Dual-Material Adaptable Aggregate Production Line for Hard Rock: Energy Saving and Cost Reduction
Aggregate Crushing Line Project Overview
Scale: 1,000–1,200 t/h, annual output of 3–3.4 million tons
Application: Dual-material (limestone/granite) mine, serving ultra-high-end projects such as cross-river bridges and high-speed rail track slabs
Challenges: High switching costs due to the need for different processes for each material; Strict requirements for aggregate gradation in high-end projects; stringent dust and noise control; low manual loading efficiency. Highlights: Medium-to-soft rock configuration (DLPCZ1820 + DLVSI1700) achieves a single-pass energy consumption of 1.22 kWh/t, 35% lower than comparable systems; Hard rock: 2×DLEV240 + 2×DLHPC400, with flake and needle content below 3.5% and liner life of 7,800 hours; triple environmental protection with emissions below 1.8 mg/m³ and noise below 67 dB; 4th-generation AIoT monitoring of 180+ devices with 28 data points, achieving 99.2% fault prediction accuracy; unmanned loading with 10 trucks operating in parallel, boosting efficiency by 55%
Aggregate Crushing Line Process Flow
Medium-Soft Rock: DLPCZ1820 heavy hammer crusher for single-pass processing - 2×DLVSI1700 shaping - screening - 0-5/5-16/16-31.5 mm (stable gradation of 27:44:29) Hard Rock: 2× DLEV240 jaw crushers - 2× DLHPC400 cone crushers - Screening and shaping - Three finished product grades Triple Environmental Protection: Enclosed conveyor galleries + 22 DLMC-2000 negative pressure dust collectors + Intelligent misting system
Aggregate Crushing Line EPC Service Scope
Design: Dual-feed process configuration + modular switching + triple environmental protection + 4th-generation AIoT architecture Equipment Manufacturing: Medium-soft rock module (DLPCZ1820 + DLVSI1700×2) / Hard rock module (DLEV240×2 + DLHPC400×2) + screening + 22 DLMC-2000 units + AIoT system + unmanned loading system Installation and Commissioning: On-site rapid switching of pre-assembled dual modules; integrated commissioning including dual-process validation and gradation stability testing Operations and Maintenance Management: AIoT remote upgrades + 5G/satellite remote diagnostics (fault resolution time reduced from 96h to 26h) + monthly inspections + multilingual management
Aggregate Crushing Line Project Case Study
Myanmar Yangon Limestone and Granite Heavy Aggregate Project
Location: Yangon Region, Myanmar | Commissioning: 2023 | Capacity: 1,000–1,200 t/h, annual output 3–3.4 million tons | Equipment: DLPCZ1820 + DLVSI1700×2 (limestone) / DLEV240×2 + DLHPC400×2 (hard rock) Quality: 98.2% particle shape compliance rate, stable 27:44:29 gradation, flakiness and elongation below 3.5%; directly supplied to the Yangon Trans-River Bridge and high-speed rail projects. Environmental Protection: Emissions below 1.8 mg/m³, noise below 67 dB; passed acceptance inspection by Myanmar’s Ministry of Environmental Conservation. Smart Technology: 4th-generation AIoT fault prediction reduces unplanned downtime by 97.8%; Unmanned loading with 10 trucks operating in parallel reduces staff by 18; 5G satellite remote diagnostics reduced troubleshooting time from 96h to 26h, with a 5-person control center saving 88% in labor costs; supports Burmese, English, Chinese, and Thai. Feedback: Significantly lower energy consumption per ton for limestone; dual-material switching completed in two weeks; unmanned loading eliminates data tampering with zero discrepancies; has become the benchmark for ultra-high-end engineering aggregates in Myanmar
Aggregate Crushing Line FAQ
Q1: How is the system switched between soft and hard rock on the same production line?
A1: Modular configuration: For soft and medium-hard rock, the heavy hammer + shaping module is activated; for hard rock, the system switches to the jaw crusher + cone module. Cone Crusher Aggregate Line Suitable for Hard and Soft Rock Screening and finished product silos are shared, with the switch taking approximately two weeks - no need to build a new line.
Q2: How is the energy consumption of 1.22 kWh/ton achieved?
A2: The heavy hammer crusher achieves one-step processing, eliminating the intermediate crushing stage. Manufacturing of Smart Aggregate Production Line Equipment Combined with AIoT collaborative control that adjusts pump station and belt speeds on demand, overall energy efficiency is improved by 15%. Actual test data from the Chibi project.
Q3: Is an emission level below 1.8 mg/m³ consistently stable over the long term?
A3: A triple-layered system combining 22 independently configured DLMC-2000 units with negative pressure, pulse cleaning, and intelligent spraying ensures that the Yangon project maintained an average emission level below 1.8 mg/m³ for 12 consecutive months.
Q4: Is 5G + satellite remote monitoring suitable for remote mining areas?
A4: Use 5G in areas with 5G coverage; switch to satellite where coverage is unavailable. Remote fault diagnosis time reduced from 96 hours to 26 hours, with a central control team of 5 people managing the entire line high performance aggregate crushing line.
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