A Crushing and Screening Plant is an industrial facility designed to process natural rocks, stones, or recycled materials into specific-sized aggregates (crushed stone). These plants produce materials essential for construction, such as road bases, concrete, and asphalt. The core processes include crushing (reducing large rocks) and screening (sorting by size).

2. Purpose

  • Aggregate Production: Crushes stones into standardized sizes for construction materials.

  • Size Classification: Screens materials into fractions (e.g., 0-5 mm sand, 5-12 mm gravel).

  • Quality Enhancement: Improves material properties like hardness and cubic shape.

  • Recycling: Processes demolition waste into reusable construction aggregates.

3. How It Works

The workflow of a crushing and screening plant includes:

  1. Feeding: Large rocks or recycled materials are loaded into a hopper via excavators or trucks.

  2. Primary Crushing: Jaw crushers or impact crushers reduce material to 100-300 mm.

  3. Secondary Crushing: Cone crushers or vertical shaft impactors (VSI) further crush material to 20-80 mm.

  4. Screening: Vibrating screens separate crushed material into sizes (dust, gravel, coarse fragments).

  5. Tertiary Crushing (Optional): Impact crushers produce fine aggregates (<10 mm).

  6. Stockpiling and Dispatch: Conveyor belts transport sorted aggregates to storage or trucks.

Technical Specifications:

  • Max Feed Size: 500-1000 mm (depends on primary crusher).

  • Output Sizes: 0-5 mm (sand), 5-12 mm (fine aggregate), 12-25 mm (coarse aggregate).

  • Capacity: 100 to 1000 tons per hour.

  • Power Requirement: 200-800 kW (varies by plant size).

4. Advantages

  • High Efficiency: Automated systems ensure continuous production.

  • Flexible Design: Mobile or stationary configurations for diverse projects.

  • Eco-Friendly: Dust suppression systems and recycling capabilities.

  • Cost Savings: Portable plants reduce transportation costs.

5. Applications

  • Construction Industry: Concrete, asphalt, and road base material production.

  • Railway Projects: Ballast (railway track foundation) production.

  • Landscaping: Decorative stones and garden design materials.

  • Industrial Facilities: Cement plants and infrastructure projects.