AIMIX Complete Crushing Production Line Solutions

What Is Crushing Process

The crushing process mainly refers to a series of technologies and operational steps that use a crushing station to process raw materials (such as rocks, ores, concrete, etc.) into the particle size and shape required by the users. This process is widely used in mining, building materials, metallurgy, chemical industry, roads and bridges and other industries, and is particularly important for the processing of hard materials such as rocks, ores, and coal.
crushing station
The crushing process not only includes the crushing of materials, but also involves subsequent processing such as screening and transportation to ensure that the final materials meet the needs of production.

Main Steps of Crushing Process

The specific crushing process usually includes the following basic steps:
crushing process

  • Raw Material Collection: First of all, raw materials need to be collected by wheel loader or excavator and then discharged on the vibrating screener.
  • Raw Material Feeding: The collected raw materials will be fed into the primary crusher by the vibrating screener.
  • Primary Crushing: The large stones are first crushed through primary crushing equipment such as jaw crusher to reduce their size to a level more suitable for secondary crushing. The materials after primary crushing are generally still relatively coarse.
  • Secondary Crushing: The primary crushed stones are further crushed by a cone crusher, impact crusher or other types of secondary crushing equipment to achieve fine crushing and further reduce the stones to the required size.
  • Screening Process: After crushing, the materials need to be screened through screening equipment such as vibrating screens to separate stones that meet specific size requirements, and large particles that do not meet the standards are sent back to the secondary crusher for re-crushing to ensure the granularity of the final product meets the requirements.
  • Washing: In some cases, in order to remove soil and other impurities from the stone, the stone may also need to be washed.
  • Material Conveying and Storage: After the crushing and screening processes are completed, the stone will be sent to the storage silos through the belt conveyors or directly put into use. Further contamination of materials needs to be prevented during transportation and storage.

Here, I attach one crushing process video to help you learn them.

In general, the entire crushing process involves a variety of different stone crusher machines and technologies. According to the hardness of the stone, finished product requirements, and other factors, it is crucial to select the appropriate crushing plant and equipment.

What Equipment Will Be Used in the Crushing Process?

There are many types of equipment used in the stone crushing process. Depending on the stage of crushing and the desired final product particle size, some of the following main types of crushing screening plants may be used.

Vibrating Feeder: Used to evenly transport large raw stones to the primary crusher, which ensures continuous and even feeding.
feeder equipment

Jaw Crusher: Used for preliminary crushing of large rocks. It crushes materials through two hard metal plates, one of which is moving and the other is fixed. It is suitable for stones of various hardness and is the most common primary crushing equipment.
jaw crushers

Cone Crusher: Used to further crush the rock that has undergone primary crushing. It uses the squeezing force between the rotating cone and the fixed wall to break the stone. Depending on the hardness of the stone and the output particle size requirements, different models of cone crushers can be selected.
cone crushing equipment

Impact Crusher: Suitable for medium-hardness stones. The hammer on the high-speed rotating rotor impacts the stone at high speed to break the stone. It is especially suitable for making aggregates with smaller particle size and good shape.
impact crushers for sale

Sand Making Machine (also known as vertical shaft impact crusher): Mainly used for fine crushing and sand production. It is suitable for crushing and shaping of soft, medium-hard and extremely hard materials. It is widely used in mineral processing, cement making, refractory materials producing, etc.
sand making machine

Vibrating Screen: Used to screen materials after crushing and classify materials according to different sizes to meet different usage needs. Stones that do not meet the standards can be sent back to the crusher for re-crushing.
screening machine in crushing process

Belt Conveyors: Used to transport crushed and screened stone to a designated location. It is an important equipment connecting various crushers and screeners.
belt conveyor

Sand Washing Machine: If you need to clean the soil and impurities on the stone surface, a sand washing machine is necessary. Suitable for cleaning, grading and dehydration of construction sand and road sand.
sand washing unit

These machines cooperate with each other in the entire stone crusher plants to complete the entire process from raw materials to finished products. Different crushing screening plant configurations and different production needs may require different equipment combinations.

How to Improve the Efficiency of the Crushing Process?

Stone crushing is a process that consumes a lot of energy and resources. Therefore, improving crushing efficiency and reducing energy consumption are also important factors that need to be considered when designing this crushing process. Improving the efficiency of the crushing process is the key to reducing costs, increasing output, and ensuring product quality. Here are some strategies to consider implementing.

  • Selection of Suitable Crushing Equipment: Choose a suitable crushing machine model based on the hardness, humidity, particle size and other characteristics of the material as well as production needs. For example, for materials with higher hardness, jaw crushers and cone crushers are preferred; for products that require good particle shape, consider using impact crushers or vertical shaft impact crushers.
  • Optimize the Crushing Process Configuration: Reasonably configure the crushing process and equipment layout. For example, the hierarchical crushing process is used to conduct coarse crushing first, and then medium and fine crushing, which can improve the crushing efficiency and reduce the production of fine powder.
  • Regular Inspection and Maintenance of Equipment: Keeping the crusher plants in good operating condition is an important condition for ensuring production efficiency. Check worn parts regularly and replace seriously worn parts promptly. Ensure that the equipment lubrication system is normal to avoid production interruptions caused by equipment failure.
  • crushing plant and equipment for sale
    crushing station for sale

  • Control the Size and Uniformity of the Feed: Ensure that the material entering the crusher is of appropriate size. Oversized stones will slow down the crushing speed and increase the burden on the equipment. The use of equipment such as vibrating feeders can ensure the continuity and uniformity of feeding and improve crushing efficiency.
  • Adjust Crushing Parameters: Adjust the working parameters of the stone crusher(such as crushing cavity type, rotation speed, feeding size, discharge port adjustment, etc.) according to the material characteristics to achieve the best crushing effect and efficiency.
  • Implement Closed-circuit Crushing Process: Through closed-circuit operation, that is, allowing materials that do not meet the requirements to pass through the crusher again, in this way, the yield of finished products can be improved and energy consumption can be reduced.
  • Adopt Automation and Intelligent Technology: Using modern automation technology and intelligent control systems, real-time monitoring and automatic adjustment of the production process can be achieved, thereby optimizing the production process, improving efficiency, and reducing labor costs.
  • Appropriately Increase the Crushing Ratio: The larger the crushing ratio is, the one-time investment will increase, but in the long run it can reduce the back-breaking process and improve the overall crushing efficiency.
  • Material Pretreatment: Preheat, dry or add appropriate amounts of auxiliary crushing materials during the crushing process if the raw materials are of high water content or high viscosity. In this way, crushing conditions and crushing efficiency can be greatly improved.

Through the comprehensive application of these strategies, the overall efficiency and economic benefits of the crushing process can be effectively improved.
crushing plant and equipment

If you have other problems about the crushing process, you are welcome to contact Aimix Group to help you figure your problems out. As a professional crusher plant manufacturer, Aimix Group has technical engineers to provide technical supports, installation services, maintenance services, training services, etc.

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