Frac Sand & Proppant Processing | Drying & Dust Control

Engineering Performance for Modern Frac Sand Operations

Frac sand plants operate under high pressure to deliver consistent throughput, reduce fuel cost per ton, and maintain strict silica dust compliance. IAC supports these demands with proven engineering, OEM equipment, and full-scope EPC services shaped by more than 45 frac sand projects across the United States. Our experience spans complete wet and dry plant design, rotary sand dryers, dust collection systems, high-capacity loadout solutions, and automated controls that protect uptime and production targets.

As a vertically integrated EPC contractor and OEM, we design, fabricate, install, and support every critical system within a frac sand facility. This approach reduces schedule risk, shortens commissioning timelines, and gives operators a single partner for the entire lifecycle of their plant.

IAC-built greenfield frac sand facility with rotary dryer, baghouse dust collection, silos, and transload systems

By the Numbers

45+ EPC frac sand and proppant projects delivered
8 months – fastest recorded greenfield frac sand plant completion (from order to sand in silos)
Industry-leading fuel efficiency in rotary drying systems
7,500+ baghouse units in service worldwide

Why It Matters
In the frac sand and proppants industry, every day of production counts. IAC’s end-to-end solutions—spanning engineering, OEM fabrication, construction, commissioning, and aftermarket services—help producers maximize throughput, meet silica dust compliance requirements, and lower cost per ton.

Industry Challenges in Frac Sand Production

Frac sand producers face a demanding operating environment where small inefficiencies quickly scale into major cost and throughput losses. Plants must balance high-capacity drying, abrasive material handling, and strict environmental controls while maintaining consistent product quality. Key challenges include:

Variable Moisture and Drying Efficiency
Moisture swings and heavy abrasion push rotary dryers to their limits. Inefficient flighting, uneven heat distribution, or outdated drum designs reduce throughput and raise fuel consumption.

Silica Dust Compliance and Air Quality Control
From screening to loadout, every transfer point generates fine particulate. Plants must use well-engineered baghouses, bin vents, and airflow management to stay in compliance and protect worker safety.

High-Wear Material Handling and Conveying
Conveyors, bucket elevators, and screw systems in frac sand applications experience faster wear than many other industries. Poor component selection or layout issues drive recurring downtime and maintenance expense.

Throughput and Reliability Requirements
Producers must move millions of tons per year with minimal unplanned outages. Mechanical failures in dryers, ductwork, silos, or dust collection systems can disrupt entire production lines.

Construction Schedule and Expansion Risk
Market demand shifts quickly. Delays in civil construction, equipment integration, or commissioning increase project risk and slow revenue generation.

To address these pressures, IAC integrates engineered equipment, advanced controls, and fast-track EPC project delivery to help frac sand producers achieve higher reliability and lower total cost of ownership.

Core Capabilities for Frac Sand Producers

IAC delivers engineered systems that support every major function inside a frac sand facility. Our expertise spans wet and dry plant operations, high-efficiency sand drying, dust collection, and bulk material handling, giving producers a single source for reliable, high-throughput performance.

Large-scale reverse air baghouse engineered and constructed for a steel manufacturing facility.

Air Pollution Control Systems

Frac sand operations rely on robust baghouses, bin vents, and cyclones to maintain silica dust compliance. IAC designs and supplies complete APC systems sized for screening, transfer points, dryers, and loadout. Our solutions reduce emissions, stabilize airflow, and protect personnel.

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Industrial Drying System

Our direct-fired rotary dryers are engineered for abrasive materials and variable moisture loads. Custom flighting, optimized heat transfer, and durable shell construction help plants increase feed rates without raising fuel consumption. IAC also provides retrofit upgrades that improve throughput and extend equipment life.

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Bulk Material Handling

We engineer mechanical and pneumatic conveying systems that withstand high abrasion and maintain consistent flow. Equipment options include belt and screw conveyors, bucket elevators, air slides, hoppers, and storage silos. Every system is configured for reliability and alignment with upstream and downstream processes.

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Automated Controls

IAC provides MCCs, PLC-based controls, and preassembled E-houses that streamline installation and support reliable operation. Our controls integrate drying, conveying, dust collection, and loadout equipment, giving operators clear visibility into plant performance.

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From abrasion-resistant dryers to high-efficiency filtration systems, IAC equipment is engineered for long service life, low maintenance, and optimal performance in even the harshest mineral processing environments.

Integrated Solutions for Every Stage of Frac Sand Production

IAC supports the complete frac sand value chain with engineered systems built for high-volume, high-abrasion environments. Our solutions are tailored for wet plant operations, dry plant performance, environmental compliance, and reliable storage and loadout.

Wet Plant Support and Process Integration

We provide engineering and equipment that connect washing, classification, and slurry handling to downstream drying and screening. Our expertise ensures stable feed to the dry plant, consistent moisture control, and improved upstream reliability.

Dry Plant Systems and Screening Efficiency

IAC designs high-capacity systems for drying, screening, dust control, and classification. Rotary dryers, screening stations, cyclones, and transfer points are engineered to deliver uniform product gradation and dependable throughput at scale.

Storage, Silos, and Loadout Facilities

Producers rely on large-capacity storage and fast loadout cycles. IAC supplies bolted or welded silos, dome storage, and truck or rail loadout systems. Each installation is supported by mechanical and electrical integration for accurate weighing and fast turn rates.

Baghouse maintenance services for industrial dust collection systems.

Dust Collection Across Plant Operations

Frac sand transfer points require consistent particulate control. Our pulse-jet baghouses, filter receivers, and bin vents stabilize airflow and reduce wear on downstream equipment. Systems are designed for silica compliance and long service intervals.

EPC Turnkey Capabilities for Frac Sand

AC is a proven EPC partner for frac sand producers seeking rapid execution, precise engineering, and dependable system integration. With more than 45 frac sand projects completed across the United States, we bring unmatched experience in designing, fabricating, constructing, and commissioning complete wet and dry plants.

Engineering & Design

50+ in-house engineers across civil, mechanical, electrical, and structural disciplines
Advanced 3D modeling, computational fluid dynamics (CFD), and process simulations for optimized layouts and airflow control
Designs tailored to high-abrasion, high-temperature, and heavy-duty applications in frac sand, cement, lime, gypsum, pozzolans, and aggregates.

Fabrication

500,000 sq. ft. in-house manufacturing facility producing baghouses, dryers, silos, conveyors, ductwork, and structural steel
Custom OEM equipment built for maximum durability and efficiency in mineral processing environments

Dry bulk storage tanks with automated truck loadout

Construction & Commissioning

Adelphi Construction LC, IAC’s wholly owned subsidiary, self-performs civil, mechanical, and electrical scopes for fast-track delivery
Dedicated commissioning teams ensure rapid production ramp-up with operator training and system optimization.

Field Services & Aftermarket Support

Keeping industrial minerals and materials facilities running at peak performance requires more than just quality equipment—it demands expert maintenance, rapid response, and a reliable parts supply. IAC’s Field Services and 55,000+ stocked parts inventory ensures your operation stays online, compliant, and productive.

IAC field technicians performing a bag and cage changeout on an industrial baghouse system.

Maintenance & Repair Services

Scheduled bag change-outs, cage replacements, and leak testing for all baghouse brands
Mechanical repairs including valve, damper, and fan replacement
Equipment conversions to upgrade older reverse-air or shaker systems to modern pulse-jet technology

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Training

On-site or virtual seminars covering baghouse operation, troubleshooting, and maintenance scheduling
Hands-on instruction from experienced IAC engineers to extend equipment life and avoid unplanned downtime

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System Optimization

Burner tuning and dryer flighting analysis to improve efficiency
Airflow balancing and ductwork inspections to reduce emissions and wear
Dust control retrofits for improved compliance and product recovery

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Parts & Components

55,000+ stocked parts for baghouses, dryers, conveying systems, and controls
Rapid shipment from strategically located warehouses to minimize downtime
OEM and compatible parts available for multi-brand systems

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Partnering with IAC for Frac Sand Processing

Vertically Integrated EPC Expertise

IAC delivers every phase of your frac sand facility in-house—engineering, OEM equipment manufacturing, fabrication, and construction—through our wholly owned subsidiary, Adelphi Construction. This single-source accountability eliminates handoff delays, reduces miscommunication, and keeps your project on schedule.

Fast-Track Project Delivery

We have a proven track record of completing full-scale greenfield frac sand plants in under eight months, significantly faster than industry norms. Our fast-track approach combines advanced scheduling tools, in-house crews, and prefabricated components for rapid deployment without sacrificing quality.

Equipment Proven in the Field

From industry-leading rotary dryers to high-capacity baghouses and precision screening systems, IAC designs and fabricates process equipment specifically for silica sand applications. Our drying systems set the standard for low BTU consumption per produced ton, maximizing profitability while reducing environmental impact.

Local Service Advantage

With a dedicated Permian Basin Service Center in Monahans, TX, and regional teams across the U.S., IAC provides rapid-response parts, maintenance, and emergency services to keep your plant running at peak performance.

Move Your Frac Sand Operation Forward

Whether you need a full greenfield plant, targeted upgrades, or performance improvements to your drying, screening, or dust collection systems, IAC is ready to help. Our engineering teams, fabrication facilities, and field service crews support every stage of your operation with reliable, high-performance solutions.

Connect with our frac sand specialists to review your goals, evaluate your current systems, and identify the fastest path to higher throughput and lower operating costs.

Start your project conversation today.
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