Concrete Batching Plant Recycling System

(Sand & Aggregate Separation + Slurry Water Recycling System)

The concrete batching plant recycling system is a core closed-loop equipment for modern eco-friendly mixing plants to treat waste concrete and mixer truck washing wastewater. It separates waste into clean aggregates and reusable slurry water, achieving zero discharge, full recycling, and cost savings. It is standard equipment for commercial mixing plants to meet environmental assessments and reduce costs.

Core Functions & Values

• Sand & Aggregate Separation: Thoroughly cleans and separates stone and sand from residual concrete; clean aggregates can be directly reused in production.
• Slurry Water Recycling: Separated cement slurry is reused for mixing or truck washing after stirring, sedimentation and filtration, with no discharge.
• Environmental Compliance: No wastewater or residue discharge, avoiding soil and water pollution, meeting environmental inspection requirements.
• Economic Benefits: Aggregate recovery rate 95%–98%; single plant saves hundreds of thousands of yuan annually on raw materials and sewage fees.

System Composition (Complete Closed Loop)

1. Sand & Aggregate Separator (Core Machine)

Mainstream type: rotary drum type (stable, efficient, standard for mixing plants)

• Rotary drum screen: rotates with spraying to break up concrete and grade aggregates.
• Spiral guide: discharges stone and sand in reverse directions for automatic stacking.
• High-pressure spraying: full-process washing ensures clean aggregates with mud content <1%.
• Non-screen / wide-slot design: resistant to blockage, low maintenance.

2. Slurry Mixing & Storage System

• Mixing tank / silo: with electric mixer (intermittent operation) to prevent sedimentation and solidification.
• Multi-stage sedimentation tank (mainly 3-stage): settles fine powder; upper clean water for washing, lower thick slurry for mixing.
• Slurry transfer pump: automatically delivers homogenized slurry to the mixing tower for batching.

3. Intelligent Control System

• Fully automatic operation: linked full process of washing → feeding → separation → mixing → water supply.
• Level linkage: automatic water replenishment, auto start/stop, high-level alarm.
• Interlock with batching plant: dosing slurry quantitatively to ensure stable concrete strength.

4. Auxiliary Structures

• Washing platform / feeding channel: fixed-position truck washing and waste guiding.
• Discharge hopper: temporary storage of separated aggregates for forklift transfer.
• Sewage & desilting system: automatic/manual sludge discharge regularly to prevent hardening.

Working Flow (Fully Automatic)

1. Washing & Feeding: Mixer truck washes at the platform; waste + wastewater enter the separator.
2. Aggregate Separation: Drum rotation + spraying separates stone → sand → slurry in 3 stages.
3. Aggregate Reuse: Clean stone and sand discharge separately and return to batching machine.
4. Slurry Homogenization: Cement slurry enters mixing tank and is stirred periodically to prevent settling.
5. Circular Reuse:
   ●Upper clean water → reused for washing and spraying
   ●Homogenized thick slurry → dosed into mixer by metering pump to replace part of fresh water
6. Zero Discharge: No wastewater discharge, full residue recovery; only small amount of sludge removed periodically.

Main Types and Selection

1. By Separator Type (Common)

• Rotary Drum Type (Recommended) :

  • Advantages: Continuous operation, high efficiency, low failure, wear-resistant

  • Capacity: 20–60 m³/h (for HZS50–180)

  • Application: Commercial mixing plants, large fixed stations

• Screw / Vibrating Type:

  • Advantages: Simple structure, low cost.

  • Disadvantages: Low efficiency, easy blockage, high maintenance.

  • Application: Small stations, short-term projects.

2. By System Configuration

• Standard (Single Station): Handles 1 mixer truck; for HZS50–90

• Double Station: Handles 2 trucks simultaneously; for HZS120–180

• Zero-Discharge Intelligent: Multi-stage cyclone + fine filtration; 100% slurry reuse, zero discharge

Key Technical Parameters (Common)

Core Performance Advantages

1. High Recovery Rate: 95%–98% aggregate recovery, 100% slurry reuse, resource circulation.
2. Eco-Friendly Zero Discharge: no sewage, residue or dust; passes environmental assessment.
3. Fully Automatic & Unattended: one-key start, auto washing, separation, mixing and water supply.
4. Stable & Durable: wear-resistant drum liner, waterproof motor, anti-blocking design; annual failure rate <5%.
5. Significant Cost Saving: saves 300,000–800,000 yuan yearly on aggregates, water and sewage fees; payback in 1–2 years.

Operation & Maintenance Points

1. Daily Operation

• Start system empty before feeding; flush and empty residue before shutdown.
• Forbid large debris and steel bars from entering separator to avoid jamming.
• Keep mixing tank stirring to prevent slurry solidification.

2. Regular Maintenance

• Daily: clean nozzles, check belts/rollers, remove accumulated material.
• Weekly: lubricate bearings, check motor reducer, tighten bolts.
• Monthly: inspect drum liner, screen slots, mixing blade wear.
• Quarterly: clean sedimentation tank sludge, overhaul pumps and valves.

Common Faults & Solutions

• Poor separation / high mud content: insufficient spraying, improper drum speed → adjust water pressure and speed.
• Slow discharge / blockage: screen slot clogging, fast feeding → stop to clear, control feeding rate.
• Slurry sedimentation & hardening: mixer not running, overtime shutdown → regular stirring, empty before shutdown.
• Water / slurry leakage: aging seal, cracked weld → replace seal, repair welding.