A Cone Crusher Plant is an industrial facility designed to crush large rocks into aggregates (sand, gravel, crushed stone) for construction purposes. The core component, the cone crusher, uses compression and crushing forces to produce cubic, uniform, and low-dust materials. These plants can operate in primary, secondary, or tertiary crushing stages.

Working Principle:

  1. Feeding and Pre-Screening: Raw material from quarries is fed into the cone crusher via a vibrating feeder. Pre-screening removes dust and fines.

  2. Crushing Process:

    • The cone crusher compresses material between a fixed outer mantle (concave) and a rotating inner cone (mantle).

    • As the inner cone rotates, material is crushed into smaller sizes within the crushing chamber.

  3. Screening and Classification: Crushed material is sorted into desired sizes (e.g., 0-5 mm sand, 5-20 mm gravel) using vibrating screens.

  4. Washing and Storage: Sand washing units (bucket or screw washers) clean the aggregates, which are then stockpiled.

Key Components:

  • Cone Crusher: High-strength steel mantle and concave.

  • Vibrating Feeder: Ensures consistent material flow.

  • Vibrating Screens: Multi-deck screens for size classification.

  • Conveyor Belts: Transport materials between stages.

  • Sand Washer: Removes dust and clay.

  • Automation System: Optimizes crusher settings and energy use.

Advantages:

  • High Efficiency: Processes hard, abrasive materials (basalt, granite) with low energy consumption.

  • Cubic Aggregates: Ideal for concrete and asphalt due to low void content.

  • Durability: Wear-resistant parts (mantle, concave) reduce maintenance costs.

  • Flexible Output: Adjustable crushing gaps enable production of multiple aggregate sizes.

Applications:

  • Aggregates for concrete and asphalt.

  • Railway ballast and road base layers.

  • Precast concrete elements and landscaping.

  • Mineral ore processing in mining.