Aggregate Crushing Line

AGICO

Definition & Classification of Aggregates

Aggregates, essential constituents of concrete, provide structural support and filling. They are analogous to the skeletal framework in the human body, thus termed as aggregates. Without aggregates, cement, when mixed with water, remains in a slurry state and cannot solidify, rendering it unusable. Therefore, aggregates are vital raw materials in construction.

aggregate-particle

Depending on their particle size, aggregates are classified into coarse and fine aggregates.

Coarse aggregate

Coarse aggregates, also known as stones, have a particle size greater than 4.75 mm and comprise natural pebbles formed through weathering or transportation by water, as well as crushed stones produced through mechanical crushing and screening. Materials such as limestone, bluestone, river pebbles, granite, and basalt can be used as raw materials for coarse aggregates.

Fine aggregate

Fine aggregates, also referred to as sand, have a particle size smaller than 4.75 mm and include natural sands like river sand, lake sand, mountain sand, and desalinated sea sand, as well as artificial sands produced through crushing rocks with sand-making machines. Similar to crushed stones, various types of rocks can be chosen as raw materials for artificial sands based on their intended applications. An aggregate production line can be understood as a production line for grinding rocks into aggregates.

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Complete Aggregate Production Line Systems

aggregate-processing

The three major systems of an aggregate production line are:

Feeding System

The feeding system of the aggregate production line supplies raw materials to various crushing and screening equipment according to the crushing and screening process. Equipment responsible for the feeding process includes vibrating feeders or other types of feeding devices. In sand and gravel production lines, vibrating feeders are commonly used to supply stone materials.

Crushing System

The aggregates crushing system is the heart of the entire set of equipment. Its function is to crush various ore materials into the required particle size of the finished product. A unified sand and gravel production line may consist of multiple aggregates crushing machines. These crushing machines, each with different performance characteristics, work together to accomplish the crushing of stone materials.

Screening and Conveying System

The screening and conveying system of the aggregate production line involves screening crushed ore materials using screening machinery. In composite sand and gravel production lines, it is necessary to separate sand and stone materials, and the graded sand and gravel materials need to be conveyed to their respective sites. Equipment commonly used in this process includes linear vibrating screens or other screening machinery.

Practical Aggregate Crushing Solution

Aggregate crushing lines can have various design configurations depending on materials and production requirements, with some design variations based on terrain differences.

Advantages of our aggregate crushing line

Energy-saving & High degree of automation in the production line

High production efficiency & large output

Low operating costs & high profitability

Adjustable & uniform particle size and good particle shape of the finished stones meet the standards for high-speed construction materials

A typical configuration for an aggregate production line includes primary crushing, secondary crushing, and washing stages.

Primary Crushing

Hammer Crusher:

Suitable for materials with compressive strength below 200 MPa, such as limestone, bluestone, coal gangue, gypsum, and bricks. This equipment can achieve primary crushing, with adjustable particle size of the finished product. It has a production capacity of around 2000-3000 tons per hour, with a feed size of 1200mm, suitable for materials of medium hardness.

Jaw Crusher:

Suitable for materials with compressive strength below 320 MPa, such as river pebbles and marble. Depending on different operating parameters, the jaw crusher can achieve varying production capacities, with a maximum output of up to 2200 tph and a maximum feed size of 1500mm.

Cone Crusher:

Suitable for materials with medium to high hardness, such as river pebbles, granite, basalt, iron ore, quartzite, diabase, iron ore, gold ore, and copper ore. Single-cylinder cone crushers have a wide range of production capacities, ranging from 225 to 1050 tons per hour. Multi-cylinder hydraulic cone crushers typically have an hourly output between 180 and 445 tons, while compound cone crushers can achieve an hourly output between 172 and 349 tons if the feed size does not exceed 300mm.

Secondary Crushing

Hammer Crusher:

Offers high production capacity, good particle shape, low power consumption, and easy maintenance, suitable for materials of medium hardness.

Impact Crusher:

Offers lower production capacity but good particle shape, suitable for materials of medium to high hardness.

Vibrating Screen:

Screens the crushed materials into different grades of finished products. Materials that do not meet the requirements are separated by the vibrating screen and conveyed back to the secondary crushing stage for recycling.

Aggregate Washing

Sand Making Machine:

If artificial sand is required in the aggregate production line, a sand making machine can be added to further crush the materials from the secondary crushing stage, producing artificial sand.

Sand Washer:

Sand washer is used to wash the produced artificial sand to remove impurities and improve the quality of the material.

Aggregate Production Line for Specific Applications

An aggregate production line for highway construction is divided into three stages: coarse crushing, medium-fine crushing, and sand making.

aggregate-production-line-for-highway-construction

Stage One: Coarse Crushing Large stones are uniformly fed into the jaw crusher from the storage hopper via a vibrating feeder. After coarse crushing, the materials are screened by a vibrating screen and then transported by a conveyor belt to a cone crusher (for hard rocks) or an impact crusher (for medium-hard or soft rocks) for further crushing.

aggregate-production

Stage Two: Medium-Fine Crushing The materials transported to the cone crusher or impact crusher undergo medium-fine crushing. After crushing, they are screened using a circular vibrating screen. Materials with a size greater than or equal to 40mm are returned to the cone crusher or impact crusher for secondary crushing.

aggregate-for-construction

Stage Three: Sand Making The crushed stone particles smaller than 40mm are sent to a sand making machine for further crushing and shaping. Materials with a size greater than or equal to 20mm are returned to the sand making machine for further fine crushing. Materials smaller than 20mm are sent to a circular vibrating screen for screening and packaging. If clean aggregate is required, they can be sent to a sand washer for cleaning.

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