Amid the sustained growth of infrastructure construction and the real estate sector, demand for manufactured sand has experienced explosive growth. Medium-sized sand production lines with an hourly output of 150 tons have become the preferred choice for many investors. Optimal equipment configuration not only ensures production capacity but also reduces operational costs and enhances product quality. This article systematically analyzes the optimized configuration plan for a 150-ton-per-hour sand production line.
I. Core Equipment Selection and Performance Parameters
1. Primary Crushing Stage: PE750×1060 Jaw Crusher
As the production line's “heart,” this equipment features a deep-chamber crushing structure enhanced with German Krupp technology. With a feed opening of 750×1060mm and powered by a Siemens 110kW motor, it achieves a processing capacity of 110-250t/h. Field data from Fujian granite quarries indicates:
When crushing granite with a Mohs hardness of 7, at a discharge opening of 150mm, the specific power consumption is only 0.78kWh/t.
The hydraulic adjustment mechanism enables discharge opening precision adjustment within ±5mm in 5 minutes.
Liner plate lifespan reaches 8,000 tons, a 40% improvement over traditional equipment.
2. Medium-Fine Crushing Stage: Technical-Economic Comparison of Dual Solutions
Solution 1: HST250 Single-Cylinder Hydraulic Cone Crusher
Crushing Principle: Laminar crushing + high-speed impact (800-900 r/min)
Suitable Materials: Hard rocks like basalt and diabase (Mohs hardness 6-8)
Performance Parameters:
Processing Capacity: 160-220 t/h
Product Shape: Cubic content ≥90%, flaky/needle-shaped particles <5%
Intelligent Control: Overload protection response time 0.3 seconds, main shaft auto-compensation accuracy ±0.5mm
Economic Indicators:
Wear Parts Cost: Liner life 1500 hours, unit price ¥12,000/set
Unit Power Consumption: 1.1 kWh/t
Option 2: PF1315 Impact Crusher
Crushing Principle: Three-chamber impact crushing + impact plate shaping
Suitable Materials: Medium-hard rocks such as limestone and dolomite (Mohs hardness 3-5)
Performance Parameters:
Processing Capacity: 130-180 t/h
Product Gradation: 0-5mm content 42-48%, 5-10mm content 35-40%
Rotor Structure: 1320mm diameter, equipped with 12 high-chromium hammers (Cr26 material)
Economic Indicators:
Hammer Life: 3000 hours, unit price ¥8,000/piece
Unit Power Consumption: 0.9kWh/t
3. Sand Making & Shaping: VSI6X1150 Vertical Shaft Impact Crusher
This equipment utilizes the “stone-on-stone + stone-on-iron” composite crushing chamber licensed from Swiss Metso technology, with a processing capacity of 120-180 t/h. Key technical parameters:
Impeller speed: 1500-1800 r/min (variable frequency adjustment)
Distributor angle: 35°-45° adjustable
Fineness Modulus Control: 2.4-3.0 continuously adjustable
Powder Content Control: ≤2.5% for Class III sand production, MB value ≤0.8
Field testing at a Zhejiang production line confirmed that the manufactured sand produced by this equipment meets GB/T14684-2011 Class I standards, with a crush value ≤10% and durability ≤8%.
II. Key Configuration Points for Auxiliary Systems
1. Screening and Conveying System
3YZS2160 Vibrating Screen
Screen Structure: Three-layer polyurethane screen mesh (5/10/20mm)
Vibration Parameters: Amplitude 10mm, Frequency 980 times/minute
Screening Efficiency: >92% (when moisture content <2%)
Special Design:
Screen Tensioning Device: Hydraulic automatic tensioning, tension error <5%
Anti-Blocking Device: Ultrasonic screen cleaning system, 60% improvement in cleaning efficiency
B1000×15m Belt Conveyor
Conveying Parameters: Belt width 1000mm, belt speed 2.5m/s, inclination angle 15°
Drive System: Electric Drum (15kW) + Hydraulic Coupler
Safety Devices:
Bidirectional Misalignment Switch (Alarm Threshold ±15mm)
Longitudinal Tear Detection Device
Speed Monitor (Accuracy ±0.1m/s)
2. Environmental Support Equipment
Pulse Jet Dust Collector
Airflow Capacity: 30,000m³/h (Covering Crusher & Screen)
Filter bag material: Polyester fiber + PTFE membrane
Emission control: Particulate matter <8mg/m³, Ringelmann blackness <Grade 1
Intelligent control: Differential pressure automatic cleaning system, adjustable cleaning cycle
Noise reduction devices
Crusher inlet: Composite silencer (28dB noise reduction)
Sand maker discharge: Resistive silencer (25dB noise reduction)
Plant Boundary Noise: Measured value 58dB (complies with GB12348-2008 Class II standard)
III. Process Flow Optimization Practices
Two-stage Closed-circuit Crushing Process
Process Flow:
Raw Material (≤500mm) → Vibrating Feeder (S5X1545) → Jaw crusher primary crushing → Cone crusher/Impact crusher secondary crushing → Vibrating screen classification → Sand maker shaping → Finished product
Key Control Points:
Circulation load rate: 35±5% (controlled via variable frequency speed regulation)
Return material handling: Dedicated return belt conveyor installed (belt width 650mm)
Buffer bin design: Capacity 50m³, equipped with automatic level sensor control
