The design of a crushing line focuses on crushing equipment, screening and classifying equipment, sand making equipment (this equipment is only needed for artificial sand making), storage and dispatching equipment and dust control equipment. This article introduces the 5 main points of crushing production line design, and highlights the design points and advantages and disadvantages of 6 different crushing equipment combinations, hoping to provide some help for your equipment selection.
1. Crushing equipment
1.1 The design consideration of material warehouse discharge
The main form of warehouse material discharge is under and outside the warehouse, as shown in the figure below.
Vibrating feeder is designed in the lower part of the warehouse discharge port, which is what we call under-bin feeding. The advantage is that it can adapt to all forms of materials and discharge smoothly; the disadvantage is that the materials in the warehouse are directly pressed on the machine, which requires higher standard of machinery and higher manufacturing cost of machinery.
Vibrating feeder design in the lower part of the warehouse outside, that is, we say outside the warehouse feeding, the advantage is that the warehouse material is not directly pressed on the machinery, the standard requirements of the machinery is low, the manufacturing cost of machinery is correspondingly small; shortcomings is that the material contains more soil or perhaps poor liquidity is easy to block the machine or discharge is not smooth.
1.2 Stone crusher selection rules
The crushing equipment in the design of stone crushing production line focuses on one break, two break and the whole type of composition, each stage of mechanical model selection focuses on the crushing power index of the rock, wear and corrosion index, the very large feed size and the performance standards of the product. Wi: crushing power index – the specification of the difficulty of material crushing, the Ai: wear corrosion index – the material to the wear specification of the machine parts, Wi of common rocks as well as Ai is shown in Table 1, Table 2. crushing machinery to the raw stone material adaptation aspects are shown in Table 3, Table 4.
The production line combinations of crushing equipment are: heavy-duty hammer impact crusher equipment, jaw crusher + impact crusher equipment, jaw crusher + cone crusher equipment, jaw crusher + fine jaw crusher equipment, jaw crusher + impact crusher + vertical impact crusher equipment and jaw crusher + cone crusher + cone crusher equipment. The selection of crushing equipment should be based on material characteristics, product shape and market needs.
(1) Heavy-duty hammer impact crusher equipment
The heavy-duty hammer impact crusher equipment consists of a heavy-duty hammer crusher and screening and classifying equipment.
Advantages: the product is formed once, the process is simple; easy to maintain and protect the operation; use less area; low investment in engineering; low energy consumption per unit of product appearance; standard grain shape of the output material, low powder content; mainly used in limestone crushing in stone quarries and cement plant crushing line.
Disadvantage: processing granite and other high hardness materials wear serious.
(2) Jaw Crusher + Impact Crusher Equipment
Advantages: the equipment capacity particle size is more, can be large output, its application field is wide; product particle size is easy to adapt; applicable in medium abrasion index materials.
Disadvantages: higher energy consumption per unit product appearance; poor adaptability to high abrasion index rocks, ordinary product shape, medium creation rate of coarse size aggregates; large dust collection air volume required for stone crusher; higher consumption of wearing parts than cone type stone crusher.
(3) Jaw Crusher + Cone Crusher Equipment
Advantages: easy adjustment of product particle size; suitable in high abrasion index materials; good shape of product, small amount of fine powder, high creation rate of coarse grain size aggregate; small dust collection air volume needed for stone crusher; low energy consumption per unit product appearance; low consumption of wearing parts.
Disadvantages: cone type stone crusher particle size is less, when the equipment capacity standard is larger when the need for three-stage crushing or need more than one stone crusher, while the protocol is complex, high engineering investment; its application areas are relatively narrower than the impact crusher.
(4) Jaw Crusher + Fine Jaw Crushing Equipment
Advantages: low overall project investment cost, low consumption of wearing parts; simple operation process; easy maintenance, protection of operation; large adjustment range of product particle size, can be large output; wide range of applicable materials; good shape of products, small amount of fine powder, wide application areas of products; high creation rate of coarse-grained aggregates; small dust collection air volume required by the stone breaker; low energy consumption per unit of product appearance;
Disadvantage: The single machine output of the fine jaw crusher is relatively low, requiring multiple fine jaw crushers when the equipment capacity standard is large.
(5) Jaw Crusher + Cone Crusher + Vertical Impact Crusher Equipment
This equipment consists of jaw crusher, cone crusher, vertical impact crusher and screening and classifying equipment, the protocol is almost the same as jaw crusher + cone crusher equipment, only to expand the vertical impact crusher to aggregate shaping to achieve high quality aggregate consumer needs. In addition to the advantages and disadvantages of the jaw crusher and cone crusher, the equipment also has the following advantages and disadvantages:
Advantages: can supply multi-performance aggregates to meet the needs of different consumers, vertical impact crusher appears more fine powder can take into account the production of artificial sand;
Disadvantages: complicated procedures, high engineering investment; high energy consumption per unit product appearance.
(6) Jaw Crusher+Cone Crusher+Cone Crusher equipment
This equipment consists of jaw crusher, cone crusher, cone crusher and screening and classifying equipment, and its protocol is almost the same as jaw crusher + cone crusher equipment, only the expansion of a cone crusher. In addition to the advantages and shortcomings of the jaw crusher + cone crusher, this equipment has the following characteristics:
advantages: it can achieve a larger standard of equipment output capacity;
disadvantages: the protocol is complex, high engineering investment.
1.3 Screening and classification machinery settings
In the stone crushing production line design of the primary crushing before the custom screening classification, so that the fine stone does not need to be crushed as well as soil sieve, and then through the screen stone machine can be screened out of the soil as well as fine aggregate, which can prevent the fine stone and then crushed to expand the appearance of energy consumption as well as expand the powder, but also to exclude the soil to reduce the dust of the later process, but also to enhance the performance of the aggregate.
1.4 Buffer pile or transit warehouse setup
In the primary crushing and medium and whole crushing of the aggregate production line between the custom-made semi-finished sand and gravel pile, the role of this semi-finished sand and gravel pile is: can balance the overall equipment capacity of the aggregate production line, medium and whole crushing stone crusher particle size model selection does not need to think about the fluctuation coefficient of the primary crushing stone crusher; if the primary crushing plant maintenance, then the downstream aggregate making plant can continue to produce; not only that, in order to Safety, many mines only in the day shift mining, then the downstream of the aggregate made workshop can still two-shift production to flexible to meet the market needs, and the downstream of the aggregate made workshop machinery units can be reduced by half or perhaps select the processing capacity of small machinery and upstream match (because the semi-finished sand and gravel pile can be flexible to adjust the capacity of equipment), the corresponding can reduce equipment investment.
2. Screening and classification equipment
The key considerations of the screening and classification equipment in the design of stone crushing production line are: the correct selection of the screen area; the skid between the upstream conveying system and the screening machine should be customized correctly to ensure that the material can be laid flat on the entire screen surface; the correct matching of the particle size of the dust collector to ensure that environmental protection standards are met; the skid between the stone screening machine and the downstream conveying system should think about anti-abrasion and anti-noise.
3. Sand making equipment
The focus of sand making equipment by the plastic sand making machine, vibrating grading screen, particle grading adjustment machine, air sieve composition, the focus of custom attention are: into the sand making machine of the raw stone material grain size closer to the product is the higher the sand making efficiency, so the production of raw stone material with smaller grain size, rather than applying super grain size raw stone material, so not only sand making efficiency is reduced, but also accelerate the loss of machinery; into the air sieve of the raw stone material moisture can not be greater than 2%, or lead to the air sieve separation efficiency, for more rain areas customized to think about rain measures.
4. Storage and shipping equipment
Aggregate storage usually adopts closed steel storage (or commercial concrete storage) and steel shed, and the corresponding shipping equipment of the storage is auto-loader, and the corresponding shipping equipment of the steel shed is forklift loading; the investment per unit storage quantity of the storage is higher than that of the steel shed, but its dust emission is less and its automatic loading efficiency is high; the investment per unit storage quantity of the steel shed is low, but its working environment is poor and its loading efficiency is low. In areas with strict environmental protection standards, priority is given to closed steel storage (perhaps mixed commercial concrete storage), which is more conducive to environmental protection acceptance.
5. Dust-proof equipment
The dust prevention equipment consists of two parts: water spraying to reduce dust and bag dust collector, and bag dust collector to collect the dust that appears. In the aggregate production line, water spraying equipment is usually installed in the discharge pile and the hopper at the head of the tape machine of each transfer station, and water spraying equipment is also installed in the finished product storage if the steel structure shed is adopted. The custom-made water spraying equipment should pay attention to the nozzle position and the number of custom-made correct, the amount of water can be adjusted, water pressure is guaranteed, otherwise the effectiveness of dust reduction is not significant also easy to block the screen stone machine screen holes lead to production. The custom-made bag filter pay attention to the bag filter particle size, number and collection duct to be customized correctly, dust collection ash needs to be set up separately for storage and should not be returned to the production line to avoid the emergence of secondary dust downstream.
Not only is it a means to reduce the necessary opening costs, but it is also a means to reduce the appearance of dust by reducing the drop of each feed chute in the customization.
The design of stone crushing production line should be based on the detailed environment, material characteristics, product shape and market needs; jaw crusher + fine jaw crusher combination form, adapt to a wide range of materials, low investment costs, to a certain extent, better than other combination forms, finished product storage closed steel warehouse (or perhaps commercial concrete warehouse) compared to the steel structure of the shed is more conducive to environmental protection, in the region of strict environmental protection standards are given priority to adopt.