- Drying and Screening Plants
IPS designs, provides, and installs state-of-the-art industrial minerals drying and screening plants that efficiently produce, store, and load out a wide range of products, serving large and diverse industries and applications.
Our drying and screening plants are specially designed to maximize drying performance, which optimizes the dried product screening and minimizes the process footprint. As a result, we achieve the lowest possible operating cost at the maximum yield, boasting one of the lowest industry personnel headcount.
Our plants are characterized by their robust and reliable designs that ensure ease of operation and excellent maintenance access.
Supported by an intelligent control system, our plants provide operators with full real-time process control while maintaining personnel and equipment safety.
Our intelligent plant control system allows the monitoring and control of all critical process variables, such as moisture content, fuel consumption, raw feed, dried product throughput, and product storage. Additionally, our intelligent control system not only allows the plant personnel to troubleshoot the entire process from the control room but from any remote location with Internet access.
In addition to our flagship intelligent control system, our plants are equipped with a high-efficiency close-capture dust collection system to meet the highest environmental standards, making our drying and screening plant the industry’s best.
- Resin Coating Plants
IPS designs the most advanced hybrid resin coating plants in the industry, our hybrid plant offers the recipe accuracy of a traditional batch plant with the production throughput of a continues plant.
Our hybrid resin coating plants are designed to process approximately 20 to 22 TPH per line with a single 2,500-pound batch mixer and have the following unique features:
• Patented heat recovery system that allows the plant to reduce fuel consumption and to optimize the sand temperature control;
• Patented sand heater unique temperature feedback control;
• Patented real-time sand mixer and sand in-let temperature measurement;
• Patented sand flow control system;
• Dust tight resin unloading and storage system;
• Accurate mixer and additives addition system (max 2% error);
• Recipe management system;
• Organic compounds emissions thermal oxidizing control system;
• Raw sand and Finished Product Handling closed caption dust collection system;
• Intelligent control system that provides critical process information to management and operation staff;
• Raw sand unloading system with automatic sampling and raw sand product inventory;
• Finished product rail and truck load-out systems with the same features as our state-of-the-art transload facilities.
- Transload Facilities
IPS’s transload facilities are designed and built to meet customer-specific needs. These facilities can unload from single spotted cars to unit trains, and have a user friendly and efficient load-out system that allows the loading out of a truck in 4 to 5 minutes, depending on the weight re-strictions. Our transload systems have the following unique features:
Unloading System
• Unloaded material screening system to prevent all foreign objects from been transferred to the storage silos;
• Empty belt unloading conveyor alarm system;
• Closed caption dust collection system to collect fugitive silica dust;
• Real-time unloading rate;
• Automatic storage silo selection;
• Real-time silos inventory management;
• Minimum personnel required.
Load-Out System
• Minimum load-out time (approximately 5 minutes, scale-in/scale-out);
• +/- 1 percent load-out accuracy;
• Closed caption dust collection system to collect fugitive silica dust;
• Accurate inventory management system that can be accessed remotely and can interface with third parties’ ERP software;
• Multilane load-out that can accommodate several trucks simultaneously;
• Custom form print-outs such as BOL, inventory, and reports;
• Minimum required personnel to run the loading system;
• Local and remote load-out controls provides real-time remote access to review the plant’s performance and inventory as well as remote support.
