Whether a gravel yard operates efficiently depends mainly on whether the matching production line is scientific and reasonable.
In actual production, the main function of any ore crushing production line is to crush various ores, gravel, etc. to a reasonable particle size and shape. Since there are many devices that make up an ore-crushing production line, and the functions of each other are intertwined, it is not a matter of forcing a scientific production line. The production line must be tailored according to the material conditions, output requirements, finished product requirements and other conditions. The purpose is to save trouble and effort.
STLT Mobile Stone Crushing Plant Solution
A key advantage of mobile crushing plants is their environmental friendliness and elimination of the need for installation and foundation, which makes them highly efficient for processing a wide range of materials such as limestone, basalt, pebbles, iron ore, and construction waste.
Moreover, mobile crushers contribute significantly to quarrying efficiency and safety by allowing on-site material processing and reducing the need for extensive material transportation.
Our crushing plant is an entire production line composed of different equipment such as jaw crusher, cone crusher, sand making machine, sand washing machine, vibrating screen, and belt conveyor.
Note:We have both mobile stone crusher plant and stationary crushing line. According to the specific needs of different customers, we can customize personalized production line configurations.
Crushing Combination Solutions for Different Stone Materials
Before configuring the crushing and sand making production line, we must first figure out the raw materials that need to be crushed, such as its size, hardness, humidity, etc.
In addition, we must clarify our own requirements for output and finished product particle size and type. This will provide the necessary scientific basis for the later configuration of suitable types of crushers and sand making machines.
For example, if a hammer crusher is selected for hard rock, the direct consequence is that the hammer head will wear out quickly and the cost of replacing accessories will be high; and the disadvantage of choosing a cone crusher for soft rock is the high cost of equipment investment and subsequent maintenance.
Solution for soft and less abrasive sand and gravel aggregates
Generally, it is divided into feeding, crushing, screening and conveying. The raw materials are conveyed to the vibrating feeder through the silo, and then conveyed to the first crushing equipment for coarse crushing by the vibrating feeder. The crushed materials are conveyed to the second crushing equipment (fine crushing) by the belt conveyor.
After crushing, the materials are conveyed to the circular vibrating screen for screening by the belt conveyor. The materials larger than the required size are returned to the second crushing for further crushing. The materials screened by the circular vibrating screen are finished materials.
If the particle shape is not good enough, you can add a vertical shaft impact sand-making machine for shaping. In this way, the particle shape of the crushed materials will be more rounded and the effect will be better.
Solution for hard and highly abrasive sand and gravel aggregates
Large hard rock materials are fed evenly to the vibrating feeder through the silo, and then enter the jaw crusher for the first crushing.
The coarsely crushed materials are screened by the vibrating screen as required and then conveyed by the belt conveyor to the cone crusher for the second medium and fine crushing.
After medium and fine crushing, the circular vibrating screen is used for screening, and the larger particles are returned to the cone crusher for crushing again. At this time, the required sand and gravel aggregates can be obtained.
If sand making and shaping are required, the materials that meet the requirements are put into the sand-making machine for further crushing and shaping. If the materials need to be cleaned, a sand washing machine can be added for cleaning. Finally, the materials that meet the requirements are classified and packaged according to different particle size ranges.
Here we take common minerals of quartz, cobblestones, sandstone, granite and limestone as examples to recommend the configuration of sand production line for you.
Quartz
- Mohs hardness: 7-7.5
- Density: 2.64g/cm³-2.71g/cm³
Quartz is a hard, wear-resistant, chemically stable silicate mineral, the main component of which is silicon dioxide. It is an important industrial mineral raw material. Generally, after crushing and sand making, it is used in glass, building materials, ceramics, and even high-tech electronics industries.
- Quartz sand production line
- Output: 30-45 tons per hour
Equipment configuration: silo + two fine jaw crushers + sand-making machine + vibrating dewatering screen + sand washing machine + fine sand recovery machine + belt conveyor
Cobblestones
- Mohs hardness: about 7
- Material advantages: hard quality, strong pressure resistance, and the main material for producing artificial sand and gravel.
Cobblestones are hard solids shaped like goose eggs after millions of years of impact from mountains and rivers and transportation by flowing water. Their main component is silicon dioxide, and the artificial sand and gravel they produce meet the requirements of artificial sand and gravel in various places.
- Cobblestone sand production line
- Production: 50-70 tons per hour
Equipment configuration: silo + two fine jaw crushers + sand making machine + vibrating dewatering screen + sand washing machine + fine sand recovery machine + belt conveyor
Sandstone
- Mohs hardness: 2
Sandstone is a sedimentary rock, mainly composed of sand particles, of which the sand content is greater than 50%. Most sandstones are composed of quartz or feldspar, and are widely used as a building stone.
- Sandstone sand production line
- Output: 60-80 tons per hour
Equipment configuration: silo + vibrating feeder + jaw crusher + impact crusher + sand making machine + dewatering screen + sand washing machine + fine sand recovery machine + belt conveyor
Granite
- Mohs hardness: 7-8 (the hardness of granite varies in different regions)
- Material advantages: Granite is known as “rock”. When the product needs to withstand wind and rain or needs to last for a long time, granite is generally chosen.
Granite has a hard and dense texture, high strength, weathering resistance, corrosion resistance, wear resistance, low water absorption, and beautiful color can be preserved for a long time. It is a good material for construction. Granite resources are abundant, mining costs are low, and product value is high.
- Granite sand production line
- Production: 80-130 tons per hour
Equipment configuration: silo + 2 jaw crushers + vibrating dewatering screen + cone crusher + sand washer + fine sand recovery machine + belt conveyor
Limestone
- Mohs hardness: 3-4
The Mohs hardness of limestone is 3, medium-low hardness. After simple processing, the improvement and expansion of application fields will also lead to the increase of its unit economic value. Generally, the simplest one is the limestone sand production line.
- Limestone sand production line
- Production: 100-150 tons per hour
Equipment configuration: silo + vibrating feeder + jaw crusher + impact crusher + sand making machine + vibrating dewatering screen + sand washing machine + fine sand recovery machine + belt conveyor
Common Crusher Solutions in the Crushing Process
In the crushing process, several types of crushers are commonly used, each designed for specific applications and material types.
Jaw crusher
The jaw crusher is used in the first crushing process of the crushing line, and can crush large particles with a compressive strength of no more than 320MPa into 100mm~300mm.
- Function: Primarily used as a primary crusher to break down large, hard materials.
- Mechanism: Utilizes a movable jaw plate and a fixed jaw plate to crush the material by compressive force.
- Applications: Suitable for crushing ores, minerals, and rocks, often used in mining and aggregate production.
Impact crusher
The impact crusher can generally handle ores or rocks below 500mm and with a compressive strength of up to 350MPa. The crushed materials are cubic particles. The impact crusher is generally used in the second crushing process of the crushing line, and can also be used as the first crushing process for materials with smaller feeds.
- Function: Designed to crush softer materials and produce a high reduction ratio.
- Mechanism: Utilizes high-speed impact forces; material is struck by hammers or blow bars and thrown against an impact plate.
- Applications: Commonly used in construction and demolition, recycling, and road building.
Cone Crusher
The cone crusher uses the principle of laminated crushing to form a protective layer of the material layer. It has the characteristics of reliable structure, high crushing efficiency, convenient adjustment, and economic use. Like the impact crusher, the cone crusher is often used in the second crushing process of the crushing line, and can also be used as the first crushing process for materials with smaller feeds. However, the feed particle size of the cone crusher is generally smaller than that of the impact crusher.
- Function: Typically used for secondary and tertiary crushing.
- Mechanism: Features a rotating cone that crushes materials against a fixed bowl liner through a combination of crushing and grinding.
- Applications: Effective for hard and abrasive materials, widely used in mining, quarrying, and recycling
Hammer Crusher
Hammer crusher has the characteristics of large crushing ratio, high production capacity and uniform product particle size. It is one of the primary equipment for fine crushing of limestone, coal or other brittle materials with medium hardness or below in metallurgy, building materials, chemical industry and hydropower industry.
- Function: Used for crushing and grinding materials into smaller particles.
- Mechanism: Uses rapidly rotating hammers to impact and break the material.
- Applications: Commonly used in the agricultural and recycling sectors for materials like biomass, wood chips, and food products.
Vibrating Screens
In addition to the main crushing equipment, some auxiliary equipment such as vibrating screens, feeders and cVionveyors are also required to complete the configuration and operation of this production line.
- Function: Used to separate materials by size, ensuring that only appropriately sized materials proceed to the next stage of processing.
- Applications: Essential for preparing feeds for crushers and ensuring consistent output grades.
Sinotech Luton Solutions: Choose Our Mobile Crushing Plant Set Over A Single Crusher
Mobile crushing plant sets combine various processes such as crushing, screening, and material handling into one integrated system, enhancing workflow efficiency. This eliminates the need for multiple separate machines, simplifying logistics and reducing capital investment.
With integrated screening and conveying systems, mobile plants can maintain a steady flow of materials, minimizing downtime between processes and improving overall efficiency. Materials can be moved directly from the crusher to the screen, and then transported to stockpiles without additional handling, streamlining operations.
Sinotech Luton’s mobile crushing plants are designed to process a wide range of materials, from aggregates to construction debris and mineral ores, catering to various project requirements.
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Stationary Crushing Plant Equipment Solutions
Fixed crushing production lines have a long service life, mature and stable technology, and most mines have fixed crushing stations. A fixed crushing station is a crushing production line that installs crushing equipment at a suitable site and cannot be moved after a one-time installation.
Semi-stationary Crushing Plant
Semi-fixed crushing station is a transitional mode from semi-mobile crushing station to fixed crushing station. From the connection with the ground, the crushing machine frame has a solid connection with the ground (anchor piles can be used in bedrock areas, and reinforced concrete foundations can be used in loose areas).
From the layout position, it is generally fixed on the fixed side of the mining site to reduce the frequency of relocation as much as possible and increase the service life, which is particularly important for rock crushing and transportation.
When a semi-fixed crushing station is relocated, only the equipment body connected to the foundation with bolts can be disassembled and moved for reuse, and the foundation buried below the surface is discarded.
Advantages: Because the semi-fixed crushing station has a solid foundation, it can be large-scale when selecting a model. It is suitable for mines with large processing capacity and has a long service cycle.
Disadvantages: It is necessary to build a fixed foundation, the construction period is long, the relocation project is large, the relocation operation time is long, and the civil engineering cost is high.
Stationary Crushing Plant
Fixed crushing stations are usually arranged outside the boundary of the stope, or set up inside the stope and combined with the chute. They are not affected by the advancement and deepening of the stope steps, and are connected to the ground with a permanent fixed foundation.
After they are built, they are used permanently and will not be moved. There are various feeding methods, such as direct unloading by cars or feeding by ore discharge devices with buffer silos. Fixed crushing stations are generally located in the crushing workshop of the ore dressing plant and have the same service life as the mine.
Disadvantages: Its biggest disadvantages are long ore transportation distance, high transportation cost, and difficulty in reasonable adjustment.
Mobile Crushing Plant Equipment Solutions
Mobile crushing stations generally integrate feeding, crushing and conveying. They are moved by crawler or tire type (there are also walking type), and can adjust their position at any time in the mining site as the working surface moves.
Replace dump trucks, reduce procurement costs; reduce transportation costs by 50% to 70%; reduce spare parts costs; reduce labor costs; reduce pit road maintenance; and have the characteristics of safety and environmental protection.
Because it is a three-in-one device, and the continuous transportation equipment connected to it is a belt conveyor, the crawler mobile crushing station is more suitable for large-scale open-pit mines and is suitable for large-scale, continuous mining processes.
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Wheeled Mobile Crushing Plant
The tire or wheeled type is moved by the front of the vehicle and needs to be towed by a truck when traveling on the road. It is generally used to process construction waste in urban areas, or in processing sites with strong mobility and the need to frequently change the work site. The machine needs to travel on a flat road, but the requirement for the site area is not high.
The integrated unit equipment installation form eliminates the complicated site infrastructure installation work of the separate components, reduces the consumption of materials and man-hours, and is a production line that integrates process equipment such as receiving, crushing, and conveying. The unit’s reasonable and compact spatial layout improves the flexibility of site deployment.
Crawler/Tacked Mobile Crushing Plant
Crawler type crusher is a fully automatic type. The crawler is driven by a hydraulic system and can be put into operation by remote control, which has a higher degree of automation.
Because the crawler has strong grip and the machine body is heavy, it can travel on hillsides and rugged roads. Therefore, this machine is often used for climbing operations and crushing operations in mountainous or uneven work sites.
According to the actual production requirements, corresponding equipment is equipped and various combinations can be made to form a “crushing before screening” or a “screening before crushing” process.
It can be combined into a two-stage crushing and screening system of coarse crushing and fine crushing, or a three-stage crushing and screening system of coarse crushing, medium crushing and fine crushing. It can also operate independently, which has great flexibility.
Sinotech Luton Helps You Choose
Mobility
The wheel-type mobile crushing station cannot be fully classified as a mobile crusher because its movement relies on being towed by a semi-trailer. Therefore, in terms of mobility, it is not as effective as the track-type mobile crusher, which is self-driven by hydraulic power.
Applicable Sites
Due to the fact that the wheel-type mobile crushing station is towed by a vehicle, it is more suitable for various applications in industries such as construction waste treatment, earth and stone projects, urban infrastructure, road construction, and construction in general, where a variety of sand and gravel materials need to be crushed.
The track-type mobile crusher features a chassis with a fully rigid boat-shaped design. It has high strength and low ground pressure, providing good adaptability to hilly and wetland environments, even enabling slope operations. Therefore, it is commonly used in harsh operational environments like mining and open-pit coal mining.
However, due to its convenient and fast mobility, it is increasingly used for processing urban construction waste, and many manufacturers now focus on producing track-type machines.
Equipment Performance
The wheel-type mobile crushing station has a short wheelbase and a small turning radius, allowing it to navigate without damaging the road surfaces. It can travel flexibly on regular highways and within work areas.
The track-type mobile crushing station operates on tracks, enabling it to turn in place. Its standard configuration includes wireless remote control, making it easy to load the crusher onto a trailer and transport it to the operational site.
Product Outcomes
Currently, mobile crushing stations are used for the processing of construction waste. The recycled aggregates produced by mobile stations have good particle shapes, which is beneficial for recycling. The semi-open discharge system is suitable for crushing construction waste containing a small amount of rebar, resulting in fine output with minimal over-crushing and well-shaped particles. This makes it particularly suitable for producing environmentally friendly bricks.
Price
Generally speaking, the price of track-type mobile crushing stations is slightly higher than that of the same series of wheel-type mobile crushing stations.
The Necessary Heavy Equipment for Mining/Crushing
In mining operations, especially during the crushing process, having the right extra heavy equipment can make a significant difference in efficiency, productivity, and safety. Here’s a list of essential equipment that complements crushing operations:
Tracked Excavators
Excavators can perform several crucial tasks in mining and stone crushing operations, including digging, lifting, and moving heavy materials. Their versatility makes them suitable for various applications such as site preparation, material handling, and breaking rock.
They are especially useful for excavating and loading materials into crushers, facilitating a continuous workflow.
Excavators can be equipped with different attachments like buckets, hydraulic hammers, or shears, enhancing their functionality (e.g., breaking large boulders before crushing).
They help in clearing the site before operations commence and can create access roads, eliminating hurdles for other equipment.
Loaders
Front-end loaders are designed to load and move materials quickly and efficiently. They can scoop, lift, and transport large volumes of gravel, sand, crushed stone, and other materials to various destinations, such as crushers or stockpiles.
They enable rapid loading of materials into trucks or conveyors, reducing downtime and improving overall productivity in the mining process.
With a variety of bucket sizes and attachments available, front-end loaders can be adapted to suit different tasks, whether it’s handling loose materials, stockpiling, or loading trucks.
Equipped with powerful engines and robust structures, these machines are capable of operating on rugged terrain common in mining environments.
Dump Trucks
Dump trucks play a crucial role in transporting raw material from the extraction site to the crushing plant and moving crushed material to processing areas or stockpiles. They are specifically designed to handle heavy loads, making them ideal for mining applications.
Modern dump trucks come with high payload capacities, allowing them to carry significant quantities of material in one trip, which reduces the number of trips and saves time.
Designed for rough terrains, dump trucks maintain stability and performance even in challenging mining conditions, ensuring safe and timely delivery of materials.
The hydraulic dumping mechanism allows for quick unloading of materials at designated locations, speeding up the operational workflow.
You may need for heavy equipment for crushing job
Why Choose SinoTech Luton?
Pre-sale Service
Provide the customers with 24-hour technical consultations and services, answer the questions of the customers in a timely with patience and passionately explain the performances and characteristics of the product to the customers in detail.
Provide the customers with the selection service before buying the machine according to relevant information offered by the
customers, and ensure the product is satisfactory and works well by checking and calculating the investment cost and investment
return for the customers.
Dispatch the engineering technicians to survey and plan the site and offer the optimized and reasonable construction scheme for the
station.
In-sale Service
Assist in formulating the construction scheme and procedure in detail, and offer the technical data, and guide the construction of the foundation.
Dispatch the experienced engineering technicians to guide installation, debugging, and trial run on the site until the equipment can run normally.
Implement technical training for the operating and maintaining personnel of the equipment for free in order to ensure they can operate independently and skillfully and remove the command fault while running the equipment.
After-sale Service
Offer maintenance service for free within the warranty period for any non-artificial quality problems. We shall reply within upon receiving the fault notice from the user and arrive at the construction site within the time prescribed in order to ensure the equipment can run normally.
Provide the customers with long-term excellent technical support and supply of spare parts at preferential prices, and ensure the equipment achieves the best working state by cooperating with the users closely.
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