Typical Set-up & Sizes of Stone Crushers There are large variations in the types of stone crusher setup across the country depending on geographical locations, type of demand for crushed products, closeness to urban areas, type of raw material, availability of plant and machinery locally etc. Primarily the stone crusher industry sector could be divided in three categories small, medium & large. The typical characteristics of each category of stone crushers are briefly discussed below. Small Size Stone Crushers There are different types of small crushers in various states with a production capacity ranging from 3 to 25 TPH. Typically, the units having only one Jaw type crusher used as primary or secondary crusher along with one or maximum 2 screens are grouped as small stone crushers. A few most representative types of small crushers are described below.

Crushers with completely manual breaking/feeding/ retrieving/stocking operation with single jaw and single rotary screen

In these types of small stone crushers, the mined raw stones are transported to the crusher site by trailors or truck and unloaded & stocked at ground level near the crusher. Big boulders are manually broken one by one to about 8-10 inch size. Typically a team of about 15-20 workers does breaking throughout the day. The coloured stones are manually sorted and separately stocked, this is done to avoid mixing of different coloured stones in the crushed products, else it may fetch less price. The broken stones are manually carried on head load to feed in the Jaw Crusher.About 10-15 workmen are engaged for the purpose. The crushed stones are discharged through a chute in to a rotary screen. The screened products of various sizes are discharged on the ground below the rotary screen and the products are manually retrieved and taken to stock piles. These type of crushers typically operate with crushing capacity in the range of about 2-5 TPH. Such crushers are highly labour intensive and about 50 to 60 persons are involved in the operations such as breaking, feeding, retrieving and stocking. These crushers claim to produce stones of good quality due to manual sorting, uniform breaking etc and lesser quantity of fines.

• Crushers with manual breaking manual/gravity feeding belt conveyors single jaw & rotary screen type

In some crushers the rotary screens are installed at elevated position and the screened products are separately collected and transported via belt conveyors to stock piles. The dust product smaller than 6 mm size is stored mostly in closed

Comprehensive Industry Document on Stone Crushers

silos. Such crushers typically operate with crushing capacity range of about 5 – 15 TPH.

The above two types of small crushers are mostly found in the state of Orissa, Bihar, West Bengal, North Eastern States, Himachal Pradesh & Tamil Nadu, Andhra Pradesh. • Mechanical/Gravity feeding, single jaw with vibratory type screens with belt conveyors In these type of crushers the mined raw stones are transported to site by trailors/trucks and are unloaded in an elevated stone well. The stones are retrieved from the stone well through a chute at the bottom side end and the stones are fed by gravity in to the primary jaw crusher. The crushed stones are conveyed to rotary/vibratory type screens by belt conveyor. The oversize from the screen is returned either to the stone well or directly in to the crusher for further size reduction. These type of crusher generally have production capacity in the range of 15-25 TPH. These types of crushers are widely found in almost all the states & the most common type of crusher set up.

• Single Jaw Bucket Elevator, Elevated vibratory screen with storage bunkers type compact units In some crushers the crushed stones from the jaw crusher are raised to a high elevation with the help of bucket elevators which discharges the material in vibratory screens and screened products are directly discharged in various storage hoppers. The Products are directly loaded in to trucks standing below the storage hopper. There are no belt conveyors in the units. These type of crusher are generally found in the States of Maharastra & MP etc.

Medium Size Crushers

Typically those crushers having than one crusher i.e., one primary and one secondary or one/two primary & two secondary crushers along with one or more vibratory screens are categorized as medium size crushers. The mined stones are transported mostly by trucks/dumpers and unloaded in to elevated stone wells. The stones are fed by gravity to primary crushers. The Crushed stones are conveyed to vibratory screens. The screened products of various sizes are conveyed to stock piles by belt conveyors. The oversize is returned to secondary crushers for further crushing and back to the vibratory screen. Such type of medium type crushers have a production capacity in the range of 25 – 100 TPH. These type of crushers are mostly located near to the bigger cities and in the vicinity of major construction projects such as Highways, Canals, Dams etc.

Comprehensive Industry Document on Stone Crushers

These type of crushers are found in the States like Maharastra, Andhra Pradesh, Tamil Nadu, Punjab, Haryana, Gujarat, Madhya Pradesh, Rajasthan, etc.

Large Stone Crushers

Those crushers typically having two or more numbers each of primary, secondary & tertiary type crushers with at least 2 or more vibratory screens with mechanized loading, unloading conveying operation s and producing more than 100 TPH crushed stones are categorized as large crushers. Typically large stone crusher are owned by bigger construction companies like L&T, Dodsal Construction, etc who have their own large construction projects demand. Such crushers have a capacity range of 100 –200 TPH. These type of crusher generally have their own/leased open-cast stone mines and a fleet of mechanical mining equipment , trucks and dumpers, loaders etc. These crushers involve high capital investment and mostly operate round the clock. All conveying operations are done through proper belt conveyors.

Photographs showing Typical set up of small, medium & large crushers are presented at Photoplate-1 to get a visual impression of various sizes of stone crushers.

Types of Technologies used

Various types of technologies are used for mining, transporting, crushing and screening operations, which are briefly described below. As mining and transporting operation are an integral part of the stone crushing industry, it is briefly discussed below:

Technologies used for Mining

The technologies used for mining of stones vary from manual excavations up to highly automized lare scale blasting with mechanical excavations. The smaller stone crushers source the raw material generally from river beds, or small hillocks in the local region or at times they procure/purchase raw stones from mine owners in the vicinity. Such small crushers crush only a few truck loads (typically less than 2 to 10 truck loads per day).

The medium size stone crusher mostly have their own open-cast mines adjacent or in close vicinity to the crusher site. The mining is done by drilling holes in the rock strata and blasting it generally once in a day. The drilling is done mostly manually or by mechanical means. The blasted rock boulders are at times manually broken to about 10 to 20 inch size so as to suit and are manually the primary jaw crusher, loaded in to trailors or trucks. Mechanical Loaders are also used for retrieving mined stones and loading in the vehicles.

Comprehensive Industry Document on Stone Crushers

Comprehensive Industry Document on Stone Crushers

In large stone crushers, the mines are generally owned or leased for long term. Scheduled and frequent blasting are carried out. A combination of primary and secondary blasting techniques are followed. In the primary blasting, substantially large area is blasted to loosen big boulders from the earth strata. The bigger boulders are further blasted during secondary blasting. The drilling is generally carried out either pneumatically or hydraulically. After blasting, the stones are excavated with the help of excavators and loaders and are loaded in to dumpers.

Transportation Technologies

The mined stones are transported to the crusher sites using vehicles of various capacities starting from bullock carts, trailors up to automatic dumpers. Most of the transportation vehicles have hydraulically operated tilting arrangement for easy and faster unloading of stones at the crusher sites.

The capacity range of smaller vehicle like trailors is about 4 tonnes whereas bigger dumpers can carry in the range of 15 – 20 tonnes materials per trip. The loading operations are manual in smaller vehicles and are mostly mechanical using material handling equipment for large dumpers and trucks. There are no continuous material handling system like long belt conveyors or trolley type conveyors to carry stones from mines to crusher sites, even in the largest stone crushers in the country and therefore transportation by vehicle is most common.

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Mineral Sands Plants

Zenith offers a range of modular plants for the beneficiation and recovery of mineral sands. These plants are based on our standard spiral concentrator and WHIMS (Wet High-Intensity Magnetic Separation) modules. Our plants for the recovery of mineral sands are custom built according to the requirements of our clients.

Depending on the feed source, each plant comprises of:

Dredger unit with primary, scavenger and cleaner spirals, plus dewatering cyclone
Wet magnetic separator to remove all magnetite in the spiral concentrate
Vibrating screen and attritioner at the HMC plant
Dryer
Rare Earth Magnetic Drum Separator (REMDS)
Shaking table

Zambia has for many years been heavily dependent upon the mining of copper which, combined with cobalt production, represents over 98% of mineral sales and 75% of export earnings (1997 figures). The industrial minerals industry within Zambia has therefore been inevitably tied to the fortunes of these two metals. The recent privatization, and break up, of ZCCM (Zambia Consolidated Copper Mines) has led to a resurgence in investment in the mining sector. Many analysts have predicted that there will be a positive effect on the Zambian economy, stimulating construction and infrastructure development and increasing the demand for industrial minerals. This paper summarises the available information on the industrial mineral resources of Zambia. Ten industrial minerals are described, with reference to some of the work carried out over recent years by the British Geological Survey, in conjunction with the Geological Survey Department of Zambia.

Introduction

Zambia is a landlocked country in central southern Africa which is bordered by Angola, the Democratic Republic of Congo (DR Congo), Tanzania, Malawi, Mozambique, Zimbabwe, Botswana and Namibia (Figure 1). It is a large country (752,614 km2) with a population of about 11 million people, mostly found within the urban centres of Lusaka, the Copperbelt, Kabwe, Kapiri Mposhi and Livingstone. Zambia is divided into nine provinces (Central, Copperbelt, Eastern, Luapula, Lusaka, North-Western, Northern, Southern and Western). It is dissected by four major river systems (Zambezi, Kafue, Luangwa and the Luapula). The road network is limited but well maintained between the main centres and there is a well-established infrastructure of domestic and international telecommunications.

Zambia is internationally recognised as a major producer of copper and cobalt (ranked as the seventh and second highest world producer respectively). It also produces precious metals (gold, silver), gemstones (amethyst, aquamarine, emerald and tourmaline), coal and industrial minerals. The production of industrial minerals is, however, small.

Alumina and Aluminum

Whether you are in the business of running an alumina refinery or an aluminum smelter, you can count on Zenith to provide a full range of cutting-edge equipment and processes in the design of your plant. For more than 50 years we have been helping customers worldwide in both segments of the aluminum process reach their goals. What sets Zenith apart from its competition? We are there to help our customers from start to finish in terms of plant design and we customize our solutions to fit your specific needs. Our processes and equipment have become industry standards and our references stretch back decades – a track record that has made us who we are today: an innovative technology provider. 

Regardless of whether you are refining or smelting, we can offer the very best with our:

Specialized engineering staff;

Long-term global reach and experience;

Proprietary process equipment;

Single source responsibility;

Modernization, upgrade and capacity enhancement projects;

Customer service.

As a supplier, we are one of the industry leaders with a broad spectrum of project services:

Initial studies;

Basic and detailed engineering;

Project management;

Plant and equipment supply for entire plants and plant sections as well as automation and process control equipment;

Installation and commissioning of plant and equipment;

Training of customer’s employees;

Customer service and after sales.

Aggregates are a combination of crushed rock (of which there are three main types: igneous, metamorphic and sedimentary) and sand and gravel. Crushed rock, sand and gravel are also used to make value-added products such as lime, asphalt, concrete and mortar. Aggregates can only be extracted where nature has placed them. A line drawn roughly from The Wash to Portland Bill would separate the two basic types of aggregates found in the UK.

Over recent years, the sea-bed around our shores has become an increasingly important contributor to national supply needs. The marine aggregate industry satisfies much of the UK’s sand and gravel needs.

Synthetic aggregate also offers an excellent environmentally-friendly alternative to quarried aggregate. This is produced from pulverised fuel ash (PFA) – a by-product of coal-burning power stations.

Screening Plant
We are engaged in offering superior quality Screening Plant which are ideally used in road construction project or patch repair works. We usually use these materials for separation of finer material from the heterogeneous mixture of coarse material. Based on the factors of application, capacity and site conditions we also provide customization facility.

Stone Crushing & Screening Plant hot

Stone Crushing & Screening Plant

We offer Stone Crushing & Screening Plant. Our offered range of screen plants is ideally used in road construction project or patch repair works made of superior quality these plants generally separates finer material from the heterogeneous mixture of coarse material. We also provide customization to the products in respect to application, capacity and site conditions.

Dry Screening Plant: We have Dry Screening plants in Goa and Hospet – Bellary region. We are also expanding our services to other places like Orissa, Jharkhand and Bihar.

Beneficiation Plants: DMP is pioneers in supply of Iron ore beneficiation plants on turn key basis. DMP has executed successfully Beneficiation plants in Goa and Hospet Bellary region.

The scope of DMP would be to supply all the equipments, fabricated structures, liasioning with suppliers of equipments other than those manufactured by DMP, followed by erection and commissioning of the plant.

Our experience shows that an appreciation of 6 to 9% can be achieved depending on the quality of ore in feed.

We have supplied plants with capacities ranging from 100 TPH to 250 TPH.

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Screening Plant for Road Construction

We are affianced in providing our clients Screening Plant for Road Construction. The plants we offer are used for the road construction and are fabricated using optimum quality component. Moreover, these are widely appreciated for their easy to use and install features. Our range of products is also tested on various industrial parameters so as to offer flawless products to the clients. These plants can be availed at industry-leading rates using different payment options. Mention below are the features of the offered products:

Less maintenance
Accuracy in quality control
Sturdy & Specious Structure

Screening Plant for Road Construction

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Screening Plant for Patch Repair Works

Screening Plant for Patch Repair Works

We deal in Screening Plant for Patch Repair Works that are applicable to be used in road construction project or patch repair works. Available in various specifications, these products are offered to fulfill the exact needs and requirements of our valued clients’. These plants are widely used in various industrial applications and are appreciated for their durability and reliability features. Below are the industries our products are widely demanded at:

Thermal power stations
Steel plants
Electrical & engineering industries

Copper Mining
A copper mine in South America used wire mesh on five tertiary screens in the plant. The copper ore is
wet, sticky and abrasive which constantly blinded over their screens. Polydeck’s Screening Process
Consulting Service reviewed the plant flow and moisture content, along with other associated issues.
A synthetic screen media design was recommended that eliminated blinding on the screen surface and
allowed the customer to operate only three of the five screening lines, while sending the same amount of
material to the leach pad. Because of the success of this solution, the mine has since expanded its
operating capacity and now uses only 4 screening lines.
Aggregate
A rock producer altered his plant flow to provide different products as the market required. He was unable to consistently meet spec on the middle and bottom deck over products (7’s & 89’s) of his ‘dry finish screens’, thus causing the need for further processing (manual transport of out-of-spec product to a rinse tower to wash and rinse before it could be sold). Polydeck’s Screening Process Consulting Service reviewed his entire plant flow, gradation data, moisture readings, equipment specs and deck loads. Using our process evaluation software, we were able to suggest changes to the feed rate and the screen panel layout that not only brought product consistently into spec (even with varying moisture contents), but eliminated the need for the final process step. The result was the ability to make in-spec products without expensive reprocessing regardless of the ambient weather conditions – a major saving of cost, time, and space.
Mining
A mine was using three decks for scalping ahead of a secondary cone crusher. The media being used was
inefficient and the three decks were barely able to keep up with the high tonnage demands. Blinding caused
by moisture content in the feed further aggravated the problem and the moisture was expected to increase
as the open pit operation approached the water table. Polydeck’s Screening Process Consulting Service
reviewed the entire plant flow, gradation data, moisture readings, equipment specs and deck loads. As
a result of the study, the recommended change in screen media allowed them to operate with
only two of the three decks, while maintaining higher availability and greater efficiency.
Make the Right Choice
Make sure that the equipment choices and specifications of your new or expanding plant are based on your priorities. Polydeck’s Screening Process Consulting Service offers an independent evaluation of your plant flow, leading to greater peace of mind and a plant that performs better from initial start-up.

Coal Crushing Plant In Indonesia Mining

Coal mine productions in Indonesia have become more exuberant in the recent few years. Now Indonesia has become the third largest exporter of the world for coal mine (just after Australia and China). According to the 2008 BP Statistical Energy Survey, Indonesia had end 2007 coal reserves of 4328 million tonnes. Indonesia is one of the leading exporters of sub-bituminous coal which represents the bulk of Indonesian coal production.

Zenith Coal crushing equipment is a type of machine which is used in coal processing industry. Because of its advantages, it is widely used in coal mining in Indonesia. It is well known in the owners of the coal mine and other stone mining.

Primary coal crushing :

At first, Zenith Jaw coal crusher and impact coal crusher will be used in the primary crushing. In this step, coal mine in type of different size will be crushed into similar size and be chosen by vibrating screen. In another way, the raw material also may be crushed by impact crusher which is designed for coal mining. These crushed materials’ pressure resistance strength is under 200Mpa.

Secondary coal crushing :

Then, the output of the primary coal crushing is processed into express size for the customer for special purpose usage. Such as metallurgy industry , fuel, depper processing and etc. The main products used in this level are cone coal crushers, like Spring Cone Crusher, CS Cone Crusher , Hydraulic Cone Crusher and HCS series cone crusher . These crushed materials’ maximal resistance pressure is 300Mpa.

Sebuku Coal Mining Project in Indonesia :

This coal mining project, located in the province of South Kalimantan, Indonesia, is an open cut truck and shovel coal-mining operation. The coal is of high volatile bituminous rank with an average in-situ ash of 12%, total sulphur of 1.05%, a calorific value of 6,085KCal/kg (air-dried basis) with an average in situ total moisture of 14%. The coal is typically lustrous with occasional bright bands.

The coal mining is by multi-pit open cut methods. Topsoil and waste material are removed by excavator and dumped as directed by the mine plan. The majority of coal is direct dumped to the hopper for processing to maximise throughput and minimise rehandle.

About 80% of selectively mined coal in the project can bypass the washing process. The bypass circuit comprises a feeder breaker as the primary crushing system where typical 500mm ROM coal is broken down to a top size of 150mm. Crushed coal is then screened at 50mm, with the oversize further crushed in a secondary roll crusher.

For coal mining, you can select Zenith Mining Machinery in your project, from coal feeding and crushing, coal grinding and conveying to coal screening. A first-of-its-level mining machinery, only on Zenith.

Karara Iron Ore Project

The Karara mine is mined through conventional open-pit methods including drilling, blasting, loading and haulage. The ore will be processed in an on-site facility. Processing will include crushing, grinding, magnetic separation, reverse flotation and thickening to produce 12Mt/y of magnetite concentrate. Approximately 85% of ore will be delivered to the crusher. The remaining 15% will be stockpiled in a ROM pad for subsequent crushing. HPC cone crusher is the major large scale crushing equipment in iron ore processing plant.

Goro Nickel Mining Project

The Goro Nickel plant is one of the largest mining projects under construction anywhere in the world. Open cast to a depth of 50-60m, the main mineral type is nickel and colbalt. Goro is considered among the world’s best-known undeveloped laterite ore bodies. The expected annual capacity of the Goro Nickel project is 60,000t of nickel and 4,300 to 5,000t of cobalt.

PY Series spring cone crusher used in the Nickel plant has a perfect reasonable structure and a great performance in manufacture, installation, operation and maintenance.

Copper-Gold-Silver Mine Project

The Escondida copper-gold-silver mine is located in northern Atacama Desert of Chile. Run-of-mine ore is hauled to in-pit large scale crushers for primary reduction before being conveyed to the coarse ore stockpiles. The stripping ratio will average around 1.7:1 over the full life of the project. Oxide copper ore is crushed and sized then heap leached.

HPC cone crusher is suitable for crushing hard run-of-mine copper ore, one unit of the capacity can be up to 1000 TPH. In addition, the cone crusher has high quality spare parts and wear parts.

Coal Mining Project

Located at 29km northeast of Elkford, BC, Canada, Fording River began production in 1971 and made its first shipment of metallurgical coal in April 1972. Designed as a 3Mt/y operation, the Fording River has the mineral type of low- to high-volatile bituminous a coals. The mine also produces and sells thermal coal for use by power utilities and associated industries.

Zenith high performance PY Series spring cone crusher is the classical crushing equipments. It uses spring as its pressure system and is featured with high capacity, long service time and high efficiency.