This article will go over the different ways that better screens can help save money over time.

Lower Maintenance Costs and Fewer Downtime Events

Few things eat into profit margins faster than unplanned downtime. Every hour your screening system is offline means lost production, idle workers, and delayed schedules. The most common operational failures in conventional screening are:

• Blinding: fine, sticky, or moist particles adhere to the screen mesh, progressively blocking the apertures
• Pegging: near-size particles become wedged in the openings
• Carryover: undersized material fails to pass through the blocked deck and contaminates the oversized product stream

Higher-quality screens are engineered to minimize these costly interruptions. For example, AEI’s BIVITEC® flip-flow screen is designed to keep material moving without clogging and blinding, even when handling difficult, high-moisture materials. That reduces the need for frequent cleaning and maintenance.

Increased Throughput and Screening Efficiency

A screen’s performance directly affects how much material your operation can process. Better screening technology can increase throughput by processing more tons per hour and improving screening accuracy. That efficiency boost reduces cost per ton and helps deliver more product in less time.

The Freedom Disc Screen – which was designed to eliminate wrapping and plugging – ensures continuous, high-capacity screening with minimal need for operator intervention.

Additionally, efficient screening reduces the amount of material that must be reprocessed or discarded, saving time and energy while improving the overall quality of the final product.

Optimized Energy and Water Efficiency

Inefficient screening equipment acts as a constant drain on an operation’s resources, silently inflating utility costs. When a screen deck becomes blinded or pegged, the effective load on the screen increases. The vibrating motors must work harder to move the accumulated mass of material, leading to a significant increase in energy consumption.

Similarly, in wet processing applications, such as sand washing and classifying, conventional equipment is often inefficient in its use of water. Traditional screw washers require massive volumes of water to wash and transport material. Meanwhile, the Ortner® sand classifier uses only one-third of the water and one-third of the power required by other sand dewatering and classifying machines.

Plus, the large volume of wastewater that’s produced by screw washers must be managed (often in settling ponds) and may require costly treatment before it can be discharged or recycled, representing a major and growing operational expense.

Minimized Maintenance and Maximized Safety

Underperforming screens demand constant human intervention, which carries both direct labor costs and severe safety risks. The most frequent and labor-intensive task associated with conventional screens is the replacement of worn-out screen media.

More important than the financial cost is the human one. In the mining and aggregate industries, each time a crew is sent to repair or replace a component, they are exposed to significant risks, including falls, entanglement in machinery, and unexpected equipment movement.

Buying the right screening equipment isn’t just about meeting today’s production targets — it’s about setting your operation up for long-term success. High-performance screens help you minimize costs, maximize output, and extend the life of your entire processing system.

At AEI, we design screening solutions that deliver long-lasting performance and measurable ROI. Contact us today to learn how our innovative screening technology can reduce costs and boost your bottom line.

The post How Better Screens Save Money Over Time appeared first on AEI Screens.

One key factor that differentiates high-performing aggregates is whether they’ve been washed. Washed aggregates have been thoroughly cleaned to remove impurities that can weaken bonds and compromise the integrity of concrete or asphalt. In this article, we’ll explain why washed aggregates are essential and how they contribute to more resilient construction materials.

The Risks of Unwashed Aggregates

Unwashed materials often contain contaminants (like silt, clay, and organic matter) that interfere with the bonding process between the aggregate and the cement paste or asphalt binder. This weak bond leads to a range of performance issues, from reduced strength to poor load-bearing capacity.

Contaminants can also prevent proper compaction, leading to voids and inconsistencies within the finished product. These flaws can result in visible surface imperfections, cracking, and accelerated wear — especially in high-traffic areas or harsh weather conditions. Over time, structures built with unwashed aggregates are more likely to suffer from early failure, increasing maintenance needs and overall costs.

By removing these impurities through washing, producers can ensure a cleaner, more consistent material that performs reliably and meets quality standards for modern construction.

Using Washed Aggregates in Concrete Production

The washing process ensures a cleaner aggregate that bonds more effectively with cement paste, leading to improved structural integrity and durability — especially important in load-bearing applications or environments with freeze-thaw cycles.

A cleaner mix is easier to place, compact, and finish, resulting in a smoother surface and fewer defects. This is especially important for decorative or exposed concrete applications, where appearance matters just as much as performance.

Using washed aggregates also reduces the risk of long-term issues, like shrinkage cracking, poor curing, or alkali-silica reaction (ASR), which can compromise concrete over time. The result is a more reliable, longer-lasting product that requires less maintenance and offers better value over the life of the structure.

Using Washed Aggregates in Asphalt Production

Washed aggregates offer a cleaner, more consistent material that leads to stronger bonds with the asphalt binder. This improved adhesion helps reduce the risk of stripping, where moisture breaks the bond between the aggregate and binder, causing pavement failures, like potholes and raveling.

Washed aggregates also contribute to more uniform gradation and better compaction during paving. This results in a denser, more stable surface with fewer voids, improving the pavement’s resistance to traffic loads, weather conditions, and wear over time.

Additionally, using washed materials helps ensure compliance with state DOT specifications and quality control standards, especially for high-performance projects, like highways, runways, and heavy-duty industrial lots. In the long run, this leads to fewer repairs, lower lifecycle costs, and greater satisfaction for both contractors and end users.

The Environmental Benefits of Washed Aggregates

• Reduced dust and air pollution: Washing removes fine particles from the aggregate surface, which lowers dust emissions during transport and processing, improves air quality on and around the construction site, and reduces the need for dust suppression methods, conserving water.
• Improved water management and recycling: Washing systems often include closed-loop water recycling, reducing water waste. And fewer fines mean less contamination in stormwater runoff from stockpiles, helping prevent water pollution.
• More durable, long-lasting pavement and structures: Clean aggregates produce stronger, longer-lasting concrete and asphalt, which reduces the frequency of repairs and replacements, minimizes resource consumption and waste, and lowers the carbon footprint associated with manufacturing and transporting new materials.
• Reduced use of cement and asphalt binder: Less cement (in concrete) or binder (in asphalt) may be required, reducing carbon emissions from cement production (a major CO₂ source) and petroleum use in asphalt binder production.
• Compliance with environmental standards: Using washed aggregates helps producers meet regulatory requirements for clean materials in construction and avoid penalties or project delays caused by using substandard or contaminated materials.

Applications that Demand Washed Aggregates

• Structural concrete: high-strength concrete is used in bridges, parking structures, and high-rise buildings
• Pavement and roadway construction: washed aggregates are critical in asphalt mixes for highways, interstates, and city streets
• Airport runways and taxiways: these high-load, safety-critical surfaces require exceptional bonding and resistance to cracking
• Ready-mix and precast concrete: used for residential foundations, sidewalks, and precast panels
• Decorative and architectural concrete: exposed aggregate finishes demand clean, visually appealing stone, and washed aggregates provide a consistent color and texture
• DOT and government projects: most state and federal infrastructure projects have strict material specifications, and washed aggregates are often required to meet these standards

Using the Ortner for Concrete and Asphalt Production

Engineered for efficiency and precision, the Ortner® washing system removes fines, clay, and silt while preserving valuable product — delivering clean, consistently graded material with minimal water usage. Its compact footprint, low operating costs, and reliable design make it an ideal choice for producers looking to meet the demands of modern concrete and asphalt production.

If you have any questions or need more information, please don’t hesitate to contact us at AEI Screens — we’re here to help.

Related Article

How the Ortner Compares to Traditional Screw and Log Washers

The post Why Washed Aggregates are Essential for Concrete and Asphalt Production appeared first on AEI Screens.

Screw washers, log washers, and the Ortner® each have their own strengths and limitations depending on the material type, end-use, and production goals, and in this article, we’ll compare them to help you determine the best solution for your operation.

Traditional Screw Washers

Screw washers (also known as spiral classifiers or fine material washers) are commonly used in aggregate washing systems to remove clay, silt, and fine particles from sand and gravel.

They consist of a sloped trough with a rotating screw (or auger) inside. As water and material enter the lower end of the trough, the screw pushes the cleaned aggregate uphill, while the dirty water and fines overflow out the back.

Their performance is adequate for basic sand classification and dewatering, but they’re not ideal for processing heavily contaminated or ultra-fine materials, as they may lose finer particles with the overflow water.

Considerations for Screw Washers

Screw washers tend to require regular maintenance due to wear on the screw shaft, flights, and bearings — especially when handling abrasive materials. Grit and debris can accelerate wear, and the submerged components are more susceptible to corrosion and mechanical breakdowns. Over time, these factors can result in higher operating costs due to frequent part replacements and maintenance downtime.

Screw washers use a relatively large amount of water compared to more modern systems, like the Ortner. They rely on constant water flow to separate fines from usable product, and much of this water is lost in the overflow process.

This equipment typically has a moderate to large footprint depending on their capacity. Installation can be relatively straightforward, but they require a reliable water supply and adequate space for water collection and disposal. Additionally, because of their overflow design, settling ponds or additional water management systems are often needed, which adds to the setup complexity.

Log Washers

Log washers are heavy-duty washing machines designed to scrub and remove tough clay, mud, and other contaminants from coarse aggregate (typically over 3/8″). They consist of a long tub with two rotating shafts fitted with paddles or blades that agitate the material aggressively. As the material moves through the washer, the paddles churn and scrub it thoroughly, breaking up stubborn clay and separating debris from the aggregate.

They are commonly used in mining, quarrying, and recycled aggregate operations where basic rinsing isn’t enough. However, they are not ideal for fine materials, as those can be washed away or lost in the process.

Considerations for Log Washers

While their aggressive scrubbing action is effective, it depends on a significant amount of water to move debris out of the washer. Because the system doesn’t reclaim water efficiently, log washers are less water-efficient than systems, like the Ortner, and typically require large settling ponds or water recycling setups to manage runoff.

Related article: Why Mine Dewatering is Essential for Efficient Mining Operations

Log washers are rugged and durable, but they are also mechanically intensive. The rotating shafts, paddles, and gearboxes are all subject to high wear, due to the abrasive nature of the materials being processed. Over time, the cost of replacing paddles and shafts, managing gearbox repairs, and handling corrosion and buildup can add up, making maintenance and operating costs fairly high compared to simpler systems.

Log washers have a large footprint, both due to the physical size of the machine and the support systems needed:

• Water supply and management
• Concrete pads or structural supports
• Settling ponds or water recovery systems

Their installation is more complex, often requiring custom foundations, heavy-duty piping, and additional infrastructure to manage water and slurry discharge.

The Ortner

The Ortner® is an advanced aggregate washing and fines removal system. Unlike traditional washers that rely heavily on water and mechanical action, the Ortner uses a combination of water, gravity, and a rotating dewatering pan to separate fines from usable material. It’s designed to efficiently clean and dewater sand, crushed stone, and other aggregates with:

• Minimal water use
• Lower energy consumption
• Minimal maintenance and downtime
• Lower operating costs 

Additionally, the Ortner is ideal for operations with space constraints. It has a smaller footprint than screw or log washers, simple installation with minimal infrastructure requirements, and no need for large settling ponds or extensive water management systems.

If you have any questions about the Ortner, please don’t hesitate to reach out to us.

The post How the Ortner® Compares to Traditional Screw and Log Washers appeared first on AEI Screens.

To ensure high-quality materials and efficient production, precise sand classification is essential. Traditional methods often struggle with fine particle recovery, water waste, and inconsistent separation, making advanced solutions like the Ortner® system a game-changer.

How is Sand Classified?

Sand can be classified by composition (silica versus calcium carbonate or heavy-mineral sand), purity, and intended use, but it’s typically classified according to grain size:

• Fine sand: particles between 0.075 mm to 0.425 mm in diameter (used in plastering, fine concrete, and glassmaking)
• Medium sand: particles between 0.425 mm to 2 mm in diameter (commonly used in construction, mortar mixes, and casting)
• Coarse sand: particles between 2 mm to 4.75 mm in diameter (typically used in concrete production and for filling purposes)
• Very coarse sand: particles larger than 4.75 mm (often found in gravel mixtures)

The Ortner is a diverse machine that can handle a wide range of material sizes. Learn how a sand classifier works.

The Role of Sand in Construction and Manufacturing

Construction

Sand is a primary component of concrete, mortar, and asphalt, providing strength and durability. Proper classification of sand ensures consistent texture and bonding, preventing cracks and structural weaknesses.

In road construction, poorly graded sand can create voids, while properly graded sand helps create smooth, stable surfaces in asphalt mixtures.

Glassmaking

Unclassified sand often contains clay, silt, and organic matter, which can compromise its quality. And the glass industry requires high-purity silica sand with a specific grain size to produce clear, strong glass. Impurities (such as iron oxides) can affect the transparency and color of the final product.

Foundries

Foundry sand is used to create molds for metal casting, shaping everything from automotive parts to industrial machinery. The sand must have consistent grain size and high thermal resistance to withstand molten metal without breaking down.

Additionally, properly classified sand improves production efficiency, reducing material waste and improving processing speed. Consistent sand size also reduces wear and tear on equipment, extending its lifespan.

Industrial Applications

Water and air filtration systems rely on precisely classified sand to remove impurities efficiently. In ceramics manufacturing, silica sand plays a role in forming and strengthening ceramic products.

Challenges in Traditional Sand Classification Methods

Wet Washing

Traditional wet washing methods consume large amounts of water, which can lead to regulatory challenges and restrictions in water-scarce regions. Plus, the process requires energy-intensive pumps and drying systems, increasing operational costs.

Screening

Standard screens have difficulty capturing fine particles, allowing valuable material to be lost in wastewater. These screens also struggle with wet or sticky sand. Excess moisture leads to blinding, where fine particles block screen openings, further hindering separation and increasing maintenance downtime.

Many screening systems rely on fixed mesh sizes, which may not effectively separate a range of particle sizes. This can lead to oversized or undersized particles in the final product, reducing its usability in specific applications.

Settling Ponds

Settling ponds are commonly used to manage wastewater and capture fine particles, but they require significant space and regular maintenance. As sediment accumulates over time, costly dredging or expansion becomes necessary to keep them functional.

The slow sedimentation process can delay operations, reducing overall productivity.

How the Ortner® System Provides Precise Sand Classification

The Ortner® sand classifier relies on moisture-based separation rather than traditional wet washing. This allows for precise classification of sand into different sizes without the excessive water usage or energy consumption found in wet processes.

One of the key features of the Ortner® is its high-frequency vibration, which ensures accurate particle separation. The vibration helps to dislodge fine particles, allowing them to be effectively sorted from the coarser grains. This results in a more efficient fines recovery compared to traditional screening methods, which often lose valuable fine sand to wastewater.

With fewer moving parts than traditional screens, the Ortner® also requires less maintenance, leading to lower downtime and cost savings.
Contact AEI today to learn how the Ortner can meet your specific needs.

The post Why Proper Sand Classification Matters in Construction and Manufacturing appeared first on AEI Screens.

What is Mine Dewatering?

Dewatering a mine, in simple terms, is the removal of excess water from a mining site. It is common practice, as mines often extend below the groundwater table, where water naturally infiltrates the area. Other common sources of excess water buildup in a mine include standing groundwater, streams, rivers, lakes, or ponds flowing into the mine as well as rainfall or snowmelt accumulation.

Implementing a dewatering system with the proper equipment to extract and redirect water build-up will ensure a smooth operation, regardless of the type of mineral extraction taking place.

The Importance of Water Management in Mining

Productivity

The efficiency of a mine can quickly be thwarted by excess water or flooded areas in a mine. Having a well-designed water management system ensures timelines and expectations are met.

Safety

While modern-day mines largely do not use manual miners (opting for automated machinery and technology instead) uncontrolled water in mines can create hazardous conditions. These include increased risk of weakened wall structures, landslides, and floods. It’s important to note that miners may still occasionally enter mines, and proper dewatering helps mitigate the risk of physical harm.

Environmental Considerations

It’s common for mining activities to significantly impact surrounding water resources as minerals, soil, and other sediments are extracted and shifted around. For this reason, regulations, such as the Clean Water Act, require mining companies to treat and properly dispose of water to prevent contamination of nearby drinking water systems and protect ecosystems.

Learn more about green mining.

Achieving a Smooth Dewatering Process

This begins with conducting a site assessment and selecting the proper dewatering equipment and method. Equipment (such as sump pumps, wellpoint systems, educator systems, and deep well dewatering methods) are used to extract water, while sand washing equipment helps remove fines from the material.

How the Ortner Improves the Mine Dewatering Process

Leaning on specialized equipment in a dewatering operation will help with cost, time, and operational savings. And the Ortner® tackles several of the key issues faced by mining dewatering operations:

• Water usage: the Ortner uses 1/3 the amount of water a traditional dewatering machine would, significantly reducing water consumption
• Power efficiency: the Ortner® uses about 1/3 of the power used by conventional dewatering machines
• Material handling: its high-frequency vibration ensures that materials are separated quickly, producing a drier product and making conveying and stockpiling easier and less prone to clogging
• Durability: the compact and lightweight design of the Ortner® minimizes wear and tear

To inquire about the Ortner® for your mine dewatering system, contact the experts at AEI today.

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Whether you’re optimizing current operations or exploring new solutions, dewatering screens offer essential benefits for modern mineral processing.

What is Mineral Processing?

Mineral processing involves isolating minerals from ores through physical and chemical methods. The process involves crushing, grinding, sizing, classifying,

concentrating, and dewatering. The goal is to produce products suitable for commercial, industrial, and other uses.

Solid-liquid separation, which extracts mineral-rich ores and fines (small particles of valuable minerals) from water, is a key component of mineral processing. It’s considered a critical step as it:

• Separates valuable minerals from the gangue (material without any commercial value) and other ore impurities, thereby improving ore concentration
• Eliminates impurities to produce final products of superior quality and composition

The isolated minerals are then processed in the next stage known as dewatering. This step focuses on removing the moisture content of the minerals to achieve the desired concentration levels before the products hit the market. The dewatering process uses mineral processing equipment, such as dewatering screens.

Dewatering Screens and Their Applications

A dewatering screen comprises a sturdy frame and a screen with openings for the liquid to pass through. Featuring a vibrating mechanism, it efficiently segregates solids from liquids. To optimize effectiveness, the speed of rotation, the angle of inclination, and other components of the machine are adjusted based on the properties of the feed material.

From mineral and ore processing to construction and waste management, dewatering screens demonstrate versatility in handling different materials, particle sizes, and moisture levels. They are available in customizable options to cater to specific operational needs. 

The Benefits of Using Dewatering Screens

Dewatering screens are integral in industries requiring solid-liquid separation. They provide several benefits, including:

• Enhanced product quality: Moisture significantly impacts the usability of minerals. By minimizing moisture content through dewatering screens, industries can improve the overall quality of end-products and simplify their handling and transport procedures. 
• Increased efficiency and throughput: Compared to traditional methods, these machines can handle high volumes of material, thus boosting overall efficiency, throughput, and productivity.
• Cost savings: Dewatering screens generally have lower energy consumption compared to other equipment, like filter presses and centrifuges, contributing to reduced production costs. 
• Minimal environmental footprint: These machines minimize the ecological impact of industrial operations by promoting water recycling, decreasing the volume of wastewater needing treatment, and ensuring compliance with environmental standards. 

Learn more about sustainable mining practices.

The Ortner: A Multi-Functional Solution for Mineral Dewatering and Classification

The Ortner is an efficient solution for dewatering various minerals and ores. Lightweight and compact, it can easily be transported and installed. In addition, it provides greater capacity, efficiency, and flexibility as it allows for various adjustments to meet different sand specifications properties.

The Ortner is not only designed for dewatering but also for removing fines, classifying, and rinsing sand and other fine materials, making it an all-in-one and cost-effective machine. Compared with other dewatering and classifying equipment, it boasts less power and water consumption and requires minimal maintenance, offering substantial cost savings.

To learn more about the operational benefits of the Ortner, contact us today. 

The post Advantages of Using Dewatering Screens in Mineral Processing appeared first on AEI Screens.

The extraction and processing of sand come with significant environmental challenges, especially in the mining industry. This article explores the environmental impact of sand mining and the crucial role of sand washing in fostering sustainability.

What Is Sand Washing?

It’s the process of cleaning and separating sand to remove unwanted materials, such as clay, silt, dust, and other fine particles. This step is essential for producing sand that meets quality standards for construction, manufacturing, and industrial applications, where consistency and cleanliness directly impact performance and durability.

The Environmental Challenges of Sand Mining

Unregulated sand mining poses severe threats to the environment, including:

• Ecosystem disruption
• Riverbed erosion
• Biodiversity loss
• Groundwater depletion
• Air pollution

The urgency to address these issues has led to a growing emphasis on sustainable practices within the mining industry.

The Role of Sand Washing in Sustainable Mining

Sand washing emerges as a key solution to mitigate the environmental impact of sand mining. 

By removing impurities and contaminants, washed sand ensures that the extracted sand poses minimal ecological harm and is of high quality. The resulting material is clean and suitable for a variety of applications, including construction, concrete production, and manufacturing.

Find out how a sand classifier works to remove unwanted grains.

Compliance with Environmental Regulations

Meeting environmental regulations is non-negotiable for sustainable mining practices. Sand washing plays a vital role in ensuring compliance by removing pollutants and contaminants, preventing the discharge of pollutants into water bodies, and mitigating airborne particle emissions.

Water Consumption and Conservation

While sand washing is effective, it is also water-intensive. Addressing this challenge involves implementing strategies for reducing water consumption in this process. Innovative technologies and practices, such as water recycling and closed-loop systems, contribute to sustainable water management in mining operations.

Energy Efficiency

Energy consumption is another aspect that requires attention. Equipment can be optimized for energy efficiency, helping reduce the environmental footprint of a sand washing system.

AEI’s Water and Energy Efficient Sand Washing Equipment

The Ortner® Sand Classifier is a specialized piece of equipment designed to improve the quality of processed sand while minimizing the environmental impact of sand mining through its innovative and sustainable features. The Ortner can remove impurities, contaminants, and fines without the use of excess energy or water. And all the water that it removes from manufactured sand can be reused to wash additional batches of sand.

For operations looking for sand washers that can handle tough and wet materials while helping minimize the environmental effects of sand mining, contact Aggregates Equipment, Inc.

The post The Environmental Impact of Sand Washing appeared first on AEI Screens.

Environmental Impacts of Traditional Mining

Traditional mining practices have long been associated with significant environmental impacts, including:

• Habitat destruction and deforestation
• Soil erosion
• Air and water pollution
• Waste generation

These impacts are no longer viewed as acceptable, and the resulting technologies have helped the industry transition to greener alternatives. 

Understanding Green Mining

Sustainable mining represents a commitment to responsible practices that minimize environmental impacts while extracting valuable minerals and resources. This approach aims to strike a balance between meeting the world’s resource demands and protecting the planet for future generations. Here are some key advancements in green mining.

Sustainable Mineral Extraction

Traditional mining methods often involve blasting and excavation, resulting in habitat destruction and land disturbance. 

Environmentally friendly mining embraces innovative techniques, like in-situ recovery and bioleaching, which minimize surface disruption and reduce the environmental footprint.

These methods are particularly useful for extracting minerals from ore bodies that are hard to access through traditional means.

Energy Efficiency in Eco-Friendly Mining

Green mining emphasizes energy efficiency by using advanced equipment, such as electric vehicles and energy-efficient machinery. Renewable energy sources like solar and wind power are also being integrated into mining operations to reduce reliance on fossil fuels.

Pollution Control

Pollution control focuses on minimizing the release of harmful substances into the air, water, and soil during mining operations. This includes using advanced filtration systems, treating wastewater, and reducing dust and emissions to protect nearby ecosystems and communities.

Water Management and Conservation

Advances in water recycling, treatment, and conservation technologies are helping mines reduce water usage as well as contamination of local water sources. This not only benefits the environment but also mitigates potential conflicts with local communities.

The Ortner dewatering equipment has the ability to efficiently dewater mining materials while minimizing the environmental impact, making it an asset for responsible and sustainable mining practices. 

Learn more about the Ortner’s energy efficient dewatering capabilities for mining, aggregate, and other industries.

Biodiversity Conservation

Sustainable mining practices prioritize biodiversity conservation by implementing responsible land reclamation and habitat restoration plans. This includes rehabilitating mining sites to their natural state after extraction, ensuring that ecosystems can thrive once again.

Sustainable Materials Handling

Efficient materials handling is essential for minimizing waste and reducing the environmental impact of mining. Innovations help increase resource recovery rates and decrease waste production. For example, bulk ore sorting separates valuable minerals from waste early in the process.

Recycling and Circular Economy

Environmentally friendly mining extends beyond extraction to include recycling and responsible resource management. Mines are increasingly implementing recycling programs for materials like batteries and electronics, contributing to a circular economy where resources are reused and repurposed.

The BIVITEC vibrating screen is equipment that can contribute to green mining by improving resource efficiency, reducing waste, conserving energy and water, and minimizing the environmental impact of mining operations. Its innovative design and efficient screening capabilities make it a valuable tool for mining companies committed to sustainability.

Learn how the BIVITEC vibrating screen can benefit your mining operation.

The post Green Mining: Advancements in Eco-Friendly and Low-Impact Mining Practices appeared first on AEI Screens.

However, there are several solutions to help improve water conservation – some options even have the potential to increase profits and productivity. 

Why Is Water Management a Problem? 

Increasing water conservation is not only a regulatory issue: water shortages in mining areas can cause a stop in production which ultimately stops profits.

In addition, local communities that may be under conservation notices add additional pressure to mining operations to reduce water consumption.

Regardless, the issue is clear: water must be conserved for an operation to remain sustainable and efficient. 

The Challenge Facing Aggregate Operations 

Washing aggregate and sand, whether natural or manufactured, traditionally uses a significant amount of water. Measuring and regulating mining water usage has also been inconsistent.

The challenge is shifting to technologies and practices that create a more sustainable aggregate mining operation while continuing to meet global supply demands and quality specifications. 

How To Identify Water Conservation Issues At Your Plant

To improve water conservation, mining operations must conduct a thorough water audit. An audit takes time and effort but will yield results. Part of the water audit should include a thorough equipment inspection.

The audit should include:

• Reviewing your operation’s water source. Is this source efficient? Are there better opportunities for sourcing?
• Inspecting equipment for efficient use of water. Is your equipment operating under ideal conditions? Is there water loss from leaks or poorly calibrated equipment?
• Identifying environmental impacts. Is wash water properly monitored for excess discharge? Are all local and federal regulations followed?

Auditing your operation’s water usage and waste is only the first step in the process. Once issues have been identified, steps can be taken to improve your plant’s water management strategy. 

What Can Be Done to Improve Sustainability in Water Management

There are several ways to improve an operation’s water management. To see the most benefit, both processes and technology must be addressed. 

Minimize Reliance on Settling Ponds

Minimizing reliance on settling ponds is another way to decrease the impact on water supply. Settling ponds have been beneficial for some operations but will not continue to be as unregulated and useful over time. Even now, settling ponds can contaminate local water systems, nearby equipment, and even cause adverse effects for workers. Looking for alternate solutions is not just smart planning, it is the future of aggregate mining. 

Reuse Water

Implementing water recycling technologies allows mining operations to treat and reuse water, reducing freshwater consumption and minimizing wastewater discharge. Advanced filtration systems and sedimentation tanks enable the recovery of water for various operational needs.

Upgrading Equipment To Meet Modern Challenges

The latest advances in equipment are evident in their water conservation efforts. The right equipment can make water management more effective and relegate settling ponds to a thing of the past.  

Older machines use more water in the washing processes, while newer machines are designed with water conservation in mind. New machines boast simple designs with easy maintenance plans but with advanced capabilities. New machines often consume less power but also operate at higher capacity and produce a drier product, increasing productivity and profit. 

AEI’s Aggregate Screening Solutions

Aggregates Equipment, Inc. offers two innovative solutions for improving water sustainability in aggregate mining operations: The Ortner and BIVI-TEC. 

The Ortner is an aggregate dewatering and classifying machine designed with water conservation in mind. A true advancement in machinery, the driver and vibrating mechanisms are mounted under the pan preventing contamination with the water and processed materials. The Ortner uses less water, about a third of conventional dewatering equipment, to produce a cleaner product that meets specifications uniformly. 

Meanwhile, the BIVI-TEC allows for efficient dry processing that eliminates the need for water. By using a dual-vibratory screening process, the BIVI-TEC eliminates clogging and blinding when processing manufactured sands, chips, and ag lime.

By upgrading equipment, aggregate mining operations can also up their stakes in water conservation. New equipment, especially that which is more efficient in design and production, is an investment that will continue to pay off over the long term rather than settling ponds and aging machinery. Contact AEI today to learn more about the benefits of The Ortner. 

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