Project Scale: Annual production capacity of 5 million tons, operating 330 days per year. The DLEV160 jaw crusher processes feed with a maximum size of 1,200 mm, achieving an hourly output of 700 to 1,000 tons. Two DLPCZ1815 hammer crushers operate at an hourly output of 400 to 900 tons. Four DL3YKZ3680 circular vibrating screens perform multi-size grading, with a finished product compliance rate exceeding 98%.
Application Scenario: Limestone aggregate plant facing capacity constraints requiring expansion; upgrading and retrofitting of existing lines; supplying aggregates for high-grade infrastructure projects.
Key Challenges: Expansion requires production shutdowns and reconstruction, resulting in a production gap of 2 to 6 months and daily losses of hundreds of thousands; existing lines suffer from lax management and high labor costs; expansion involves significant investment with a long payback period; high risk of losing customers during production downtime.
Solution Highlights: Modular expansion allows new equipment to seamlessly integrate with the existing system's conveyor belts and hoppers without production downtime or capacity gaps; DCS intelligent mine management enables one-click start/stop with 12-parameter monitoring; RFID-enabled unmanned material collection and intelligent loading reduce errors to ±0.5% and cut labor costs by 40%; off-peak electricity production reduces specific energy consumption by 18%; modular design saves 15% to 20% compared to demolition and reconstruction, with a payback period of 1.5 to 2.5 years; If annual production of 5 million tons is not achieved, service fees will be refunded proportionally.
Limestone Aggregate Expansion Project Process Flow
Primary Crushing: DLEV160 jaw crusher with a maximum feed size of 1,200 mm and an hourly capacity of 700 to 1,000 tons; modular design seamlessly integrates with the existing system's belt hoppers and foundations, eliminating the need for major civil engineering modifications.
Fine Crushing: Two DLPCZ1815 heavy-duty hammer crushers with a maximum feed size of 800 mm and an hourly output of 400 to 900 tons; high-chromium alloy hammer heads and high-manganese steel liners offer a 30% longer service life than comparable models, enabling one-step processing of low-hardness limestone.
Screening: Four DL3YKZ3680 circular vibrating screens enable precise grading across multiple specifications, consistently achieving an annual production target of 5 million tons with 330 days of operation.
Intelligent Control: The DCS intelligent mine management system features a 3D visualization interface for one-click start/stop operations, real-time monitoring of 12 parameters, and automatic audible and visual alarms for anomalies. RFID identification at the feed end enables automatic weighing to eliminate human tampering, while PLC-controlled intelligent loading at the finished product end maintains an accuracy of ±0.5%. Maintenance schedules are pushed to mobile devices, increasing fault resolution efficiency by 60%. Mine Manager App: Remotely monitor production output, equipment health, and inventory without visiting the site; the energy consumption module automatically analyzes peak and off-peak electricity rates, reducing unit electricity consumption by 18%.
Limestone Aggregate Expansion Project EPC Service Scope
Solution Design: Modular expansion plans enable seamless integration of new equipment with existing systems without production downtime. We offer on-site surveys or remote assessments of existing production lines to develop upgrade proposals, customized based on current equipment status and target capacity to ensure no unnecessary expenses.
Equipment Manufacturing: In-house production of main units including jaw crushers, hammer crushers, and circular vibrating screens. Core wear-resistant components—such as high-chromium alloy hammer heads and high-manganese steel liners—offer a 30% longer service life than comparable products. The entire production line is ISO 9001 and CE certified, ensuring seamless export compliance.
Installation and Commissioning: Modular, phased installation allows new modules to be integrated into the existing line segment by segment without halting production. There is zero downtime during the process. The system is delivered only after successful joint commissioning and testing to ensure compliance with standards.
Operation and Maintenance Management: If annual production falls short of 5 million tons, service fees will be refunded proportionally. The replacement frequency of wear parts for hammer crushers is reduced by 40%, and annual maintenance costs are lowered by nearly 30%. Core equipment comes with a one-year warranty, and wear parts are supplied for the lifetime of the equipment. The DCS system provides remote monitoring and regularly pushes process optimization recommendations.
Limestone Aggregate Expansion Project Project Case Studies
Project Scale: Expansion to an annual production capacity of 5 million tons
Raw Material Characteristics: Low-hardness limestone; the existing line, with a capacity of 400 tons per hour, was insufficient
Process Configuration: DLEV160 jaw crusher + two DLPCZ1815 hammer crushers + four DL3YKZ3680 circular vibrating screens + DCS intelligent mine management system + fully enclosed dust collection system
Finished Product Specifications: Four sizes: 0–5 mm, 5–10 mm, 10–20 mm, and 20–31.5 mm
Customer Feedback: Modular expansion allowed the old line to continue operating without production downtime or capacity gaps; new modules were integrated segment by segment, resulting in zero loss of customer orders. Total investment was 12% lower than comparable local projects, and environmental protection investment accounted for only 15%—significantly lower than the industry average of 25%. The DCS system's RFID-enabled unmanned material collection eliminated human tampering, with intelligent loading accuracy within ±0.5% and a 40% reduction in labor costs. Electricity consumption per unit of production during off-peak hours decreased by 18%. Replacement frequency of hammer crusher wear parts reduced by 40%, with annual maintenance costs decreasing by nearly 30%; finished product of 98%, directly supplying local high-speed rail and ready-mix concrete projects, resulting in a 10% to 15% product premium; the entire line successfully obtained CE certification and cleared customs, with a payback period of 1.5 to 2.5 years.
Limestone Aggregate Expansion Project FAQ
Q: How can we expand production without halting operations on the existing line?
A: Modular expansion allows new equipment to seamlessly integrate with the existing system's conveyor belts and hoppers. The existing line continues normal production while new modules are installed, commissioned, and integrated in stages, ensuring zero production downtime and zero loss of customer orders. This approach saves 15% to 20% in investment compared to the tear-down-and-rebuild model.
Q: Is the DCS intelligent control system compatible with existing equipment?
A: The DCS system supports unified management of both new and existing equipment. It enables one-click start/stop, monitors 12 key parameters, and pushes maintenance alerts to mobile devices. RFID-enabled unmanned material collection and intelligent loading reduce labor by 40%. Zero Production Interruption Crushing Upgrade The Mine Manager app allows remote monitoring of production output, equipment health, and inventory without on-site visits, while off-peak electricity production reduces energy consumption by 18%.
Q: How much does expansion investment save compared to a tear-down and rebuild?
A: The modular approach saves 15% to 20% compared to the tear-down and rebuild model. The Low Dust Emission Limestone Production Line total investment for the Vietnam project is 12% lower than similar projects, and environmental investment is only 15%—far below the industry average of 25%. Replacement of hammer crusher wear parts is reduced by 40%, and annual maintenance costs are cut by nearly 30%. With 98% of the finished product supplied to high-end customers at a 10% to 15% premium, the payback period is 1.5 to 2.5 years.
Q: What happens if the 5 million metric ton production capacity target is not met?
A: The contract stipulates a proportional refund of service fees if the annual production target of 5 million metric tons is not met. Energy Saving Intelligent Aggregate Line The DCS system monitors output and equipment health in real time to ensure full production capacity is achieved. The Vietnam project has consistently met its actual production capacity targets, and the entire line has successfully obtained CE certification and cleared customs.
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