A stone crushing plant is an industrial facility designed to process large rocks into smaller, usable aggregates (e.g., sand, gravel, crushed stone) for construction, infrastructure, and industrial applications. It uses crushers, screens, and conveyors to transform raw materials into specific sizes (0-5 mm, 5-12 mm, 12-25 mm, etc.).

2. Purpose:

  • Size Reduction: Breaks down rocks into manageable sizes.

  • Classification: Sorts aggregates by size using vibrating screens.

  • Quality Control: Produces uniform materials for high-performance construction.

  • Environmental Compliance: Minimizes dust and optimizes resource use.

3. How Does It Work?

Stages:

  1. Feeding:

    • Raw stones (200-800 mm) are transported to the plant via trucks or loaders.

    • Pre-Screening: Grizzly screens remove dirt and fine debris.

  2. Crushing Process:

    • Primary Crushing:

      • Jaw Crusher: Reduces rocks to 150-300 mm using compressive force.

      • Impact Crusher: Shatters rocks with high-speed rotors (ideal for soft stones like limestone).

    • Secondary Crushing:

      • Cone Crusher: Crushes rocks between a mantle and concave to 25-50 mm.

      • Vertical Shaft Impactor (VSI): Produces cubical aggregates (0-25 mm).

    • Tertiary Crushing:

      • Hammer Mill or Grinders: Creates fine sand (0-5 mm).

  3. Screening:

    • Multi-Deck Vibrating Screens: Classify aggregates into sizes:

      • 0-5 mm: Concrete sand or asphalt mixtures.

      • 5-12 mm: Precast concrete elements.

      • 12-25 mm: Road base layers.

      • 25-50 mm: Railway ballast.

  4. Washing (Optional):

    • Log washers or sand screws remove clay and impurities.

  5. Storage & Dispatch:

    • Aggregates are stored in stockpiles or silos. Automated loaders transfer materials to trucks.

4. Applications:

  • Construction: Concrete, asphalt, prefabricated structures.

  • Infrastructure: Roads, bridges, dams.

  • Railways: Ballast stone production.

  • Landscaping: Decorative gravel and paving.

  • Industrial: Fillers for glass, ceramics, and paint.

5. Key Components:

  • Crushers: Jaw, cone, impact, VSI.

  • Screens: Vibrating screens, grizzly screens.

  • Conveyors: EP rubber belts for material handling.

  • Dust Control: Water sprayers, bag filters.

  • Control System: PLC-based automation.

6. Key Benefits:

  • High Capacity: Processes 50-500 tons per hour.

  • Versatility: Handles various rock types (basalt, limestone, granite).

  • Sustainability: Recycles construction waste (e.g., concrete rubble).