A Crushing and Screening Plant is an industrial facility designed to break down and classify materials such as rocks, ores, concrete debris, or natural stones into specific sizes. These plants play a vital role in producing aggregates (sand, gravel, crushed stone) for construction, mining, and recycling industries.

Components:

  1. Primary Crusher (Jaw or Impact Crusher): Reduces large materials (up to 1 m³) to 100-300 mm.

  2. Secondary Crusher (Cone or Impact Crusher): Further crushes materials to 20-100 mm.

  3. Tertiary Crusher (Vertical Shaft Impactor): Produces fine sand (0-20 mm).

  4. Screening Equipment:

    • Vibrating Screens: Classify materials into 4-5 size fractions (e.g., 0-5 mm, 5-12 mm).

    • Grizzly Screen: Removes soil and fines before primary crushing.

  5. Belt Conveyors: Transport materials between stages.

  6. Dust Suppression Systems: Minimize environmental impact via water sprays or filters.

  7. Control Panel: Manages automation and energy efficiency.

Operating Principle:

  1. Feeding: Material is loaded into a hopper via excavators or trucks.

  2. Primary Crushing: Jaw crusher breaks down large rocks into coarse aggregates.

  3. Pre-Screening: Grizzly screen removes fines to protect crushers.

  4. Secondary/Tertiary Crushing: Achieves desired final particle size.

  5. Final Screening: Vibrating screens sort aggregates into grades for stockpiling or direct use.

Applications:

  • Concrete and asphalt production,

  • Railway ballast and road base material,

  • Ore processing in mining,

  • Recycling construction waste,

  • Quarrying sand and gravel.

Advantages:

  • High Efficiency: Processes 200-2000 tons per hour.

  • Versatility: Handles materials like basalt, granite, and limestone.

  • Automation: Ensures consistent output via PLC systems.

  • Sustainability: Dust control and closed-loop water systems reduce environmental impact.