Stone crusher plant

1. Background. In recent years, with the development of capital construction around the world, the demand for sand and gravel materials is increasing day by day. In the background of the restriction of river sand mining and the shortage of sand, many places encourage and support the investment for sand and stone crusher plant. Affected by the high sand prices, many investors want to understand the process and equipment configuration of sand and gravel production, this article introduces the combination of stone crusher plant with two typical materials basalt and limestone. 2. Basic process diagram A. Raw materials exploitation -Mining Survey, planning and design -Excavator to pick up the surface of the mountain, clean up the dump -Raw material blasting layer by layer, includes drilling, charging, blasting -Large pieces of raw material break to small ones by rock drill -Loading, typically by excavator or loader -Transport materials to crushing site stockpile B. Stone crusher plant design and installation -Stone crusher plant site design, it should take into consideration of the site geomorlogy, area, and transportation, production capacity and other factors, etc. Things to consider when design the stone crusher plant Site leveling and arrange the layout, made according to Deya Machinery’s drawings Foundations preparation, made according to Deya Machinery’s drawings Arrival of the equipment and checking one by one Equipment installation, guided by Deya Machinery’s technician Commissioning of the equipment Trial production Re-adjust the equipment if there is any problem Formal production Maintenance according to the manuals supplied by Deya machinery C. Stone crushing and processing Raw materials stock pile Vibrating feeder for feeding evenly and continuously Primary crushing, typically by jaw crusher Belt conveyor to next stage Secondary crushing, typically by Symone cone crusher or impact crusher Belt conveyor to next stage Tertiary crushing or re-shaping, typically by VSI sand making machine Belt conveyor to vibrating screen Vibrating screening to different sizes Qualified sand and gravels are sent to different stockpile by belt conveyors Oversize materials will be send back to secondary crusher or tertiary crusher Larger capacity stone crusher plant involves more vibrating screen and crushers Depends on local environment protection rules, the dust collecting equipment may be necessary 3. Detailed key equipment list in stone crusher plant Raw materials exploitation and stacking: rock drill, excavator, dump truck, loader, etc. Feeding: Vibrating feeder Primary crushing: Jaw crusher, sometimes gyratory crusher can also be used according to the plant’s process capacity Secondary crushing: Symons cone crusher , impact crusher, hammer crusher Tertiary crushing: Symons cone crusher short head, impact crusher, hammer crusher, re-shaping crusher like VSI Screening: Vibrating screen Dust removal: Dust collector Separating material transportation: belt conveyors Electrical parts, transformer, cables, motor control panels. If mine site is short of electricity, the generator set needed. Lab equipment for product testing: Aggregate sieving equipment includes complete sets of sieves, weighing equipment, pressure testing equipment, etc. 4. Equipment selection basis 1. In general, the configuration of the stone crusher plant production ld first consider the type and hardness of the raw materials, whether it is limestone, granite, pebble or basalt, the Mohs hardness of the rocks(Mohs hardness above 7 is a very hard rock), whether the rock is soft brittle or hard brittle, soft brittle rocks need high manganese steel equipment, like jaw crusher, impact crusher, hammer crusher, etc. Hard brittle rocks need high content of chrome equipment, like Symons cone crusher and VSI sand making machine. 2. Second thing is to consider the performance (crushing ratio) and applicability of the crusher. Jaw crusher has a large crushing ratio, working principle by extrusion crushing, and the crushed products granularity are more needle-like, it is suitable for primary crushing. Impact crusher and VSI sand crusher have good product granularity, they are suitable for secondary and tertiary crushing. Both impact crusher and hammer crusher are suitable for medium hardness or soft stones, while Symons cone crusher and VSI sand crusher are suitable for hard stones. 3. Thirdly, the process capacity should be considered, which requires good match between the equipment in the whole production astly, consider whether there is special quality requirements for the products, if there is high requirements for the sand and gravel shape, the re-shaping equipment should be added to produce good cubic products. 5. Stone crusher plant equipment combination Generally speaking, a complete set of stone crusher plant production ly includes vibrating feeder, jaw crusher, Symons cone crusher, impact crusher, vibrating screen, belt conveyor, dust collecting equipment, centralized electric control system, etc. Sometimes it is also equipped with re-shaping crusher. Take two typical types of raw materials for example, namely basalt and limestone, Deya Machinery introduces the common equipment combinations. 5.1. Basalt crushing plant equipment combinations Basalt has high hardness and silica content, it is hard and tough material with high abrasiveness. Basalt is difficult to crush in actual crushing operation, or operational cost is higher than other types of rocks. In the design of the stone crushing plant, the lamination crushing principle is used as much as possible to reduce the wearing parts cost. Normally the basalt crushing production ination includes the following, (1) Feeding: vibrating feeder (2) Primary crushing: Jaw crusher (3) Secondary crushing: Symons cone crusher or PEX series secondary jaw crusher (4) Tertiary crushing: Symons cone crusher, impact crusher or VSI for re-shaping (5) Screening and dust collection: vibrating screen, and dust collector (6) Shaping: impact crusher or VSI sand crusher. After tertiary crushing and screening, qualified products will be sent to the stockpile by the belt conveyors, while the materials whose size and shape do not meet the standards will be sent to the impact crusher or VSI sand crusher for further crushing and shaping. (7)Large capacity basalt crushing plant needs more vibrating screen and belt conveyors (8)Materials conveying: belt conveyors (9)Electrical Control system Notes: In order to reduce dust and mud, the stone after primary crushing is conveyed to the secondary stage crusher by vibrating belt conveyor. Whether or not the dust removal equipment is installed depends on the clean the crushed stone and whether there is a water washing process, if there is a water washing process, there is no need to install dust removal equipment. Re-Shaping crusher crushes stones by the way of "stone hitting stone" and produces more powder. If the aggregate shape after crushing by Symons cone crusher or impact crusher can meet the requirements, try not to use re-shaping crusher. Fine crushing or re-shaping process may need the dust collectors depends on the local government’s policy for environment protection. 5.2 Limestone crushing plant equipment combinations Limestone Mohs hardness is 4-5, which is very low, and the silica content in the stone is low, too, thus the abrasiveness to the crusher wearing parts is low. It is easier to crush due to the low hardness and brittle, the operational cost will be lower comparing with hard stones. In the design of the crushing process, the crushing equipment by impact principle is chosen as much as possible. The normal limestone crushing production pment combination as follows, (1) Feeding: vibrating feeder (2) Primary crushing: Jaw crusher (3) Secondary crushing: Impact crusher, hammer crusher or box crusher (4) Screening and dust collection: vibrating screen, and dust collector (5) Shaping: impact crusher or VSI sand crusher. After tertiary crushing and screening, qualified products will be sent to the stockpile by the belt conveyors, while the materials whose size and shape do not meet the standards will be sent to the impact crusher or VSI sand crusher for further crushing and shaping. (6)Large capacity basalt crushing plant needs more vibrating screen and belt conveyors (7)Materials conveying: belt conveyors (8)Electrical Control system Notes: In order to reduce dust and mud, the stone after primary crushing is conveyed to the secondary stage crusher by vibrating belt conveyor. Whether or not the dust removal equipment is installed depends on the clean the crushed stone and whether there is a water washing process, if there is a water washing process, there is no need to install dust removal equipment. In conclusion If a complete stone crusher plant production the following features, high degree of automation, appropriate equipment and good performance, good matching between equipment, high production efficiency, low operating costs, high process capacity, good revenue, finished stone with uniform particle size and good grain shape, and meets the products sales requirements, then it can be called a successful stone crusher plant. us for more information,