The present invention relates generally to apparatus used for separating and washing sand, clay, shale and other contaminants from raw material aggregates, and more

particularly to an aggregate washing plant.

Traditional aggregate washing plants are designed to be broken down into constituent parts for stowage and travel from one location to the next. This results in considerable set-up times on-site and the use of many vehicles to move the constituent parts into position. There have been several attempts to improve this traditional situation by providing these aggregate washing plants on a single mobile chassis unit to reduce the time spent during setup and provide ease of transport. However these single mobile chassis units still require

considerable time of the order of days to construct and modify on-site and also require the use of multiple specialised operators during set-up and decommissioning. Furthermore single chassis aggregate washing plants typically require that specialised transporters be employed to transport the equipment from one location to the next.

It is an object of the present invention to further mitigate the abovementioned set-up and transport problems of the traditional aggregate washing plants and to provide an aggregate washing plant which requires reduced delivery and set-up/decommissioning times. It is also an object to reduce the requirement for additional equipment and/or specialised operators to aid in the set-up and decommissioning processes; thus reducing expenses occurred.

Accordingly, the present invention provides an aggregate washing plant comprising a plurality of individual aggregate washing and processing components being adapted to form a modular aggregate washing plant capable of being assembled and stored within the internal boundaries of at least two framed containers, the aggregate washing plant being fully operable while stored in the containers. Ideally, the framed container is an ISO standard container or a HiCube Shipping Container.

Preferably, the framed container is an ISO 40ft standard container.

Advantageously, these containers can be transported on any trailer.

Furthermore, the containerised aggregate washing plant can be shipped in their operating state though any port or on any road without prior consent or escort from authorities or using specialist transport.

Preferably, the aggregate washing plant comprising aggregate washing means, trash screening means, aggregate washing screening means, sand plant means, storage means for process products and waste bi-products, clean/grey water pump means, power generating and distribution means and means for interconnecting interoperable components of the aggregate washing plant.

Ideally, the framed containers being capable of engaging one another.

Preferably, the aggregate washing apparatus being reconfigured from traditional known working orientations to ensure that protrusions of the individual components do not extend laterally and/or longitudinally beyond that of the internal boundary of the stackable framed container when housed within the container in use and/or stowage.

Ideally, the aggregate washing components being configured to ensure that protrusions of the individual components do not extend laterally and/or longitudinally beyond that of the internal boundary of the stackable framed container when housed within the container in use and/or stowage.

Ideally, the containerised aggregate washing plant comprises quick connect and operate means for connecting interoperable components in adjacent containers.

Preferably, by quick connect and operate means we are referring to the functionality where the containerised aggregate washing plant comprises means which enable an operator to simply and quickly connect the components held within each container to enable the full operation of a working aggregate washing plant without the requirement of complex mechanical mechanisms or equipment or specially trained personnel which would not ordinarily be on-site.

Ideally, the quick connect and operate means are provided by mechanical quick attach and release components.

Preferably, the quick attach and release components are provided by any of or any combination of press fit, snap fit, twist lock, threaded screw or bayonet connection between two of the interconnecting interoperable washing and processing components.

Ideally, quick connect and operate clamping means such as toggle clamps or any suitable quick connecting clamping means may be used.

Alternatively, magnetic coupling means may be used between interconnecting interoperable washing and processing components.

Advantageously, this enables the containerised modular aggregate washing plant system to operate by the simple connection of constituent parts without the requirement for complex equipment. Conventional aggregate washing plants are required to be built and modified by extending jacking legs, having chute work fitted, cross bracing expansions etc. on site. The containerisation and quick connect and operate features of the present invention significantly reduces the time required during apparatus set-up and decommissioning and also removes the requirement for specialised service engineers on-site. This reduction in time has been recorded as a reduction from two to three days, requiring two trained operators to as little as two to three hours for one non-specialist operator.

Further advantageously, an aggregate washing plant confined within the internal boundaries of at least two framed containers provides an operator with a system that can be easily transported from one location to the next, without the need to collapse the washing plant into the individual components; such is the requirement with the traditional set-up. Furthermore once on site the compact nature of the plant provides a minimal footprint for ease of use within confined areas but also provides a greater manoeuvrability of the product should this be required.

Ideally, the aggregate washing plant is operable while mounted on a trailer. Preferably, the aggregate washing plant confined within the internal boundaries of at least two framed containers mounted on a trailer provides an operator with a system that can be easily transported from one location to the next, without the need to collapse the washing plant into the individual components.

Ideally, the framed containers have correspondingly located engagement means for securely retaining one another together.

Preferably, at least one framed container comprises an aggregate washing means. Ideally, at least one framed container comprises a trash screening means.

Preferably, at least one framed container comprises an aggregate washing screening means.

Ideally, at least one framed container comprises sand plant means.

Preferably, at least one framed container comprises an aggregate washing means, a trash screening means, an aggregate washing screening means and a sand plant means.

Ideally, at least one framed container comprises a plurality of storage units for process products and waste bi-products.

Preferably, at least one framed container comprises clean/grey water pumps.

Ideally, at least one framed container comprises power generating and distribution means

Preferably, at least one framed container comprises a plurality of storage units for process products and waste bi-products, clean/grey water pumps, and a power generating and distribution means.

Preferably, the framed containers are stackable upon one another so that the container containing an aggregate washing means, a trash screening means, an aggregate washing screening means and a sand plant means (the upper framed container components) are locatable above the framed container containing a plurality of storage units for process products and waste bi-products (the lower framed container components) in a fully operational mode of the aggregate washing plant. By fully operational mode we mean that the aggregate washing plant can operate as a fully functional washing plant.

Advantageously, the stackability of the containers provides the aggregate washing plant with a means to utilise gravity rather than conveyors typically utilised in the traditional aggregate washing plant set-ups to move the particulates and waste waters from the processing components located in the upper container to the storage units held within the lower container.

Preferably, interoperable upper and lower framed container components are connectable by use of a connecting means.

Ideally, the connecting means connecting the upper and lower framed container components are conduits.

Preferably, the upper and lower framed containers comprise correspondingly located apertures located proximal to the base of the upper framed container and proximal to the ceiling of the lower framed container.

Most preferably, the upper and lower framed containers maintain correspondingly located apertures located within the base of the upper framed container and within the ceiling of the lower framed container.

Ideally, once the framed containers are stacked one upon another the apertures align with one another.

Preferably, upon alignment of the apertures, aggregate washing plant connecting members are extendable between the components of the upper container and the interoperable components of the lower container.

Ideally, the aggregate washing plant connecting members provide a means of transferring the aggregate and bi-products from the aggregate washing components in the upper framed container to the storage units of the lower framed container.

Preferably, the aggregate washing plant connecting members are elongate tubular conduits. Ideally, the connecting members are fixed in position during the assembly in the containers.

Preferably, the elongate tubular conduits are movable into position from a storage position during transport.

Ideally, the movable connecting members are securely held against the internal walls of the container during transport.

Preferably, the movable connecting members are movable between the storage position and the in-use position.

Advantageously, connecting members that are fixed in position would further reduce the set-up times of the aggregate washing plant for use on site by a single operator.

Ideally, this moving/folding of the connecting members can be manual or automatic via a remote mechanism.

In an alternate embodiment the aggregate washing apparatus connecting members are elongate conveyors.

Ideally, these elongate conveyors are also movable/foldable.

Ideally, the aggregate washing means is a screw type, logwasher and/or a course aggregate washer and/or a fines material washer.

Preferably, the diameter of the screw of the aggregate washing means is in the range of 600mm and 1200mm to suit the application of use.

Ideally, the diameter of the screw of the aggregate washing means is 1000mm.

Preferably, the orientation of the motor/drive/gearbox of the aggregate washing means has been rotationally displaced from a normal orientation so as to reduce the overall height of the aggregate washing means to within the internal boundary of the container.

Ideally, the orientation of the motor/drive/gearbox has been rotated through 90° about the longitudinal axis of the aggregate washing means from the normal orientation so as to reduce the overall height of the aggregate washing means to within the internal boundary of the container.

Preferably, the trash screen is transversely mounted across the container. Ideally, the grey water / trash exit chute has been rotationally displaced to allow the trash screen to be transversely mountable across the container.

Preferably, the grey water / trash exit chute is rotated through 90° to allow the trash screen to be transversely mountable across the container.

Advantageously, this transverse mounting of the trash screen reduces the overall longitudinal length of the aggregate washing plant.

Ideally, the mounting platform and / or legs of any or all of the components of the aggregate washing plant are reduced in height.

Advantageously this allows the entire components of the aggregate washing plant to be situated within the height confines of the container.

Preferably, the aggregate washing means comprises a raw material infeed chute.

Ideally, the raw material infeed chute has been adapted to accommodate any raw material feed conveyor.

Advantageously, as the raw material infeed chute can accommodate any feed conveyor this reduces the amount of specialised apparatus required to be transported on- site.

Preferably, the raw material infeed chute comprises a raw material receiving channel extending from the aggregate washing means to the external boundary of the container and defined by the internal profile of a plurality of inter-connectable panels.

Preferably, the raw material receiving channel tapers upon extension from the container external boundary in the direction of the aggregate washing means.

Advantageously, the tapering of the raw material infeed chute reduces the possibility of spillage of material from the varying feed conveyors that may be utilised at different on-site locations.

Preferably, the width of the trash screen means is in the range of 600mm to 1500mm dependent upon the application of use. Advantageously, this reduction of width of the trash screen enables the trash screen to be transversely mounted reducing the overall longitudinal length of the aggregate washing plant.

Preferably, the sand plant is a sand cyclone and dewatering screen or a high frequency dewatering device.

Ideally, the overall height of the one or more sand plant cyclones and dewatering screens or high frequency dewatering devices is in the range of 2000mm to 2500mm to suit the application of use.

Preferably, the overall width of the one or more sand plant cyclones and dewatering screens or high frequency dewatering devices is in the range of 1000mm to 2200mm to suit the application of use.

Alternatively, the sand plant cyclone has been inclined from a normal upright orientation so as to reduce the overall height of the sand plant to within the internal boundary of the container.

Further alternatively, the overall height and width of the one or more sand plant cyclones is in the ranges of 2000mm to 2500mm and 1000mm to 2200mm respectively and inclined from a normal upright orientation so as to reduce the overall height of the sand plant to within the internal boundary of the container.

Ideally, the sand plant comprises a removable sand collection sump.

Preferably, the sand collection sump of the sand plant is independently mountable.

Ideally, the independently mountable sand collection sump of the sand plant is located in the lower container.

Advantageously, a sand collection sump that is capable of being independently mountable within the lower container provides the aggregate washing plant with a storage means with greater storage capacity.

Further advantageously, this greater storage capacity enables the aggregate washing plant with greater throughput of product and also maintains water level balance throughout the system. Ideally, the aggregate washing screen chute work for finished products is permanently fixed or movable between storage and in use position.

Preferably, the aggregate washing screen comprises a removeable sand collection sump.

Ideally, the sand collection sump of the aggregate washing screen is independently mountable.

Preferably, the independently mountable sand collection sump of the aggregate washing screen is located in the lower container.

Advantageously, a sand collection sump that is capable of being independently mountable within the lower container provides the aggregate washing plant with a storage means with greater storage capacity.

Further advantageously, this greater storage capacity enables the aggregate washing plant with greater throughput of product and also maintains water level balance throughout the system.

The invention will now be described with reference to the accompanying drawings which shows by way of example only one embodiment of an aggregate washing plant in accordance with the invention. In the drawings;

Figure 1 is a perspective view of the aggregate washing plant in an operational state.

Figure 2a is a detailed view of the of the aggregate washing means

motor/drive/gearbox in normal orientation.

Figure 2b is a detailed view of the of the aggregate washing means

motor/drive/gearbox in the rotationally displaced orientation of the present invention; and Figure 3 is a perspective view of a further embodiment of an aggregate washing plant in an operational state. In the drawings, there is shown an aggregate washing plant indicated generally by the reference numeral 1 comprising a plurality of individual aggregate washing and processing components (2) being adapted to form a modular aggregate washing plant (1 ) assembled and stored within the internal boundaries of at least two framed containers (3), the aggregate washing plant (1 ) being fully operable while stored in the containers (3). The framed containers (3) generally being an international standard twist lock 40ft container or a Hicube Shipping Container. These containers (3) can be transported on any trailer (not shown). Furthermore, within these containers (3) the containerised aggregate washing plant (1 ) can be shipped in their operating state through any port or on any road without prior consent or escort from authorities or using specialist transport. The framed containers (3) are capable of engaging with one another, stacked one on top of the other as illustrated in Figure 1 .

The aggregate washing plant (1 ) comprising an aggregate washer (4), a trash screen (5), an aggregate washing screen (6), a sand plant (7), storage for process products and waste bi-products (8), clean/grey water pumps (12/9), a power generating and distribution means (10) and members (1 1 ) for interconnecting interoperable components of the aggregate washing plant.

The aggregate washing components (2) are reconfigured from traditional known working orientations to ensure that protrusions of the individual components do not extend laterally and/or longitudinally beyond that of the internal boundary of the stackable framed containers (3) when housed within the containers in use and/or stowage. The containerised aggregate washing plant (1 ) comprises quick connect and operate features for connecting interoperable components in adjacent containers (3). By quick connect and operate features we are referring to the functionality where the containerised aggregate washing plant (1 ) comprises arrangements which enable an operator to simply and quickly connect the interoperable components held within each container to enable the full operation of a working aggregate washing plant (1 ) without the requirement of complex mechanical mechanisms or equipment or specially trained personnel which would not ordinarily be on-site. This enables the containerised modular aggregate washing plant (1 ) to operate by the simple connection of constituent parts without the requirement for complex equipment. Conventional aggregate washing plants are required to be built and modified by extending jacking legs, having chute work fitted, cross bracing expansions etc. on site. The containerisation, interconnecting members (1 1 ) and quick connect and operate features of the present invention significantly reduces the time required during apparatus set-up and decommissioning and also removes the requirement for specialised service engineers on-site. This reduction in time has been recorded as a reduction from two to three days, requiring two trained operators to as little as two to three hours for one non-specialist operator. Further advantageously, an aggregate washing plant (1 ) confined within the internal boundaries of at least two framed containers (3) provides an operator with a system that can be easily transported from one location to the next, without the need to collapse the washing plant 1 into the individual components; such is the requirement with the traditional set-up. Furthermore once on site the compact nature of the plant (1 ) provides a minimal footprint for ease of use within confined areas but also provides a greater manoeuvrability of the plant (1 ) should this be required.

One framed container (13) houses the aggregate washer (4), the trash screen (5), the aggregate washing screen (6) and the sand plant (7). Another framed container (14) houses a plurality of storage units for process products and waste bi-products (8), clean/grey water pumps (9), and power generating and distribution equipment (10).

The framed container (13) is stacked upon framed container (14) so that the container (13) containing the aggregate washer (4), the trash screen (5), the aggregate washing screen (6) and the sand plant (7) is located above the framed container (14) containing the storage units for process products and waste bi-products (8) in a fully operational mode of the aggregate washing plant (1 ). By fully operational mode we mean that the aggregate washing plant (1 ) can operate as a fully functional washing plant. The stackability of the containers (13 and 14) provides the aggregate washing plant (1 ) with a means to utilise gravity rather than conveyors typically utilised in the traditional aggregate washing plant set-ups. In the present invention, gravity is used to move the particulates and waste waters from the processing components located in the upper container (13) to the storage units held within the lower container (14). In the present invention the interoperable components in the upper and lower framed container (13 and 14) are connectable by use of connecting members (1 1 ) such as conduits. These conduits (1 1 ) provide for the transfer of the aggregate and bi-products from the aggregate washing components in the upper framed container (13) to the storage units of the lower framed container (14).

The upper (13) and lower (14) framed containers have correspondingly located apertures (not shown) located proximal to and preferably in the base of the upper framed container (13) and proximal to and preferably in the ceiling of the lower framed container (14). Once the framed containers (13 and 14) are stacked as shown in Figure 1 , the apertures align with one another. Upon alignment of the apertures, the aggregate washing plant connecting conduits (1 1 ) are extendable between the interoperable components of the upper container (13) and the lower container (14). The connecting members (1 1 ) are movable between a storage position and an in-use position for connecting the interoperable components of the upper container (13) and the lower container (14). The connecting members (1 1 ) are securely held against the internal walls of the containers (13 and 14) during transport. This moving/folding of the connecting members (1 1 ) can be manual and/or automatic via a remote mechanism. In an alternate arrangement, the connecting members (1 1 ) are fixed in the in-use position. Advantageously, connecting members (1 1 ) that are fixed in position would further reduce the set-up times of the aggregate washing plant (1 ) for use on site by a single operator.

In an alternate embodiment the aggregate washing apparatus connecting members (1 1 ) are elongate conveyors (not shown) which are also movable/foldable or alternatively fixed in an in-use position.

The aggregate washer (4) is one of a screw type, logwasher, a course aggregate washer or a fine material washer. The diameter of the screw (not shown) of the aggregate washer (4) is between 600mm to 1200mm to suit the application of use. The orientation of the motor/drive/gearbox (16) of the aggregate washer (4) has been rotated through 90° about the longitudinal axis of the aggregate washer as shown in Figure 2b. This adjustment from a normal orientation as shown in Figure 2a has been made so as to reduce the overall height of the aggregate washer (4) to within the internal boundary of the container (13).

The grey water / trash exit chute (17) has been rotated preferably through 90° to allow the trash screen (5) to be transversely mountable across the container (13). This transverse mounting of the trash screen (5) reduces the overall longitudinal length of the aggregate washing plant (1 ).

The mounting platform and / or legs (18) of any or all of the components of the aggregate washing plant (1 ) are reduced in height so as to allow the entire components of the aggregate washing plant (1 ) to be situated within the height confines of the container (13).

The aggregate washer (4) comprises a raw material infeed chute (19) which has been adapted to accommodate any raw material feed conveyor. As the raw material infeed chute (19) can accommodate any feed conveyor this reduces the amount of specialised apparatus required to be transported on-site. The raw material infeed chute (19) comprises a raw material receiving channel (20) extending from the aggregate washer (4) to or proximal to the external boundary of the container (13). The raw material infeed chute (19) is defined by the internal profile of a plurality of inter-connectable panels (21 and 22). Four panels define an open top and bottom chute above the opening into the aggregate washer (4) and at least one and in in the embodiment shown three panels are interconnected and flare away from the top of the chute. The flared open end of the raw material infeed chute (19) tapers in the direction of the aggregate washer (4). This tapering of the raw material infeed chute (19) reduces the possibility of spillage of material from the varying feed conveyors that may be utilised at different on-site locations.

The width of the trash screen (5) is 600mm to 1500mm dependent upon the application of use. This range of widths for the trash screen (5) enables the trash screen (5) to be transversely mounted reducing the overall longitudinal length of the aggregate washing plant (1 ). The sand plant (7) is a sand cyclone and dewatering screen or a high frequency dewatering device. The overall height and width of the one or more sand plant cyclones is in the ranges of 2000mm to 2500mm and 1000mm to 2200mm respectively. Alternatively, the sand plant cyclone (7) has been inclined from a normal upright orientation so as to reduce the overall height of the sand plant (7) to within the internal boundary of the container (13). Further alternatively, overall height and width of the one or more sand plant cyclones is in the range of 2000mm to 2500mm and 1000mm to 2200mm respectively and inclined from a normal upright orientation so as to reduce the overall height of the sand plant (7) to within the internal boundary of the container (13).

The sand plant (7) comprises an independently mounted sand collection sump (23) located in the lower container (14). This provides the aggregate washing plant (1 ) with a storage means with greater storage capacity. Further advantageously, this greater storage capacity enables the aggregate washing plant (1 ) with greater throughput of product and also maintains water level balance throughout the system.

The aggregate washing screen chute work (24) for finished products is permanently fixed or movable between storage and in use positions. The aggregate washing screen (6) also delivers material to the independently mounted sand collection sump (23). This further provides the aggregate washing plant (1 ) with a storage means with greater storage capacity. Further advantageously, this greater storage capacity enables the aggregate washing plant (1 ) with greater throughput of product and also maintains water level balance throughout the system.

Referring to the drawings and now to Figure 3, there is shown a further embodiment of aggregate washing plant indicated generally by the reference numeral 31 comprising the same fundamental design namely two framed containers 3 stacked one on top of the other and the individual aggregate washing and processing components (2) being adapted to form a modular aggregate washing plant (1 ) assembled and stored within the internal boundaries of at the two framed containers (3). The aggregate washing plant (31 ) is fully operable while stored in the containers (3) in the stacked configuration. The framed containers (3) generally being an international standard twist lock 40ft container or a Hicube Shipping Container. These containers (3) can be transported on any trailer (not shown). Furthermore, within these containers (3) the containerised aggregate washing plant (1 ) can be shipped in their operating state through any port or on any road without prior consent or escort from authorities or using specialist transport.

The aggregate washing plant (31 ) comprising an aggregate washer (4), a trash screen (5), an aggregate washing screen (6), a sand plant (7), storage for process products and waste bi-products (8), water pumps (9), a power generating and distribution means (10) and members (1 1 ) for interconnecting interoperable components of the aggregate washing plant. In addition the embodiment illustrated in Figure 3 shows a chute 33 connecting the aggregate washing screen 6 to an outlying conveyor 34 for delivering product away from the washing plant 31 . The chute 33 is movably mounted on the frame 3 so as to be movable between the in use position illustrated in Figure 3 and a storage and transport position where it is located within the confines of the body of the container 3. The conveyor 34 is retractably mounted on a base frame 35 which is located on the floor of the container 3 between the extended in use position as illustrated in Figure 3 and a transport and storage position where it is located within the confines of the body of the container 3. A further chute 36 is movably mounted on the frame 3 so as to be movable between the in use position illustrated in Figure 3 and a storage and transport position where it is located within the confines of the body of the container 3. Chute 36 is used for delivery materials from the upper stacked container 3 to the lower container 3.

In relation to the detailed description of the different embodiments of the invention, it will be understood that one or more technical features of one embodiment can be used in combination with one or more technical features of any other embodiment where the transferred use of the one or more technical features would be immediately apparent to a person of ordinary skill in the art to carry out a similar function in a similar way on the other embodiment. In the preceding discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of the said values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of said parameter, lying between the more preferred and the less preferred of said alternatives, is itself preferred to said less preferred value and also to each value lying between said less preferred value and said intermediate value.

The features disclosed in the foregoing description or the following drawings, expressed in their specific forms or in terms of a means for performing a disclosed function, or a method or a process of attaining the disclosed result, as appropriate, may separately, or in any combination of such features be utilised for realising the invention in diverse forms thereof as defined in the appended claims.