Against the backdrop of growing demand for sand and gravel aggregates, 900-1000 tons/hour stone aggregate production lines require precise design based on the raw material characteristics and the intended use of the finished product. The following provides equipment adaptation solutions categorized by three scenarios: soft rock, medium-hard rock, and hard rock. We also detail our technological advantages and full-lifecycle services, ensuring stable production and cost control.
1. Soft Rock Production Line (Mohs Hardness ≤ 3, such as shale and gypsum)
Core Requirements
The raw material is easily crushed but has a high mud content. It is commonly used as roadbed filler and brickyard raw material. It requires rapid processing of bulk material while minimizing fines generation. Equipment Configuration
Coarse Crushing: Two PE1200×1500 jaw crushers (each with an hourly output of 600-700 tons), each with a 1200×1500mm feed opening, can process materials ≤1000mm in size, and a crushing ratio of 10-12. The shallow crushing chamber, designed for soft rock, reduces fines caused by overcrushing.
Shaping Crushing: Three PF1520 impact crushers utilize the impact crushing principle to refine coarse material ≤250mm in size. The output particle size is adjustable from 10-50mm, and the flake content in the finished product is ≤12%, meeting roadbed filling requirements.
Auxiliary Systems: Two ZSW750×2000 vibrating feeders (with 50mm grate screens) separate fine sludge in advance; three 3YK3070 vibrating screens provide grading; and two sand washers are used to control sludge content. Wastewater is recycled through sedimentation tanks.
II. Medium-hard rock production line (Mohs hardness 4-6, such as limestone and sandstone)
Core Requirements
Raw material with moderate hardness and high purity, suitable for commercial concrete and general construction applications, requires a stable output of aggregates in various sizes, ranging from 5-30mm, with balanced particle shape and gradation.
Equipment Configuration
Coarse Crushing: One CJ140 jaw crusher (800-1000 tons per hour). This heavy-duty design handles intermittent large aggregates. An optimized crushing chamber improves processing efficiency by 15%, with a discharge size of ≤300mm.
Secondary Crushing: Three SC1300 single-cylinder cone crushers. Their laminated crushing principle reduces equipment wear. The discharge opening is adjustable from 10-30mm, and each unit has an output of 350-400 tons per hour, ensuring uniform delivery of secondary crushed material to the next step. Fine Crushing and Shaping: Two VSI1140 sand making machines operate in a "stone-on-stone" mode, processing medium-sized aggregate ≤50mm, producing 5-10mm and 10-20mm cubic aggregate (≤8% needle-like flakes), meeting C30-C50 concrete standards.
Auxiliary Systems: Four 3YK3680 vibrating screens (1,000 tons per hour) provide grading. A PLC control system coordinates the feeding and crushing equipment to avoid overload shutdowns, achieving an overall equipment utilization rate of over 90%.
III. Hard Rock Production Line (Mohs Hardness 7-9, such as granite and basalt)
Core Requirements
The raw material must be high in hardness and wear resistance. For use in high-speed rail and water conservancy projects, the finished product must have a compressive strength of ≥80 MPa and excellent particle shape (≤5% needle-like flakes). The equipment must also be wear-resistant and highly stable. Equipment Configuration
Coarse Crushing: One HX1400 gyratory crusher (900-1100 tons per hour), with a large feed opening (1400mm) suitable for hard rock ≤1200mm. A heavy-duty frame and wear-resistant lining (lifespan ≥800 hours) are used to withstand high impact loads.
Secondary Crushing: Two HPT750 multi-cylinder cone crushers, with hydraulically adjustable discharge openings (8-20mm). Layered crushing ensures uniform material distribution and reduces over-crushing. Each unit has an hourly capacity of 500-550 tons.
Fine Crushing and Shaping: Three VSI1380 sand making machines, featuring a "stone-beating-iron" mode for enhanced crushing. Equipped with a wear-resistant alloy throwing head (30% longer lifespan than conventional materials), these crushers ensure the finished product meets the required particle shape and meets the aggregate requirements for high-speed ballastless track. Auxiliary systems: 5 4YK3685 vibrating screens for fine classification; fully enclosed system + 6 pulse dust collectors (dust emissions ≤ 10mg/m³); equipped with an oil purification system to extend the life of hydraulic components in the cone crusher and sand making machine.
IV. Our Core Technological Advantages: Solving Industry Pain Points and Improving Production Line Value
1. Customized Crushing Chamber Design Technology
The crushing chamber is specifically optimized for different hardness materials: a "shallow chamber, wide mouth" design for soft rock reduces fines generation; a "deep chamber, laminated" design for hard rock improves crushing efficiency and reduces liner wear. This increases equipment throughput by 10-15% compared to standard industry chamber designs and extends liner replacement intervals by 20%.
2. Intelligent Linkage Control System
The independently developed PLC intelligent system collects 12 key data points in real time, including equipment load, oil temperature, and discharge port size. Using AI algorithms, it achieves coordinated adjustment of "feed rate - crushing load - screening efficiency." When raw material hardness fluctuates, the system automatically adjusts the feed rate and crushing gap to avoid overload shutdowns. This ensures a stable continuous operation rate of over 95% for the production line, reducing downtime by 30% compared to traditional manual control.
3. High-Efficiency Energy-Saving Technology
Variable Frequency Drive: Core equipment (crushers and conveyor belts) utilize variable frequency motors that adjust speed based on actual production capacity requirements, keeping unit power consumption at ≤0.75 kWh/ton, a 15-20% reduction compared to the industry average.
Waste Heat Recovery: The hydraulic systems of the cone crusher and sand making machine are equipped with waste heat recovery devices, which convert heat generated by equipment operation into workshop heating or preheating water for sand washing, saving approximately 80,000-120,000 yuan in energy costs annually.
4. Wear-Resistant Component Enhancement Technology
The liner and blasting head of the core equipment in the hard rock production line are made of a "high-manganese steel + alloy composite" material. High-temperature quenching treatment results in a hardness of HRC58-62, extending their service life by 30-50% compared to ordinary high-manganese steel components. A "component wear warning" service is also provided. Sensors monitor component thickness in real time, providing a 7-10 day advance warning for replacements to prevent unexpected failures.
V. Full-Life Cycle Service Guarantee: From project launch to sustained profitability, we provide comprehensive support.
1. Preliminary: Customized Survey and Design
The technical team conducts raw material testing (hardness, mud content, particle size distribution), site surveys, and environmental standards research to ensure the solution meets actual needs. Cost-Optimized Design: Optimize equipment configuration based on the customer's investment budget and the intended use of the finished product. For example, the soft rock production line reduces expensive sand-making equipment, while the hard rock production line focuses on strengthening wear-resistant components, helping customers reduce initial investment by 10-15%.
2. Mid-Term: Efficient Installation and Commissioning
Modular Installation: Utilizing a "factory prefabrication + on-site assembly" model, core equipment is pre-installed and commissioned at the factory in advance. This shortens the on-site installation period to 30-55 days, a 20% reduction compared to traditional installation methods, enabling rapid commissioning.
Precise Commissioning: During the commissioning phase, at least three experienced engineers are stationed on-site to optimize parameters (such as crushing gap and feed rate) for each unit until the production line reaches a stable production capacity of 900-1000 tons/hour and a finished product qualification rate of ≥98%.
3. Post-Term: Operations, Maintenance, and Value-Added Services
A 24-hour after-sales service hotline has been established to respond to customer needs at all times. If a customer encounters equipment malfunction or technical issues, the after-sales service team will contact the customer immediately to understand the problem and provide guidance through phone or video calls for preliminary troubleshooting and resolution. For issues that cannot be resolved remotely, after-sales personnel will arrive on-site as quickly as possible to provide repairs and technical support.
VI. Return on Investment Reference
Leveraging customized configuration and technological advantages, the payback period for production lines in different scenarios is manageable:
Soft rock production line: Low raw material cost (approximately 30-40 RMB/ton), finished product selling price 50-70 RMB/ton, annual net profit at full production of approximately 50-70 million RMB, and a payback period of less than 2 years.
Medium-hard rock production line: Raw material cost 40-60 RMB/ton, finished product selling price 80-120 RMB/ton, annual net profit approximately 80-120 million RMB, and a payback period of 2-2.5 years.
Hard rock production line: Raw material cost 60-80 RMB/ton, finished product selling price 120-180 RMB/ton, annual net profit approximately 150-220 million RMB, and a payback period of 2.5-3 years. Through technological optimization and service assurance, we help clients control costs while further shortening their payback period and achieving long-term, stable profitability.
