A Bauxite Crushing and Screening Plant is an industrial facility that processes bauxite ore—the primary source of aluminum—into specific sizes for refining or direct use. Bauxite, a mixture of aluminum hydroxides, iron oxides, and silica, requires mechanical processing to meet the specifications of alumina refineries.

    2. Operational Process
    A. Raw Material Extraction and Preparation:

    • Bauxite is extracted via open-pit mining using excavators or blasting.

    • Grizzly Screen: Filters oversized rocks (>1 meter) before primary crushing.

    B. Crushing Stages:

    • Primary Crushing:

      • Jaw Crusher or Impact Crusher: Reduces bauxite blocks to 100-300 mm.

      • Impact crushers are preferred for clay-rich bauxite to minimize clogging.

    • Secondary Crushing:

      • Cone Crusher or Rotary Crusher: Further reduces material to 20-50 mm.

    • Tertiary Crushing (If Required):

      • Vertical Shaft Impactor (VSI): Produces fine particles (3-15 mm).

    C. Screening and Classification:

    • Vibrating Screens: Separate crushed bauxite into sizes (e.g., 0-5 mm fines, 5-20 mm granules).

    • Washing Units (Optional): Remove clay and impurities using log washers.

    D. Material Handling:

    • Belt Conveyors: Transport materials between stages.

    • Stockpiles: Store graded bauxite for shipment to refineries.

    E. Automation and Safety:

    • PLC Systems: Monitor throughput, energy use, and equipment health.

    • Moisture Sensors: Optimize crusher performance based on ore moisture.

    3. Applications

    • Alumina and Aluminum Production:

      • Bauxite is refined into alumina (Al₂O₃) via the Bayer process.

      • Electrolysis converts alumina into pure aluminum (used in aerospace, construction).