stay within the legal transportable height of 13.5 feet.
"The two trailers and a skid have the sumps and pumps, the cyclones, the Hydrosizer and dewatering screen," says Neil Hise, CEMCO president and CEO. In addition to frac sand, the system can produce concrete sand and masonry sand.
Erected size for each unit is 11.5 feet wide by 44 feet long by 30 feet high and 8.5 feet wide by 50 feet long by 12.5 feet high. Four hoses connect the units, creating an integrated plant. Units can be customized to meet customer specifications.
"Basically it uses a flat-bottom classifier," says Chris Kelley, general manager, aggregate processing, for McLanahan. "The reason we use the flat bottom classifier instead of the conical bottom discharge is because of height restraints. The other unique thing is it uses a split-deck screen," he says. "The dewatering screen discharges two separate products from one screen, which adds to the compactness. There also are leveling capabilities.'' The trailer levels the weir on the flat-bottom classifier (FBC).
Sand is fed into a sump where water is added. The slurry, approximately 30 percent solids, is pumped to a cyclone above the hydraulically self-erecting Hydrosizer separation system. Overflow from the cyclone containing unwanted -200 mesh fines flows to a tailings sump. Partially dewatered underflow from the cyclone enters the FBC through a top entry well, which eliminates turbulence and evenly distributes the feed (approximately 60 percent solids). Injection water enters the Hydrosizer through multiple, replaceable nozzles located in the bottom of the FBC.
Solids in the upper sorting chamber are met by the rising water and form a fluidized (teeter) bed. Lighter or smaller particles discharge over a peripheral weir, while coarser particles drop to the base and discharge through underflow plunger valves. A PLC control system measures teeter bed density and maintains a set point by controlling the rate of underflow discharge. Underflow (8 mesh by 70 mesh) from the FBC discharges into the coarse product sump below and is pumped to a second cyclone above a vibrating dewatering screen that discharges a +70 mesh product.
Overflow from the FBC flows to a second sump and is pumped to a third cyclone, which dumps material onto the other side of the vibrating screen, discharging a -70 stockpile.
The all-electric powered plant (motors and pumps) has few moving parts for lower maintenance and less downtown. Wear-resistant polyurethanes are used throughout the plant for increased durability. Operations are controlled from a touch-screen control panel. 814/695-9807; www.mclanahan.com.