I. Crushing Equipment: Core Configuration for Graded Crushing
Jaw Crusher (Primary Crushing Stage)
As the initial crushing equipment in the production line, it employs the squeezing crushing principle of a moving jaw and fixed jaw, capable of processing raw materials such as marble and granite with diameters ≤1.5 meters. Its V-shaped deep cavity structure design increases material throughput by 20%, achieving a crushing ratio of 6-8. For example, when processing limestone with 1.2-meter feed size, the output can be controlled between 150-300 mm, meeting the feed requirements for medium and fine crushing equipment.
Medium-Fine Crushing Equipment Combination
Impact Crusher: Suitable for medium-hard materials (e.g., limestone, shale). Achieves crushing through the collision of impact plates and counter plates, with adjustable discharge sizes below 50 mm. Its advantages include excellent product shape (needle and flake content <10%) and a 15% lower wear rate compared to cone crushers.
Cone Crusher: Designed for high-hardness materials (e.g., granite, basalt), it employs a layer compression crushing principle. With an adjustable discharge opening range of 3-60 mm, it produces cubical particles (flake and needle content <8%). For instance, when processing granite with ≤200 mm feed size, the discharge size can be precisely controlled between 10-30 mm.
II. Sand-Making Equipment: High-Speed Impact and Shaping Technology
Impact sand-making machines (e.g., VSI series) refine materials to 0-5 mm via “stone-on-stone” or “stone-on-iron” mechanisms. Core advantages include:
Controllable Fineness Modulus: By adjusting rotor speed (1500-2000 r/min) and feed size, it produces Class I sand (for C60 concrete) with a fineness modulus of 2.6-3.0, or Class II sand (for C30-C60 concrete) with 2.3-2.6.
Optimized Gradation: Produces continuous sand particle gradation, with 65%-75% of particles falling within the 0.15-2.36 mm range, meeting GB/T 14684-2011 standards.
Enhanced Efficiency: Single-unit sand production capacity of 50-150 tons/hour, representing a 30% efficiency increase over traditional sand makers.
III. Screening and Conveying Equipment: Fully Automated Process Integration
Linear Vibrating Screen
Utilizes multi-layer screens (typically 3-4 layers) to simultaneously classify coarse sand (2.36-4.75 mm), medium sand (1.18-2.36 mm), and fine sand (0.6-1.18 mm). With a screening efficiency exceeding 95%, it handles 50-200 tons per hour. For instance, in a 100-ton-per-hour sand and gravel production line, a three-layer vibrating screen can process 1.67 tons of material per minute.
Belt Conveyor
Utilizing variable frequency speed control technology, it enables continuous material conveyance with a maximum length of 1000 meters and belt widths ranging from 650 to 1400 mm. Key advantages include:
Energy Efficiency: Power consumption reduced by 40% compared to screw conveyors;
Sealed Design: Optional dust covers minimize dust pollution during transportation.
IV. Auxiliary Equipment: Full-Process Optimized Configuration
Feeder
Utilizes vibratory feeding. By adjusting amplitude (2-5 mm) and frequency (50-150 Hz), it ensures uniform material distribution and prevents crusher overload. For example, when processing limestone, it achieves a feeding capacity of 200 tons/hour, guaranteeing stable operation of the jaw crusher.
Sand Washer
Removes surface silt from sand particles through spiral blade agitation and water flow rinsing (reducing silt content from 3% to below 0.5%). Processing capacity: 20-150 tons/hour. Water consumption: 0.8-1.2 cubic meters per ton of sand.
Dust Collection Equipment
Utilizes pulse jet baghouse dust collectors with 99.5% efficiency, achieving dust emission concentrations below 10mg/m³. For instance, in a 200-ton-per-hour crushing production line, a dust collector with a 30,000m³/h air handling capacity effectively controls workshop dust levels.
V. Other Configurations: Customized Production Requirements
Bulk Material Storage Bin
Constructed with steel or concrete structures, with capacities ranging from 50 to 500 cubic meters. Can store 3-7 days' worth of raw materials to ensure continuous production. For example, a production line processing 1,000 tons of sand and gravel per day requires a 200-cubic-meter storage bin to meet two days' production needs.
Tailings Recovery Unit
Combines hydrocyclones with dewatering screens to recover lost fine sand (0.075–0.6 mm particle size) with over 85% recovery rate. For instance, processing sand-water mixtures with 20% silt content yields 15–20 tons/hour of recovered fine sand, enhancing resource utilization.
VI. Customized Production Line Adjustment Cases
Phosphate Ore Production Line
Adding flotation equipment (e.g., mechanically agitated flotation machines) enables separation of phosphate ore from gangue through chemical addition, achieving concentrate grades exceeding 30%. For instance, a phosphate mine equipped with three 10m³ flotation machines processes 500,000 tons annually with an 85% concentrate recovery rate.
High-Moisture Material Production Line
For clay materials with moisture content >15%, install dryers (e.g., triple-drum dryers) to reduce moisture below 8%. For example, when processing shale with 20% moisture, dryers achieve a capacity of 50 tons/hour with thermal efficiency >70%.
VII. Production Line Efficiency and Economic Benefits
Example: 200-ton-per-hour sand and gravel production line
Equipment Configuration: Jaw Crusher (PE900×1200) + Cone Crusher (HPT300) + Impact Sand Maker (VSI5X) + Vibrating Screen (3YK2460) + Belt Conveyor (B1200×10m)
Energy Consumption: Total power consumption approx. 400kW, energy consumption per unit product 0.2kWh/ton;
Costs: Equipment investment approx. 3 million RMB, annual operating costs (including labor, electricity, and wear parts) approx. 1.5 million RMB;
Revenue: Based on market price of 80 yuan/ton for manufactured sand, annual output value reaches 57.6 million yuan (calculated at 7,200 operating hours/year), with profit margin of approximately 30%.
Through modular equipment integration and intelligent control, modern crushing and sand-making production lines achieve efficient, eco-friendly, and cost-effective aggregate production, meeting diverse demands across construction, industrial, and environmental sectors.
