A Crushing and Screening Plant is an industrial facility that mechanically processes natural stones, ores, or recycled materials into smaller, classified sizes. These plants transform raw materials into usable forms (aggregates, sand, gravel) for construction, mining, roadworks, and recycling industries.

2. Operational Process
A. Raw Material Feeding:

  • Raw materials (rocks, ores, concrete waste) are loaded into the feed hopper via excavators or trucks.

  • Grizzly Screen: Filters oversized chunks (>1 meter) to prepare for crushing.

B. Crushing Stages:

  • Primary Crushing:

    • Jaw Crusher: Reduces material to 100-300 mm using compressive forces between fixed and moving jaws.

    • Impact Crusher: Fragments soft rocks via high-speed impacts.

  • Secondary Crushing:

    • Cone Crusher: Achieves 20-50 mm particles through interparticle crushing.

    • Horizontal Shaft Impactor (HSI): Ideal for medium-hard materials.

  • Tertiary Crushing:

    • Vertical Shaft Impactor (VSI): Produces fine aggregates (3-15 mm) for sand or specialized uses.

C. Screening and Classification:

  • Vibrating Screens: Multi-deck screens sort materials by size (e.g., 0-5 mm sand, 5-20 mm gravel).

  • Washing Units (Optional): Log washers or wheel buckets remove dust and clay.

D. Material Handling:

  • Belt Conveyors: Transport materials between crushers, screens, and stockpiles.

  • Storage Silos and Stockpiles: Products are stored for dispatch or direct use.

E. Automation and Safety:

  • PLC Systems: Monitor production efficiency, energy usage, and equipment status in real time.

  • Sensors and Alarms: Prevent overloads, screen blockages, and conveyor malfunctions.

3. Applications

  • Construction Industry:

    • Concrete and asphalt production (aggregates, sand).

    • Road base layers and backfill materials.

  • Mining:

    • Ore preparation (iron, copper, gold).

    • Processing industrial minerals (limestone, basalt).

  • Recycling:

    • Reusing concrete and asphalt waste.

  • Agriculture and Environment:

    • Soil stabilization (crushed stone).

    • Water filtration systems (gravel).

  • Energy and Chemical Sectors:

    • Processing coal and salt.

4. Maintenance and Sustainability

  • Routine Maintenance:

    • Replacement of crusher liners, screen meshes, and conveyor belts.

    • Lubrication and bearing inspections.

  • Eco-Friendly Practices:

    • Dust suppression via water sprays or air filters.

    • Recycling process water.

    • Noise barriers and quarry rehabilitation.