A stone and mineral crushing-screening plant is an industrial facility designed to crush, size, and classify natural rocks, mineral ores, or recycled materials. These plants are integral to aggregate production, mineral processing, and construction waste recycling. They typically integrate equipment such as primary crushers, secondary crushers, tertiary crushers, screens, feeders, and conveyor systems.

2. Purpose

  • Crushing: Reduces large rocks and ores to usable sizes (e.g., 0-50 mm).

  • Classification: Sorts crushed materials by size to produce homogeneous aggregates.

  • Recycling: Converts construction waste (concrete, asphalt) into reusable materials.

  • Efficiency: Optimizes raw material preparation for mining and construction projects.

3. Key Components

  • Primary Crusher: Reduces large rock blocks (1-1.5 m) to 100-300 mm (Jaw crusher, impact crusher).

  • Secondary Crusher: Further crushes primary output to 20-100 mm (Cone crusher, impact crusher).

  • Tertiary Crusher: Produces fine aggregates (0-25 mm) with cubical shapes (Vertical shaft impactor).

  • Screening Systems: Vibrating screens classify material into 2-4 sizes (e.g., 0-5 mm, 5-12 mm).

  • Feeders & Conveyors: Regulate material flow and enable intra-plant transport.

  • Dust Suppression: Water spray or filter systems minimize environmental impact.

4. Working Principle

  1. Feeding: Material from quarries is fed into the primary crusher via excavators.

  2. Primary Crushing: Jaw crushers break down large rocks into coarse fragments.

  3. Secondary Crushing: Cone crushers reduce material to medium sizes.

  4. Screening: Vibrating screens sort material; oversized particles return to secondary/tertiary crushers.

  5. Tertiary Crushing: Vertical shaft impactors refine material into sand or fine aggregates.

  6. Stockpiling: Sized material is stored in stockpiles or loaded onto trucks.

5. Advantages

  • High Capacity: Processes 50-1500 tons per hour.

  • Automation: PLC-controlled systems for real-time monitoring.

  • Eco-Friendly: Dust and noise reduction technologies.

  • Modular Design: Scalable with additional crushers or screens.

6. Applications

  • Quarries: Aggregate production (sand, gravel).

  • Mines: Processing iron, copper, and gold ores.

  • Construction Sites: Preparing materials for concrete/asphalt.

  • Recycling Plants: Repurposing construction debris.