L’efficienza di una cava di ghiaia dipende principalmente dal fatto che la linea di produzione abbinata sia scientifica e ragionevole.
Nella produzione effettiva, la funzione principale di qualsiasi linea di produzione per la frantumazione di minerali è quella di frantumare vari minerali, ghiaia, ecc. fino a una dimensione e forma delle particelle ragionevoli. Poiché una linea di produzione per la frantumazione di minerali è composta da molti dispositivi, le cui funzioni sono interconnesse, non si tratta semplicemente di imporre una linea di produzione scientifica. La linea di produzione deve essere progettata su misura in base alle condizioni del materiale, ai requisiti di produzione, alle specifiche del prodotto finito e ad altre condizioni. Lo scopo è ridurre al minimo sforzi e complicazioni.
Soluzione STLT per impianto mobile di frantumazione della pietra
Un vantaggio chiave degli impianti mobili di frantumazione è la loro ecocompatibilità e l’eliminazione della necessità di installazione e fondazioni, il che li rende altamente efficienti per la lavorazione di un’ampia gamma di materiali, quali calcare, basalto, ciottoli, minerale di ferro e rifiuti da costruzione.
Inoltre, i frantumatori mobili contribuiscono in modo significativo all’efficienza e alla sicurezza nelle cave, consentendo la lavorazione in loco dei materiali e riducendo la necessità di trasporti estesi.
Il nostro impianto di frantumazione è un’intera linea di produzione composta da diversi apparecchi, quali frantumatore a mandibola, frantumatore conico, macchina per la produzione di sabbia, lavatrice per sabbia, vagliatore vibrante e nastro trasportatore.
Nota:Offriamo sia impianti mobili per la frantumazione della pietra sia linee fisse di frantumazione. In base alle esigenze specifiche di diversi clienti, possiamo personalizzare configurazioni di linee di produzione.
Soluzioni combinate di frantumazione per diversi tipi di materiali lapidei
Prima di configurare la linea di produzione per la frantumazione e la produzione di sabbia, dobbiamo innanzitutto identificare i materiali grezzi da frantumare, ad esempio le loro dimensioni, durezza, umidità , ecc.
Inoltre, dobbiamo chiarire i nostri requisiti specifici in termini di portata produttiva e dimensione e tipo del prodotto finito. Questo fornirà la necessaria base scientifica per la successiva scelta di frantumatori e macchine per la produzione di sabbia adeguati.
Ad esempio, se si sceglie un frantumatore a martelli per rocce dure, la conseguenza diretta è un’usura rapida delle teste dei martelli e costi elevati per la sostituzione degli accessori; viceversa, l’utilizzo di un frantumatore conico per rocce tenere comporta costi elevati per l’investimento iniziale e per la manutenzione successiva.
Soluzione per linea di produzione lapidea e linea di produzione di sabbia
La configurazione comune di una linea completa di produzione lapidea utilizza generalmente processi di frantumazione a due o tre stadi. La maggior parte
delle cave di ghiaia utilizza solitamente un processo a circuito chiuso a due stadi, ossia il frantumatore secondario e l’apparecchio di vagliatura formano un circuito chiuso,
garantendo che le dimensioni del prodotto soddisfino i requisiti per gli aggregati di sabbia e ghiaia.
Le configurazioni generali degli apparecchi sono le seguenti.
- Alimentatore vibrante + frantumatore a mandibola + frantumatore a impatto + nastro trasportatore + vagliatore vibrante circolare:
Alimentatore vibrante + frantumatore a mandibola + frantumatore conico + nastro trasportatore + vagliatore vibrante; - Alimentatore vibrante + frantumatore a mandibola + frantumatore a impatto + macchina per la produzione di sabbia + nastro trasportatore + vagliatore vibrante circolare
Linea di produzione di sabbia è composta da un alimentatore vibrante, un frantumatore a mandibola, un frantumatore conico, un frantumatore a impatto (macchina per la produzione di sabbia), un vagliatore vibrante, una lavatrice per sabbia (classificatore di sabbia), un nastro trasportatore, un sistema di trattamento delle acque e un sistema di controllo elettronico centralizzato. Possiamo inoltre aggiungere alla linea un separatore di polveri per soddisfare requisiti specifici dei nostri clienti. Possiamo assemblare la linea di produzione in base ai requisiti di vari processi per garantire prestazioni ottimali.
Soluzione per aggregati di sabbia e ghiaia morbidi e poco abrasivi
Generalmente, essa è suddivisa in alimentazione, frantumazione, vagliatura e trasporto. I materiali grezzi vengono convogliati all’alimentatore vibrante tramite il silos e quindi trasportati dall’alimentatore vibrante al primo apparecchio di frantumazione per la frantumazione grossolana. I materiali frantumati vengono trasportati dal nastro trasportatore al secondo apparecchio di frantumazione (frantumazione fine).
Dopo la frantumazione, i materiali vengono trasportati dal nastro trasportatore al vagliatore vibrante circolare per la vagliatura. I materiali di dimensioni superiori a quelle richieste vengono restituiti al secondo apparecchio di frantumazione per ulteriore frantumazione. I materiali vagliati dal vagliatore vibrante circolare costituiscono il prodotto finito.
Se la forma delle particelle non è sufficientemente buona, è possibile aggiungere una macchina per la produzione di sabbia a impatto verticale per la modellatura. In questo modo, la forma delle particelle frantumate risulterà più arrotondata e l’effetto sarà migliore.
Soluzione per aggregati di sabbia e ghiaia duri e altamente abrasivi
Materiali lapidei duri di grandi dimensioni vengono immessi in modo uniforme nell’alimentatore vibrante tramite il silos e quindi entrano nel frantumatore a mandibola per la prima frantumazione.
I materiali frantumati grossolanamente vengono vagliati secondo le esigenze dal vagliatore vibrante e quindi trasportati dal nastro trasportatore al frantumatore conico per la seconda frantumazione media e fine.
Dopo la frantumazione media e fine, viene utilizzato un vibratore circolare per la selezione, e le particelle più grandi vengono reinviate al frantoio a cono per una nuova frantumazione. In questo momento, è possibile ottenere gli aggregati sabbiosi e ghiaiosi richiesti.
Se è necessaria la produzione di sabbia e la modellatura, i materiali conformi ai requisiti vengono introdotti nella macchina per la produzione di sabbia per un’ulteriore frantumazione e modellatura. Se i materiali devono essere lavati, è possibile aggiungere una lavatrice per sabbia per il lavaggio. Infine, i materiali conformi ai requisiti vengono classificati e confezionati in base alle diverse fasce granulometriche.
Qui prendiamo come esempi minerali comuni quali quarzo, ciottoli, arenaria, granito e calcare per consigliarti la configurazione della linea di produzione di sabbia.
Quarzo
- Durezza Mohs: 7-7,5
- Densità : 2,64 g/cm³–2,71 g/cm³
Il quarzo è un minerale siliceo duro, resistente all’usura e chimicamente stabile, il cui componente principale è il biossido di silicio. È una materia prima minerale industriale importante. Generalmente, dopo la frantumazione e la produzione di sabbia, viene utilizzato nell’industria del vetro, delle costruzioni, della ceramica e persino dell’elettronica ad alta tecnologia.
- Linea di produzione di sabbia di quarzo
- Portata: 30–45 tonnellate all’ora
Configurazione degli impianti: silos + due frantoi a mandibola fini + macchina per la produzione di sabbia + vibratore di drenaggio + lavatrice per sabbia + macchina per il recupero di sabbia fine + nastro trasportatore
Ciottoli
- Durezza Mohs: circa 7
- Vantaggi del materiale: elevata durezza, forte resistenza alla compressione ed è il materiale principale per la produzione di sabbia e ghiaia artificiale.
I ciottoli sono solidi duri dalla forma simile a uova d’oca, formatisi dopo milioni di anni di impatto proveniente da montagne e fiumi e trasportati dall’acqua corrente. Il loro componente principale è il biossido di silicio e la sabbia e la ghiaia artificiale da essi prodotte soddisfano i requisiti di sabbia e ghiaia artificiale in diverse località .
- Cobblestone sand production line
- Production: 50-70 tons per hour
Configurazione degli impianti: 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
Configurazione degli impianti: silo + vibrating feeder + jaw crusher + impact crusher + sand making machine + dewatering screen + sand washing machine + fine sand recovery machine + belt conveyor
Granito
- 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
Configurazione degli impianti: 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
Configurazione degli impianti: silo + vibrating feeder + jaw crusher + impact crusher + sand making machine + vibrating dewatering screen + sand washing machine + fine sand recovery machine + belt conveyor
Conventional Process Plan for Different Crushing Capacity Needs
We have professional hard and soft stone crushing process plans for different needs, with capacities ranging from 100tph to 700tph.
Please share your project details and specific requirements with us, and we’ll work together to create a customized solution that fits your needs perfectly.
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.
More featured crusher and crushing plant equipment to check!
Sinotech Groups 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.
Our 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.
. Cosa possiamo offrire
Cost Effective
Dal gruppo SinoTech
Tell us your needs,we offer customized solutions!
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.
Impianto fisso di frantumazione
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.
See more hot selling mobile crushing plants options
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 Groups Helps You Choose
MobilitÃ
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.
Prezzo
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 Group?
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.
. Cosa possiamo offrire