Project Overview

Calcite sand is a core raw material for high-end glass production, demanding strict standards for particle uniformity and screening purity. The client's existing production line utilized a 1.6-meter circular tumbler screen to process the sand; however, issues such as insufficient capacity, low classification precision, and product contamination (mixing of grades) rendered it unsuitable for mass production requirements. Based on the specific material characteristics and operational conditions, we recommended a custom 1536 Rectangular gyratory screen featuring a 3+3 configuration, helping the client achieve their goals of improved quality, increased output, and production stability.

Material and Equipment Conditions

Material to be screened: Calcite sand (specialized for glass production)

Core production requirement: Precision screening of the 1.0–1.5 mm target fraction, ensuring material purity without grade mixing.

Particle size distribution:

- 1.5–2.0 mm: 25%

- 1.0–1.5 mm: 55% (Target product specification)

- 0.5–1.0 mm: 20%

Original equipment status: 1.6 m circular tumbler screen. Production line feed rate was 10–12 t/h, yet the equipment's actual capacity was only 5 t/h. Long-term operation under overload conditions resulted in inconsistent 

screening efficiency and product pass rates.

Key Pain Points of the Original Equipment

1. Capacity Mismatch: The processing capacity of the original circular tumbler screen was far below the production line's feed rate; the resulting capacity bottleneck severely constrained overall production efficiency.

2. Low Screening Precision: The equipment's screening trajectory was limited, leading to the mixing of coarse and fine particles. Large particles and fine dust contaminated the finished product, compromising the quality of the glass sand.

3. Poor Material Adaptability: Calcite sand exhibits high fluidity; the circular tumbler screen suffered from low screen surface utilization and incomplete material passage, resulting in excessive raw material loss. IV. Customized Solution: 1536 Rectangular Gyratory Screen (3+3 Configuration)

Tailored to the client's material particle size distribution, feed load, and quality requirements, this solution utilizes the Model 1536 rectangular tumbler screen with a specialized "3+3" configuration. Featuring a large screening surface and a multi-layer design, it is custom-engineered for the fine classification of glass sand and mineral sand, serving as a perfect replacement for traditional circular tumbler equipment.

Core Equipment Advantages

1. Precision Multi-Layer Screening for High Purity: The "3+3" dual-layer structure enables targeted classification of three particle sizes. It precisely isolates the core 1.0–1.5mm product, effectively eliminating issues like material mixing and leakage, thereby meeting high-end glass raw material standards.

2. High Capacity to Meet Production Demands: With an extra-large effective screening area of 1500×3600mm, the system ensures uniform material spreading and an extended screening trajectory. It fully accommodates feed rates of 10–12 t/h, ensuring stable, full-load operation and effectively doubling production capacity.

3. High Screening Efficiency and Reduced Material Loss: The specialized rectangular tumbling motion is optimized for the flow characteristics of calcite sand. By extending material residence time on the screen, it achieves higher throughput rates, effectively minimizing raw material waste and maximizing material utilization.

4. Eco-Friendly, Low-Consumption, and Easy Maintenance: The fully enclosed, dust-proof design prevents dust leakage, ensuring compliance with environmental standards. Low operating noise and a low failure rate significantly reduce long-term operation and maintenance costs.

Project Retrofit Results

1. Full Capacity Realization: The equipment perfectly matches the production line's feed load, completely resolving the capacity bottlenecks of the original machinery and significantly boosting overall line efficiency.

2. Product Quality Enhancement: The core product—calcite glass sand—features uniform particle size with no grade mixing; the qualified product rate consistently meets standards, thereby enhancing market competitiveness.

3. Enhanced Operational Stability: The equipment operates under a balanced load, eliminating overload-related failures and enabling long-term continuous operation, which effectively reduces downtime losses and production costs.

Case Summary

Addressing the screening requirements for calcite glass sand—characterized by high precision and high feed volumes—the 1536 rectangular gyratory screen (featuring a 3+3 deck configuration) effectively resolves the pain points associated with traditional circular screens, such as low capacity, poor precision, and high material loss. With strong adaptability and stable screening performance, this equipment is an ideal choice for the classification of fine aggregates like glass sand, quartz sand, and mineral sand, serving as a proven reference for similar production line upgrades.