A Limestone Crushing and Screening Plant is an industrial facility designed to mechanically process limestone rocks into various sizes for commercial use. These plants are critical in mining and construction sectors, transforming raw materials into usable products like aggregates, powders, and gravel.

Detailed Operational Process

  1. Raw Material Feeding and Pre-Processing:

    • Large limestone blocks are loaded into a feed hopper using excavators or dump trucks.

    • Grizzly Screen: Filters oversized rocks (>1.5m) to ensure uniform feeding into crushers.

  2. Crushing Stages:

    • Primary Crushing:

      • Uses Jaw Crushers (compression force) or Impact Crushers (high-speed impacts).

      • Reduces rocks to 100-300 mm.

    • Secondary Crushing:

      • Cone Crushers (interparticle crushing) or Horizontal Shaft Impactors (HSI) further reduce fragments to 20-50 mm.

    • Tertiary Crushing (Optional):

      • Vertical Shaft Impactors (VSI) produce finely crushed material (3-15 mm) for specialized applications.

  3. Screening and Classification:

    • Vibrating Screens: Multi-deck screens separate materials into sizes (e.g., 0-5 mm sand, 5-20 mm gravel).

    • Washing Units (Optional): Log washers or scrubbers remove impurities like clay.

  4. Material Handling and Storage:

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

    • Storage Silos: Store categorized products (e.g., coarse aggregates, fine sand).

  5. Automation and Safety:

    • PLC systems monitor throughput, energy consumption, and equipment health.

    • Emergency stop mechanisms and dust suppression systems enhance safety.

Applications (Detailed):

  • Construction Industry:

    • Concrete production (coarse/fine aggregates), asphalt mixes, precast concrete.

    • Road base layers and railway ballast.

  • Cement Manufacturing:

    • Calcination of limestone to produce clinker.

  • Agriculture:

    • Soil pH correction (agricultural lime).

    • Livestock feed additives (calcium carbonate).

  • Environmental Projects:

    • Flue gas desulfurization (FGD) in power plants.

    • Water treatment for pH stabilization.

  • Other Uses:

    • Glass manufacturing, decorative stones, ceramics.

Maintenance and Sustainability:

  • Regular lubrication of crusher bearings and replacement of wear parts (mantles, liners).

  • Dust Control: Fog cannons or bag filters minimize airborne particles.

  • Recycling process water and rehabilitating quarried sites post-operation.