Crushed Stone Production Plant is an industrial facility that processes large rocks into aggregates (crushed stone, gravel, sand) through mechanical crushing, screening, and washing. These plants produce essential materials for construction projects such as roads, concrete, railways, and infrastructure.

How It Works?

  1. Raw Material Supply:

    • Rocks (1-1.5 meters in diameter) extracted from quarries are transported to the plant and dumped into feed hoppers.

    • Pre-Screening: Some plants use vibrating screens to remove soil, clay, and fines.

  2. Crushing Stages:

    • Primary Crushing:

      • Jaw Crusher or Impact Crusher reduces rocks to 10-30 cm.

    • Secondary Crushing:

      • Cone Crusher or Impact Crusher breaks materials into 2-5 cm pieces.

    • Tertiary Crushing:

      • Vertical Shaft Impactor (VSI) produces 0-5 mm sand with a cubic shape.

  3. Screening and Classification:

    • Vibrating Screens: Separate crushed materials into sizes:

      • 0-5 mm: Fine sand (for concrete and asphalt).

      • 5-15 mm: Gravel (road sub-base).

      • 15-25 mm: Crushed stone (railway ballast).

    • By-Pass Screen: Diverts oversized materials back to crushers or stockpiles.

  4. Washing and Cleaning:

    • Bucket Wheel Washer or Screw Washer removes dust and clay using water.

    • Water Recycling Systems: Treat and reuse water via sludge separators.

  5. Storage and Dispatch:

    • Clean aggregates are conveyed to stockpiles.

    • Aggregates are shipped to construction sites via trucks or trains.

Key Equipment and Technology:

  • Crushers: Jaw, cone, impact, VSI crushers.

  • Screening Systems: Vibrating screens, bypass screens.

  • Washers: Bucket, screw, trommel.

  • Conveyor Belts: Horizontal and inclined conveyors.

  • Automation: PLC systems optimize energy use and product quality.

Advantages:

  • High Capacity: Produces 500-10,000 tons per day.

  • Multi-Size Production: Sand, gravel, and crushed stone in one plant.

  • Eco-Friendly: Dust suppression, water recycling, and noise barriers.

  • Mobile Plants: Portable crushers and screens for temporary projects.

Applications:

  • Concrete and Asphalt: Fine and coarse aggregates.

  • Road Construction: Gravel for base layers.

  • Railways: 15-50 mm crushed stone as ballast.

  • Landscaping: Decorative stones and drainage materials.