1. Overview
This is an 8,000t/d sand and aggregate production line designed for processing limestone. The line adopts a two-stage crushing process combining a heavy hammer crusher for primary crushing and a hammer shaping crusher for secondary shaping, complemented by multiple sets of circular vibrating screens for precise multi-size classification. The overall equipment configuration is simple and efficient, with a relatively low investment. All equipment is housed in enclosed structures, resulting in no dust pollution and energy-efficient, environmentally friendly operation. The finished aggregates feature a cubic particle shape and excellent quality.
2. Main Equipment Configuration
The entire line consists of four core equipment categories—vibrating feeding, heavy crushing, shaping, and screening—along with belt conveyors for material handling. The specific configuration is as follows:
Vibrating Feeder
One DLZGC1550Z vibrating feeder is deployed, with a processing capacity of 400 to 900 t/h. This unit feeds limestone raw material steadily and uniformly into the heavy hammer crusher, ensuring continuous operation of the downstream crushing stage.
Heavy Hammer Crusher (Primary Crushing)
One PCZ1620 heavy hammer crusher serves as the primary crushing equipment, offering a processing capacity of 800 to 1,000 t/h. The crusher utilizes high-speed rotating hammers to impact and crush the limestone in a single pass, achieving a large reduction ratio and directly producing aggregates suitable for further shaping.
Hammer Shaping Crusher (Secondary Shaping)
One XPC1216 hammer shaping crusher is installed for secondary fine shaping, with a processing capacity of 400 to 500 t/h. This unit further refines the particle shape of the pre-crushed material, eliminating elongated and flaky particles and producing aggregates with a cubic shape and excellent quality.
Vibrating Screens (Classification)
Six circular vibrating screens are configured for multi-stage classification:
Two 2YKZ3070 double-deck screens, each with a processing capacity of 450 to 500 t/h;
Two 3YKZ3070 triple-deck screens, each with a processing capacity of 400 to 500 t/h;
Two 3YKZ2060 triple-deck screens, each with a processing capacity of 180 to 280 t/h.
These screens work together to accurately classify the crushed and shaped material into multiple finished product sizes, with a wide variety of output specifications available.
Belt Conveyors
Multiple belt conveyors are arranged throughout the line to handle material transfer between equipment and the stockpiling of finished products.
3. Production Process Flow
The line operates on a simple and efficient two-stage crushing process: "vibrating feeder → heavy hammer crusher (primary crushing) → hammer shaping crusher (secondary shaping) → circular vibrating screens (classification) → finished stockpiles." The overall process is streamlined, with only crushing and screening stages involved.
Raw Material Feeding Stage
Limestone raw material is loaded into the hopper of the DLZGC1550Z vibrating feeder by a loader. The feeder uses vibration force to discharge the material evenly and continuously into the inlet of the heavy hammer crusher, ensuring that the crushing equipment operates at full load with a uniform feed.
Primary Crushing Stage
The material enters the PCZ1620 heavy hammer crusher, where it is subjected to high-speed rotating hammers that crush the stone in a single pass. The crusher achieves effective primary crushing with a large reduction ratio. Material reaching the required particle size is discharged and conveyed to the next stage.
Secondary Shaping Stage
The pre-crushed material enters the XPC1216 hammer shaping crusher for further fine processing. Through the grinding and trimming action between the hammers and the liners, the sharp edges and elongated or flaky shapes of the particles are eliminated. The finished aggregates produced at this stage feature a cubic shape and excellent particle quality.
Screening & Classification Stage
The shaped material is conveyed to the circular vibrating screens for multi-stage classification. Through the combined operation of two 2YKZ3070 screens, two 3YKZ3070 screens, and two 3YKZ2060 screens, the material is accurately separated into finished products of various specifications. The classified aggregates are then conveyed by belt conveyors to their respective stockpiles.
Environmental Protection & Enclosed Operation
All processing equipment is housed within enclosed structures, effectively preventing dust dispersion during production. No dust escapes during equipment operation, ensuring energy-efficient and environmentally friendly production throughout the entire line.
4. Key Performance Advantages
Simple Equipment Configuration with Low Investment
The production line features a simple and practical equipment configuration with only one heavy hammer crusher and one hammer shaping crusher as the core processing units. This streamlined approach results in a relatively low initial investment, making it a highly cost-effective solution for large-scale sand and aggregate production projects.
Two-Stage Crushing for Excellent Product Quality
The line adopts a two-stage crushing process combining heavy hammer crushing and hammer shaping. The heavy hammer crusher provides efficient primary crushing, while the hammer shaping crusher refines the particle shape to a cubic form. The finished aggregates are of high quality with low flaky particle content, suitable for high-standard construction applications.
Wide Variety of Output Specifications
Equipped with six vibrating screens of different specifications and screen layers, the line can produce a wide range of finished aggregate sizes to meet diverse market demands. The multi-screen configuration ensures accurate and efficient classification.
High Production Capacity
Designed with a daily output of 8,000 tons, the line delivers powerful processing capabilities to meet large-scale continuous production demands. The equipment capacities across all stages are well-matched, ensuring smooth and efficient operation with high productivity.
Environmentally Friendly Enclosed Production
All processing equipment is enclosed, ensuring that no dust overflows during operation. This design achieves energy-efficient and environmentally friendly production with low processing costs, meeting modern green mining and sustainable production standards.
Our sand and gravel aggregate production lines boast extensive and all-round coverage, and we offer a complete range of configurations from individual standalone equipment to full turnkey production lines, including Crushing Equipment, Sand Making Equipment, Screening Equipment, Feeding Equipment, Mining Conveyor and Mobile crusher. We provide customized crushing and processing solutions for a full spectrum of materials including bluestone, limestone, basalt, granite, pebble, coal gangue, calcite, quartz stone, dolomite, iron ore, barite, diabase, tuff and high calcium limestone, as well as targeted processing solutions for kaolin. We also deliver professional crushing solutions for industrial solid wastes such as slag and tailings, and comprehensive treatment solutions for construction & demolition waste. In addition to fixed production line solutions for various materials, we also supply flexible Mobile Crawler Unit Solutions to meet diverse on-site operation needs of sand and gravel aggregate production.
