Amid the surge in demand for aggregates in infrastructure construction, 1000-1100 tons/hour aggregate production lines require precise matching of equipment based on aggregate grade to achieve a balanced balance of production capacity, quality, and cost. The following classification by aggregate grade clarifies the key equipment selection logic.
1. Low-grade aggregate (high impurities, Mohs hardness ≤ 4)
Core Characteristics
Commonly used in applications with low particle shape requirements, such as roadbed filling and bedding, these aggregates have high mud content and low hardness (such as weathered rock and soft shale), requiring controlled crushing costs and minimal equipment wear. Equipment Configuration
Coarse Crushing: Two PE1500×1800 jaw crushers are used, offering a crushing ratio of 10-15. They can process large lumps ≤1200mm, with a single unit capacity of 1000-1200 tons per hour. They are suitable for low-hardness materials and offer low procurement costs, slow tooth plate wear, and easy maintenance.
Fine Crushing: Three PF1820 impact crushers utilize the impact crushing principle to rapidly refine coarse material ≤300mm, producing a relatively regular finished product (with a needle-like content ≤10%), meeting the requirements for bedding aggregate. These crushers require no complex adjustments and are easy to operate.
Auxiliary Equipment: Two ZSW800×2000 vibrating feeders (with grizzly screens) pre-screen fines ≤50mm, reducing the crushing load. Three 3YK3070 vibrating screens rapidly grade finished products to ensure production meets production standards.
II. Medium-grade Stone (Medium Hardness, Mohs Hardness 5-6)
Core Characteristics
Used for commercial concrete and general building structures, this product requires high-purity raw materials (such as limestone and sandstone) and requires a stable output of 10-30mm aggregate with a balanced particle shape and strength.
Equipment Configuration
Coarse Crushing: Utilizes two PCZ1615 heavy-duty hammer crushers, each with an hourly output of 800-1000 tons. These crushers can directly crush materials ≤1000mm, reducing the number of steps required by a single crusher. Energy consumption is 15% lower than that of a jaw crusher, making them suitable for efficient crushing of medium-hardness materials.
Secondary Crushing: Utilizes three CSB875 cone crushers, utilizing the laminated crushing principle to refine coarse aggregate ≤200mm. The discharge opening is adjustable from 5-25mm, ensuring a uniform finished particle size with a compressive strength of ≥30MPa, meeting concrete aggregate standards. Auxiliary Equipment: Two ZSW850×2100 vibrating feeders for precise feed rate control; four 3YK3680 vibrating screens for multiple sizes (5-10mm, 10-20mm, 20-30mm), with a screening efficiency exceeding 95%.
III. High-Grade Stone (Low Impurities, Mohs Hardness 7-8)
Core Features
For high-standard applications such as high-speed rail and water conservancy projects, the raw material must be high hardness (such as granite and diabase). The finished product must have excellent particle shape (≤5% needle-like flakes) and high strength (compressive strength ≥60MPa). The equipment must be wear-resistant and highly stable. Equipment Configuration
Coarse Crushing: Two HX1600 crushers are used, each with a 1600mm feed opening, capable of processing large hard rock lumps ≤1500mm. Each unit has an hourly output of 1200-1500 tons. The crushing chamber is constructed of wear-resistant materials to mitigate wear on hard materials, ensuring continuous, trouble-free operation.
Secondary Crushing + Fine Crushing: Three HPT800 multi-cylinder cone crushers are used for secondary crushing, refining coarse material ≤300mm. Discharge openings range from 5-15mm, ensuring uniform material distribution into the fine crushing stage. Fine crushing is complemented by two VSI1380 sand making machines, which use a "rock-on-rock" process to shape the material, producing cubic aggregate (excellent particle shape). This also improves the strength of the finished product, meeting the aggregate requirements for high-speed rail ballastless track. Auxiliary Equipment: Two ZSW900×2200 vibrating feeders (high-precision frequency conversion control) ensure stable material feeding; five 4YK3685 vibrating screens provide fine grading of finished products in various specifications. Two fine sand recovery machines minimize fine material loss and ensure production output.
IV. General Auxiliary Systems (Full-Grade Compatibility)
Conveying Equipment: Twelve B1200 belt conveyors (with anti-slip devices) are used, each with a conveying capacity of 1,200 tons/hour, ensuring continuous material transfer and adapting to the full production capacity of the line.
Environmental Protection Equipment: The entire system is enclosed and equipped with four 48-bag pulse dust collectors (dust collection rate ≥ 98%). Sand washing wastewater is treated by two 600 m2 filter presses and then recycled, meeting environmental requirements.
V. Optimization Recommendations for Selection
Low-grade stone production lines: Prioritize low-cost, easy-to-maintain equipment to avoid over-configuration and waste.
Medium-grade stone production lines: Focus on "efficient crushing + foundation shaping" to balance cost and quality.
High-grade stone production lines: Invest in wear-resistant, high-precision equipment to ensure that finished products meet standards and avoid rework losses.
Our Technology and Services
In the construction and operation of stone production lines, advanced technology and high-quality service are key to ensuring efficient and stable operation and meeting the diverse needs of our customers.
We have a professional R&D team dedicated to the innovation and optimization of stone production technology. Team members possess extensive industry experience and deep professional knowledge, keeping pace with cutting-edge international technological trends and continuously developing new technologies and processes based on actual production needs.
In terms of service, we always adhere to the principle of "customer first," providing customers with comprehensive, one-stop, high-quality services. From the early stages of project planning, we arrange for professional technicians to conduct in-depth discussions with customers to understand their production needs, site conditions, investment budget, and other information, and then tailor a personalized stone production line solution for them.
During the equipment installation and commissioning phase, we dispatch experienced technical engineers to provide on-site guidance to ensure quality and effective commissioning. Our engineers meticulously install and commission each piece of equipment, strictly adhering to equipment installation specifications and commissioning procedures, ensuring optimal operation before commissioning. During the installation and commissioning process, we also provide on-site training for our customers' operators to familiarize them with equipment operation methods, maintenance points, and safety precautions, cultivating a team of professional operators and maintenance personnel.
After the equipment is operational, we provide comprehensive after-sales service. We have established a 24-hour after-sales service hotline to respond to customer needs at any time. If a customer encounters equipment malfunction or technical issues, our after-sales service team will contact the customer immediately to understand the problem and provide initial troubleshooting and resolution via phone or video. For issues that cannot be resolved remotely, our after-sales service team will arrive on-site as quickly as possible to perform repairs and provide technical support. We also offer equipment upgrade and modification services. Based on our customers' production needs and technological trends, we perform technical upgrades and modifications on existing equipment to enhance performance and efficiency, creating greater value for our customers.
