Driven by the accelerated pace of infrastructure construction and the deepening of the "Dual Carbon" policy, the demand for large-scale, intelligent, and green production lines in the sand and gravel aggregate market continues to rise. 1,100-1,200 tons per hour aggregate production lines, core equipment for key projects such as highways, high-speed railways, and large-scale water conservancy projects, often present investors with multiple difficulties, including "low hard rock crushing efficiency," "restricted site layout," "non-compliance with environmental standards," and "high operation and maintenance costs." This article combines cutting-edge industry technologies with practical experience to provide a comprehensive solution, demonstrating our technical strength and service guarantee, to help projects achieve efficient and profitable implementation.
I. Core Application Scenarios: Precisely Matching Production Capacity and Quality Requirements in High-Demand Sector
With a production capacity of 1,100-1,200 tons per hour, this production line is specifically designed for applications requiring a continuous and stable supply of high-quality aggregate. Its application requirements precisely cover three core areas, and differentiated technical standards are imposed on the production line:
(I) Transportation Infrastructure
Highway and high-speed railway construction place stringent demands on aggregate gradation stability and flake content. For example, aggregate for high-speed ballastless track must have a flake content of ≤5% and a compressive strength of ≥120 MPa. This production line can stably produce aggregate in various sizes, including 5-10mm, 10-20mm, and 20-30mm, suitable for diverse applications such as roadbed fillers and concrete mixing. A single production line can achieve an annual production capacity of 8-9 million tons, meeting the continuous material supply needs of major projects such as the Beijing-Shanghai High-Speed Railway Line 2. (II) Water Conservancy Projects
Reservoir and dam projects require extremely high aggregate impermeability and wear resistance, and must cope with complex materials such as pebbles and diabase. The production line, with its customized crushing chamber design, can process a wide range of stone materials with a Mohs hardness of 5-8. The finished aggregate has a mud content of ≤1%, fully meeting the C60 concrete material standard for water conservancy projects. It has been successfully used in multiple water conservancy projects in the Yangtze River Economic Belt.
(III) Urban Construction and Mining Development
Ready-mixed concrete mixing plants require a diversified supply of aggregates, while pre-processing of metal and non-metallic ores prior to beneficiation requires efficient crushing and grading. The production line is equipped with a flexible screening system that can adjust the finished product specifications according to demand. It also supports the crushing of hard rocks such as granite and tuff (compressive strength ≤150 MPa), providing high-quality manufactured sand for ready-mixed concrete and pre-processing services for the development of strategic minerals such as spodumene.
II. Core Configuration of the Production Line: Addressing Four Industry Pain Points with Intelligent Combinations
To address the four key concerns of investors regarding production capacity, site requirements, environmental protection, and cost, the production line utilizes a core configuration of "four-stage crushing + intelligent control + green supporting facilities" to maximize efficiency.
(I) Raw Material Pretreatment System: Laying a Solid Foundation for Efficient Production
The raw material silo utilizes a large 1500×3000mm steel structure and is equipped with two ZSW850×2100 vibrating feeders. Frequency conversion technology controls the feed rate, ensuring uniform conveyance of large rocks (≤1200mm) and preventing blockages. A grizzly screening device is installed below the feeder to pre-separate fines ≤50mm for direct feed to the finished product system, reducing the subsequent crushing load and improving raw material pretreatment efficiency by 30%. (II) Multi-stage Crushing System: The Core Engine for Efficient Hard Rock Crushing
To address the pain points of "low hard rock crushing efficiency and rapid equipment wear," a four-stage crushing system consisting of a jaw crusher + single-cylinder cone crusher + multi-cylinder cone crusher + impact crusher is used to accommodate materials of varying hardness:
Primary Crushing: Two PE1600×2100 jaw crushers, equipped with custom alloy tooth plates and a high-strength frame, are designed to crush large hard rocks, achieving a processing capacity of up to 2,000 tons per unit hour. The tooth plate life is 50% longer than traditional equipment, reducing maintenance costs from the source.
Secondary Crushing: Three DS800 single-cylinder hydraulic cone crushers, with hydraulically adjustable discharge opening size (15-50mm), precisely process post-primary crushing materials, ensuring uniform feed and increasing crushing efficiency by 25%.
Three-stage fine crushing + shaping: Four HPY600 multi-cylinder hydraulic cone crushers, leveraging their "fixed spindle + high speed" technology, overcome the physical resistance of hard rock. Two VSI1380 impact crushers provide shaping. The final aggregate's needle-like and flake content is strictly controlled to less than 5%, and its particle shape meets cubic standards.
(III) Screening and Environmental Protection System: Balancing Quality and Green Production
The screening process is equipped with eight 3YKJ3685 vibrating screens. Their "in-line" design with a customized chute reduces horizontal space usage by 40%, easily addressing the challenges of limited operating space in mountainous areas. They can simultaneously separate four finished product specifications, achieving a screening efficiency exceeding 98%. The environmentally friendly configuration utilizes a "fully enclosed + multi-stage purification" solution: The jaw and cone crushers are equipped with high-pressure spray dust suppression devices, and the vibrating screens are equipped with a fully enclosed negative pressure dust removal system, achieving a dust collection rate exceeding 95%, ensuring dust emissions are ≤10mg/m³. Eight DR3050 fine sand recovery machines and six 600-square-meter filter presses form a "water purification matrix," achieving 100% recycling of sand washing wastewater. Mud is filtered into cakes for backfilling, achieving "zero wastewater discharge and full sludge utilization," fully meeting the environmental protection requirements of projects located near ecological protection areas.
III. Technical Advantages: Overcoming Production Difficulties with Core Competence
Leveraging 15 years of experience in large-scale production line design and leveraging three core technological advantages, we provide projects with solutions that far exceed industry standards:
(I) Dedicated Hard Rock Crushing Technology
For hard rock, such as tuff, with a compressive strength exceeding 128 MPa, we have developed specialized wear-resistant liners and optimized crushing chambers. Utilizing a "laminated crushing" principle, this technology improves crushing efficiency while reducing equipment wear. This results in a hard rock processing capacity 15-20% higher than similar equipment in the industry. This technology has been successfully deployed in a 9.9 million ton annual hard rock aggregate project in Cangnan, Zhejiang Province.
(II) Spatial Optimization Layout Technology
Learning from the "space folding" design philosophy, through innovative solutions such as compact equipment arrangement, three-dimensional belt conveyor layout, and customized chute diversion, a full suite of over 30 large-scale equipment can be accommodated within a 7-10 mu (approximately 16-18 acres) site, saving 40% compared to traditional layouts and perfectly suited for confined locations such as mountainous areas and mining areas.
IV. Full-Cycle Service Guarantee: One-Stop Support from Project Planning to Operations and Maintenance
We understand that the implementation and stable operation of large-scale production lines require professional services. Therefore, we have established a "Five-Pronged Service System" to address customer concerns with rapid response and in-depth empowerment:
(I) Customized Survey and Design Services
Our technical team conducts comprehensive research, including geological surveys, site measurements, and raw material analysis. Taking into account project capacity requirements, material characteristics, and environmental standards, we develop a personalized solution that combines "raw material matching, site optimization, and cost control."
(II) Full-Process Installation and Commissioning Services
We have established a professional installation team and adopted a "modular installation method" to shorten construction timelines, ensuring that the entire line is installed within 30 days. During the commissioning phase, process engineers are stationed on-site throughout the entire process to optimize crushing parameters and screening accuracy until the line reaches its designed capacity and quality standards, achieving "installation and commissioning." (3) Personnel Training Services
We provide 15 days of systematic training covering equipment operation, parameter adjustment, safety procedures, and troubleshooting. This "theory + practice" approach ensures operators are proficient in using the intelligent system. Regular technical upgrade training is organized to allow customers to benefit from cutting-edge industry advancements.
(4) Lifetime Technical Upgrade Services
We provide free technical consultation throughout the life of our equipment. We offer value-added services such as dust removal system upgrades and capacity expansion modifications based on environmental policy updates and market demand. For example, to meet the newly issued PM2.5 emission standards, we can quickly upgrade existing production lines to high-efficiency bag filter dust removal systems, ensuring continued compliance.
V. Return on Investment and Case Verification
Leveraging our technological and service advantages, our 1,100-1,200 ton per hour production line has demonstrated strong profitability. With raw material costs of 60-80 yuan/ton and finished product prices of 120-150 yuan/ton, annual net profits at full capacity can reach 120-180 million yuan, shortening the payback period to 2-3 years. In a granite aggregate project in Pakistan, the production line we built for a client successfully processed Mohs 7 granite, achieving a stable daily production capacity of 28,000 tons and a dust emission concentration of only 8mg/m³, earning praise from the local environmental protection department. In a supporting water conservancy project in Bangladesh, the production line operated continuously for 18 months without major failures, achieving a 100% qualified finished aggregate yield, and securing a long-term supply contract for a key project.
Conclusion
The key to the successful operation of our 1,100-1,200 t/h stone aggregate production line lies in "solving production pain points with intelligent technology and ensuring project success with professional services." Leveraging core technologies such as hard rock crushing, space optimization, and energy conservation and environmental protection, combined with a full-lifecycle service system, we not only provide clients with production lines that meet "green mine" and "smart factory" standards, but also offer field-proven solutions and guaranteed profitability, making us a trusted choice for investors in large-scale stone aggregate projects.
