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Drum Dryers, Rotary Kilns, and Crushing Equipment: Complete Solutions for Quartz Sand Processing​

    The global surge in solar energy projects and construction activities has driven unprecedented demand for high-quality quartz sand and photovoltaic sand. These materials require precise processing to meet strict purity and particle size standards, with crushing, drying, and calcination being critical stages. Sentai Machinery’s jaw crushers, six-layer rotor compound sand makers, drum dryers, and rotary kilns form a complete processing line, delivering consistent results in quartz sand production worldwide.​

Jaw Crushers: Primary Crushing for Quartz Ore​

    Quartz ore extracted from mines often comes in large chunks, some exceeding 500mm in diameter. Our jaw crushers serve as the first step in reducing these raw materials to manageable sizes. With a robust frame and high-manganese steel jaws, they efficiently crush hard quartz ore to 50-100mm particles.​

    A key advantage is the adjustable discharge setting, allowing operators to tailor particle size to downstream needs. For photovoltaic sand production, where uniformity is critical, the crusher’s 6:1 reduction ratio ensures consistent output. A quartz mine in Brazil increased primary processing efficiency by 25% after replacing its old crusher with our model, thanks to the enhanced toggle plate design that minimizes downtime during maintenance.​

Six-Layer Rotor Compound Sand Makers: Shaping High-Quality Particles​

    After primary crushing, our six-layer rotor compound sand makers transform quartz fragments into precisely graded sand. The unique six-layer rotor design creates multiple impact zones, producing cubical particles with tight size distribution—essential for both construction and photovoltaic applications.​

    Operating at 1200-1500 RPM, the sand maker achieves 80% yield of 0.15-5mm particles, reducing oversize and undersize waste. For photovoltaic sand, the adjustable rotor speed allows fine-tuning of particle shape to meet solar glass manufacturers’ strict standards. A processing plant in Malaysia reported a 30% increase in high-grade sand output after adopting this machine, attributing the improvement to the six-layer rotor’s ability to break down quartz without generating excessive fines.​

Drum Dryers（Rotary Dryer）: Precision Moisture Control​

    Quartz sand, after crushing, typically contains 15-25% moisture, which can hinder subsequent processing. Our three-pass drum dryers reduce moisture to 0.5-1%, ideal for further purification. The internal flighting tumbles sand through three heat-exchange zones, maximizing efficiency. Operating at 120-200°C, it dries gently without altering the crystalline structure—vital for photovoltaic use. An Australian producer saw 30% energy savings due to the heat recovery system.​

Rotary Kilns: Purification and Activation​

    After drying, photovoltaic sand requires calcination to remove impurities like iron oxides. Our rotary kilns, operating at 1000-1200°C, create an oxidative environment that volatilizes contaminants. Equipped with multi-zone thermocouples, they maintain temperature uniformity within ±10°C. A European solar glass manufacturer using our 3.2m×45m kiln achieved 99.99% silica purity, meeting photovoltaic wafer standards.​

Integrated Processing Line​

    A typical workflow combines these machines:​

    Jaw crusher reduces ore to 50-100mm.​

    Six-layer rotor sand maker produces 0.15-3mm particles.​

    Drum dryer lowers moisture to 0.5-1%.​

    Rotary kiln calcines to remove impurities.​

    A Chinese supplier integrated this line, increasing high-grade sand production by 40% and cutting reject rates from 15% to 3%.​

Meeting Industry Challenges​

    Our equipment addresses key challenges:​

    Energy efficiency: Crushers and sand makers with variable frequency drives adjust power usage; dryers and kilns use waste heat.​

    Purity control: Closed-circuit design minimizes contamination, while kilns’ precision heating ensures impurity removal.​

    For producers capitalizing on the solar boom, Sentai Machinery’s complete line offers reliable solutions. Contact us to design your tailored processing system.