First, a reference point for this capacity range: based on 10-12 hours of daily operation and 300 working days per year, the annual capacity is approximately 1.2-1.4 million tons, sufficient for commercial concrete and engineering materials in a county-level market, and also aRegional Aggregate Production Line, the main specification for large-scale mixing plant support.
Whether it is large or small depends on who it serves: for the regional commercial concrete market it is the main line; for supporting a ten-million-ton mine, it is an auxiliary line. Scale is measured by the market, and configuration is determined by ore and discharge requirements.
Complete equipment configuration approach
Configuration approach for this line: the three major stages of coarse crushing, medium crushing and screening must all be complete; if one stage is missing, both output and particle shape suffer. The following plan takes the Shuangjin 400-ton production line as an example:
| No. | Model | Name | Quantity | Main unit power consumption (kW) |
|---|---|---|---|---|
| 1 | GZS1560 | Bar grizzly feeder | 1 unit | 30 |
| 2 | PE900×1200 | Jaw crusher | 1 unit | 185 |
| 3 | ZW1118 | Vibrating feeder | 2 units | 1.5×2×2 |
| 4 | SJ1650 | Cone crusher | 2 units | 250×2 |
| 5 | 2YA2760 | Circular vibrating screen | 2 units | 37×2 |
| 6 | 3YA2460 | Circular vibrating screen | 2 units | 30×2 |
Table: Main equipment list of the 400 t/h sand and gravel production line
This configuration has two cost-saving details: first,Bar grizzly feederpre-screening, crushed material below 65 mm falls directly through the bar gaps and does not enter the jaw crusher, reducing both load and power consumption; second, two SJ1650 units operate in parallel to handle the 400 t/h throughput, so if one is under maintenance, the entire line keeps running.
The total installed power of the main equipment in the table above is about 855 kW, and at full load the main-equipment power consumption is about 2 kWh per ton (excluding auxiliary equipment such as conveyor belts). The more uniform the feeding and the more the load rate is kept at 70–80%, the lower the power consumption per ton.
Process flow: how the closed-circuit cycle runs
Material flow along the entire line: trucks dump raw material into the large hopper, the GZS1560 bar feeder first screens out fines below 65mm, large blocks are fed into the PE900×1200 jaw crusher for primary crushing and sent to the intermediate stockyard; two ZW1118 vibrating feeders feed evenly to two SJ1650 cone crushers for secondary crushing; the discharge first passes through two 2YA2760 circular vibrating screens, material larger than 31.5mm is returned for re-crushing, and the rest flows down; finally, two 3YA2460 screens produce four finished products: 0-5mm, 5-16mm, 16-25mm, and 25-31.5mm.
This is a closed-circuit cycle: non-conforming material never hits the ground, and is returned for re-crushing until the particle shape is qualified before leaving the line. The finished product has uniform gradation and few elongated or flaky particles, giving it good market appeal and keeping its price competitive.
How to adjust the configuration for different materials
The configuration above is suitable for medium-hard materials such as limestone and marble. If the raw material is changed to hard and abrasive rock such as granite or basalt, the secondary crushing stage should be equipped withMulti-cylinder hydraulic cone crusher(SK.D series, feed size 105-350mm, processing capacity 145-1150t/h) — laminated crushing delivers 15%–25% higher finished product yield at the same power consumption; for high-grade aggregates with strict particle shape requirements, add a vertical shaft impact crusher after fine crushing for shaping.
Final words
Every configuration is unique: raw materials, site conditions and sales channels all affect the equipment list. If you have a plan in mind, feel free to call 400-006-1987, submit an inquiry on this website, or visit our headquarters in Hangzhou for an on-site inspection and a thorough discussion of your solution.