I. Design Principles
Tailored for basalt’s high hardness and abrasiveness, ensuring equipment durability, process stability, and production of high-quality cubical aggregates.
II. Process Flow
Three-Stage Closed-Circuit Crushing System (Recommended Scheme)
Raw Material Bin → Vibrating Feeder (Pre-screening) → Jaw Crusher (Primary) → Cone Crusher I (Secondary) → Cone Crusher II (Tertiary) → Screening System → Product Bins
↑_________________Recycling Conveyor System_____________________↑
III. Equipment Configuration (300TPH Baseline)
| Process Stage | Equipment | Model/Specification | Qty | Power (kW) | Output Size |
|---|---|---|---|---|---|
| Feeding | Heavy-Duty Vibrating Feeder | ZSW600×1300 | 1 | 30 | <500mm |
| Primary Crushing | Jaw Crusher | C160/CJ615 class | 1 | 250 | <250mm |
| Secondary Crushing | Hydraulic Cone Crusher | HP400/CH440 class | 2 | 2×250 | <60mm |
| Tertiary Crushing | Short-Head Cone Crusher | HP300/CH430 class | 2 | 2×200 | <30mm |
| Screening | Triple-Deck Vibrating Screen | 2.4×6.0m | 3 | 3×22 | Grading |
| Conveying | Belt Conveyors | B800-B1200 | 15-18 lines | As required | – |
| Dust Control | Pulse Bag Filter | Centralized System | 1 set | 75 | – |
IV. Product Specifications (Adjustable)
Manufactured Sand: 0-5mm Small
Aggregate: 5-15mm
Medium Aggregate: 15-25mm
Large Aggregate: 25-40mm
V. Key Design Points
- Wear Resistance: High manganese steel liners for all crushing chambers; maintain critical spare parts inventory.
- Dust Control: Fully enclosed conveying + centralized bag filter system; dust emission <20mg/m³.
- Automation: PLC central control system monitoring current, temperature, and vibration.
- Maintenance Design: Service platforms and lifting facilities for liner replacement within 8 hours.
- Layout Requirements: Equipment spacing ≥1.5× equipment width with clear maintenance access.
VI. Main Technical Parameters
- Processing Capacity: 200-400TPH (adjustable)
- Total Installed Power: ≈1800kW
- Required Area: ≈8000-12000㎡
- Operating Staff: 3-5 persons/shift
- Equipment Utilization Rate: ≥85%
VII. Project Execution
- Design Period: 4-6 weeks
- Manufacturing & Installation: 4-5 months
- Commissioning: 2-3 weeks
- Investment Scale: Medium-sized quarry equipment configuration
Scheme Features: Simplified flow, easy maintenance, excellent product shape, suitable for highly abrasive basalt conditions. Recommended to equip with a condition monitoring system for optimized wear parts replacement planning.
BASALT CRUSHERS
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