Modular Crushing Line for River Pebble Aggregate Production
Aggregate Production Line Project Overview
Project Scale: Current capacity of 2,000 tons per hour; designed annual production capacity of 10 million tons; modular design allows for expansion to 5,000 tons per hour. Application Scenario: River pebble resources in Southeast Asian industrial parks; high-temperature, high-humidity, and rainy environments. Key Challenges: High hardness of river pebbles leads to severe abrasion and rapid hammer head wear; dry sand-making methods cause screen clogging and excessive dust during the rainy season; High production capacity requirements but significant initial investment pressure. Solution Highlights: Wet sand-making process with full-cycle water washing and dust removal, resulting in dust levels <5 mg/m³, finished product with <3% fines, and particle roundness >98%, meeting the GB/T 14684-2022 standard for construction sand; Modular design with reserved equipment interfaces and foundations allows for expansion to 5,000 t/h by simply adding modules; NM700 liner with Brinell hardness ≥680, 15 times more wear-resistant than ordinary steel, plus 70 HRC high-chromium alloy hammer heads with wet lubrication and cooling, extending the service life of a single hammer head to nearly two months; AI predictive maintenance issues hammer wear warnings 168 hours in advance, increasing MTBF by 40%, achieving an availability rate >95%, and reducing downtime by 65%; EPC commissioning in 45 days with a 28% reduction in investment.
Aggregate Production Line Process Flow
Raw river pebbles - Feeding - Primary crushing Secondary crushing and shaping Wet sand making (sand maker + water washing with full-process lubrication and cooling) - Sand washing and dewatering module (removes fine powder, controls powder content <3%, and ensures dewatering meets standards) - Circular vibrating screen classification - Storage in enclosed silos
Water is involved throughout the wet sand-making process; dust is carried away with the water, resulting in clean, rounded finished sand. The problem of dry screen clogging during the rainy season is completely eliminated. High-hardness river pebbles result in more economical hammer head consumption in the wet process. Water provides lubrication and cooling, allowing a single set of 70 HRC high-chromium alloy hammer heads to last nearly two months—a significant extension compared to the dry method. Modular design with reserved interfaces and foundations allows capacity to be expanded from 2,000 t/h to 5,000 t/h simply by adding modules.
Aggregate Production Line EPC Service Scope
Process Design: The wet sand-making process is optimized for Southeast Asia's hot, humid, and rainy climate. The modular design allows for future expansion, ensuring controllable initial investment and waste-free, on-demand capacity growth. Equipment Manufacturing: NM700 ultra-wear-resistant steel liners + 70 HRC high-chromium alloy hammer heads specifically designed for river pebble and hard rock applications; sand washing and dewatering modules are integrated with the sand-making system; equipment bodies undergo anti-corrosion and anti-rust treatment for normal operation between -20°C and +45°C. Installation and Commissioning: The EPC contractor comprehensively manages surveying, design, equipment manufacturing, civil engineering supervision, installation, and commissioning. 45 days from design to production, saving 30% of the construction time compared to a decentralized procurement model; total investment is 28% lower than decentralized procurement plus third-party construction. Operation and Maintenance Management: 20-day on-site wet sand-making technical training covering crushing parameter adjustment, sand washing water flow control, and maintenance of hammer heads and liners based on changes in river pebble particle size; AI predictive maintenance system continuously pushes replacement plans 168 hours in advance.
Aggregate Production Line Project Case
The wet sand-making production line project for river pebble aggregates on Java Island, Indonesia, commenced operations in late 2018. The current configuration has a design capacity of 2,000 tons per hour and an annual production capacity of 10 million tons. With modular expansion provisions, it can be scaled up to 5,000 tons per hour. The entire line features an integrated wet sand-making, sand washing, and dewatering system. Since commissioning, hourly output has remained stable at 2,000 tons. The finished sand meets local construction sand standards with a powder content <3% and roundness >98%, while dust emissions <5 mg/m³ ensure consistent compliance with environmental regulations. 70 HRC high-chromium alloy hammer heads, combined with wet lubrication and cooling, last nearly two months per set—a significant improvement over dry methods. NM700 liners offer 15 times the wear resistance of ordinary steel. AI predictive maintenance provides early warnings 168 hours in advance, ensuring an availability rate >95%, a fault resolution rate of 99%, and a 65% reduction in downtime. Anti-corrosion coatings withstand Indonesia's year-round high temperatures and humidity without corrosion. Customers report that the EPC solution is hassle-free, and the modular design allows for flexible expansion.
Aggregate Production Line FAQ
Q: How is wet sand making better than dry sand making?
A: In Southeast Asia, where rainfall is frequent and humidity is high, dry screening is prone to clogging. The wet sand-making process involves water throughout, carrying away dust and resulting in clean, rounded finished sand with a powder content of <3% closed environmental protection aggregate line. Dust emissions are <5 mg/m³, ensuring environmental compliance at all times. For high-hardness raw materials such as river pebbles, the wet method provides lubrication and cooling, making hammer head consumption more economical. A single set of 70 HRC high-chromium alloy hammer heads can last nearly two months, a significant improvement over the dry method.
Q: How is modular expansion achieved?
A: The current configuration of 2,000 tons per hour meets the needs of most industrial parks. Equipment interfaces and foundations are designed with expansion in mind. EPC Turnkey Contract for River Pebble Sand Production When increased production is required, simply adding modules allows for expansion up to 5,000 tons per hour without the need for demolition or reconstruction. Initial investment is manageable, and expansion on demand prevents waste.
Q: How much does an EPC turnkey contract save compared to self-construction?
A: EPC provides comprehensive management of the entire process—including surveying, design, equipment manufacturing, civil engineering, supervision, installation, and commissioning. Clients do not need to coordinate with seven or eight subcontractors. Total investment is 28% lower than the "separate procurement + third-party construction" model, and the construction period is 45 days—30% shorter than the separate procurement model AI predictive maintenance aggregate line. After 20 days of on-site training, clients can independently operate the entire line.
