We design and build processing lines that turn low-grade surface material into products that meet specification — drying, size reduction, classification, de-sanding and surface treatment in one continuous circuit.
Most processing plants run drying, milling, classification and treatment as separate machines, with handling, storage and re-agglomeration between each one. We run them as a single gas circuit, with the material carried in suspension from end to end.
Not a catalog machine. Each line is dimensioned from your own sample — your moisture at its worst, your clay content, your target cut points.
Cut points are set by the geometry of the classifiers, not by an operator. Output quality stops tracking the variability of the input.
The whole line runs under negative pressure. Bag filters rated at 99.9%, retaining particles to 0.5 µm.
The line is modular. Which stages are used, in what order, and how many of each, is set by the mineral, the particle size distribution and what you need at the outlet.
In a rotary drum, heat reaches a particle through the pile it is buried in. In a gas suspension, every particle is surrounded on all sides. We report thermal efficiency of 85–92%, against 40–50% commonly cited for rotary drum dryers.
The same geometry is what makes surface treatment work. Coverage does not depend on how long material sits in a mixer, or on whether agglomerates were broken first — because there are no agglomerates. The particles are already apart.
Capacity is governed by water, not by solids. Above roughly 6% feed moisture, throughput is set by evaporative duty.
A line rated 20 t/h at 6% moisture delivers about 12.5 t/h at 8%.
We size lines against the wettest season rather than the annual average. Slurried feedstocks are not candidates for a dry process at any sensible cost, and we will say so before you spend money finding out.
The evidence behind each material is stated plainly. Materials shown as demonstrated have run at commercial scale; materials shown as designed have costed process studies behind them and no verified installation.
| Material | What is produced | Evidence |
|---|---|---|
| Coal combustion residuals | Mineral filler at 50 µm for asphalt; fine fraction at 5 µm for concrete | Demonstrated |
| Quartz sand | Dry and treated sand for mortars, glass sand, foundry sand, coated proppant | Demonstrated |
| Aluminosilicate microsphere | Lightweight cementing additive at 75 kg/m³ bulk density | Demonstrated |
| Calcium carbonate | Treated ground and precipitated grades for polymers and coatings | Demonstrated |
| Bentonite | Sodium-activated bentonite with sorption properties preserved | Designed |
| Aluminum hydroxide | Dry, three-way classified, surface-treated ATH | Designed |
| Bauxite | Dried below 0.5% moisture, de-sanded, classified | Designed |
| Chromite sand | Reclaimed foundry sand; calcining to 600 °C | Designed |
| Rutile | Medium fraction at 50 µm to metallurgy; fine fraction to grinding for coatings | Designed |
| Iron ore concentrate | Concentrate dried from 8–12% to 0.5% after wet beneficiation | Designed |
One test screens most enquiries. If a feedstock is dry enough and fine enough, the process applies. If it arrives as slurry, it does not.
A deposit or a waste stream has no single value. The same ton is worth different amounts depending on how narrowly it is graded, how clean it is, and whether the surface has been treated. Most operators value their material at the price of what they make today, rather than what they could make.
You almost certainly already have the data we need to start. If your material has been assayed and sieved — and most has — no sample needs to move for us to model what the process would do with it.
Send the analysis you already hold. We model the process against it and return a result in about a week. Nothing ships.
Where the desk study says the case is worth making, we test the material itself and confirm or correct the model.
A model built from your data sheet is exactly as good as the data sheet. It predicts; it does not measure. Where the number matters enough to spend money against — a capital decision, a supply contract, a specification you will be held to — the material has to be tested.
We will tell you which of those two situations you are in before you pay for anything.
Both stages are paid work and modest in budget. The fee is credited in full against a subsequent order. The result is yours either way.
Regolith is the loose material lying over bedrock — ash, tailings, overburden, sand, soil. It is the largest and least valuable material stream on any industrial site, and it is the one we work on.
The processing technology behind the company has been in commercial operation since 2008 and in continuous production since 2018, with more than thirty lines built at capacities from 3 to 50 t/h across construction materials, glass, foundry, and oil and gas.
Regolith Materials Processing, Inc. is a Florida corporation, formed to bring that process to North American feedstocks. Our priority is a result generated here, on material from here — which is why a study on your own feedstock is the first thing we offer rather than the last.
Describe the material, the moisture at its worst, and the fraction you wish you could sell. We will tell you quickly whether the process applies — including when it does not.
samples@regolithprocessing.comRegolith Materials Processing, Inc.
Florida, United States