Large rocks are characterized by high hardness and enormous size. At the stage of rock crushing, most quarries, mining enterprises, and construction sites usually face problems like equipment blockage, unequal size of the output product, fast wear of the spare parts, and insufficient production capacity. The reasons are usually improper choice of equipment, lack of standardization of the crushing process, and improper feeding control. Based on 15 years of experience in manufacturing crushing equipment for mining enterprises and thousands of successful projects, MP gives recommendations about standardized crushing process of large rocks, criteria of equipment selection, adaptation of the working conditions, and main aspects of construction.
Standard Industrial Crushing Process for Large Rocks
Natural large rocks have feeding sizes of 500 mm to 1200 mm. Owing to high hardness and irregular size, they cannot be crushed in one operation to obtain the finished products. Two-stage closed crushing process with automatic feeding and screening devices allows performing constant crushing, classification of the output products, reprocessing of the wastes, standardization of the product, obtaining stable production capacity, and rational use of raw material.
Step 1: Feeding with Vibrating Grizzly Feeder for Pre-Feeding and Material Conditioning
The raw rocks are uniformly fed into the vibrating feeder with the help of a loader. The feeder is equipped with the frequency regulation technology which ensures continuous and uniform feeding, as well as separation of soil, fine powder, and impurities at the early stage. In this way, foreign objects do not enter the crushing chamber and wear of the equipment decreases. Uniform feeding allows eliminating unexpected peaks of material, blockage owing to oversize rocks, and ensuring constant performance of the subsequent crushing equipment. Vibrating feeder is the base of the whole production line.
Step 2: Jaw Crusher for Primary Crushing and Size Reduction
The oversized rocks are fed into the Jaw Crusher for primary crushing. Through compression force created with the help of the moving and fixed jaw plates, the oversized rocks with the size of about 1000 mm are crushed into the medium-size material from 100 mm to 300 mm. Jaw Crusher is the key primary crushing equipment for large rocks. It is characterized by strong compression resistance, large feed opening, and reliable work. It is designed for processing high-hardness materials in continuous heavy-duty working conditions. It provides the material of proper size for subsequent secondary crushing.
Step 3: Impact Crusher for Secondary Crushing and Shape Improvement
After the primary crushing, the material is fed through the belt conveyor into the Impact Crusher for further processing. Owing to high-speed rotor impact and multiple collision of the material with impact plates, the equipment performs secondary crushing and shape improvement of the particle. The result is high-quality crushed stone and manufactured sand from 0-50 mm. The output products have low percentage of flakiness, perfect particle shape, and optimal grading. They fully satisfy requirements for infrastructure construction, concrete mixing plants, and road aggregate applications.
Step 4: Screen Vibrating Screen for Closed-Circuit Classification
After crushing, the mixture of materials is supplied to multi-layer vibrating screen for classification of the particles depending on their size. Qualified finished products are separated and stored; oversized materials are returned to the crushing equipment for secondary processing. The closed circuit production line allows avoiding waste of the raw material, increasing qualification rates of products, and increasing productivity.
Parameters and Advantages of Key Equipment for Large Rock Crushing
Considering peculiarities of large rocks, including their oversized feed size, high hardness, and great abrasiveness, MP Mining Equipment has developed and manufactured the whole set of crushing and screening equipment. The whole range of equipment has been tested under industrial pressure, wear resistance, and constant operation and can be used in any harsh conditions of mining and construction. The whole equipment range is characterized by reliability, stable production capacity, and economic efficiency. The company supplies full-machine supply and spare parts, as well as individual solutions based on the particular project requirements.
Jaw Crusher (Primary Crusher for Large Rocks)
The Jaw Crusher is currently one of the most popular and effective pieces of equipment for crushing of large raw rocks. It is characterized by large feed opening, high crushing strength, and reliability of its work. It is suitable for processing of various high-hardness materials including granite, basalt, iron ore, limestone, and river pebbles. The equipment is equipped with reinforced integral steel structure, high manganese steel wear-resistant jaw plates, and robust reinforced bearing assemblies. With the strong structure and high impact resistance, it can constantly process oversized raw rocks without problems with blockage, wear, and deformation of the equipment. Our range of Jaw Crushers includes small mobile and large stationary crushing systems with capacity from 5 to 800 tons per hour. The equipment can flexibly satisfy requirements for small construction sites with dispersed crushing and large mining enterprises with requirement for constant mass production. At the same time, we store all original spare parts of the equipment, including jaw plates, eccentric shafts, liners, springs, bearings, and other critical elements. Thus, you can rapidly replace worn-out spare parts and avoid losses because of stoppage of the equipment.
Impact Crusher (Secondary Crushing and Shaping Equipment)
The Impact Crusher is the key secondary crushing equipment in the aggregate production lines. It is used for crushing and shape improvement of materials after primary crushing and is suitable for processing limestone, construction waste, coal gangue, medium-hard stone, and other materials. The equipment has an optimized crushing chamber design and reinforced rotor structure that ensures uniform impact force and high crushing efficiency. It solves many typical problems in traditional crushing equipment like material blockage, return of the excess material, and high percentage of flaky particles. The processed aggregates have uniform size, good quality, and improved particle shape. They are ideal raw material for high-quality infrastructure projects, highways, and bridge construction. The manufacturer provides full-range of wear-resistant spare parts of the equipment, including blow bars, impact plates, screen plates, and liners. Custom-made processing and rapid delivery of spare parts are also available.
Feeder (Core Equipment for Stable Material Feeding)
Feeder is an important piece of equipment which ensures continuous and automated operation of crushing production line. It eliminates manual feeding and ensures stable, quantitative and uniform feeding of large rocks.With variable-frequency speed control system, the feeder can flexibly adjust feeding speed in accordance with the requirements of production capacity and characteristics of rocks. It can effectively prevent overload of crusher, material blockage and idle operation of the equipment.It is characterized by low energy consumption, low noise, strong wear resistance and perfect dust resistance. Thus, it is especially suitable for the operation in open environment like mine and construction site. The equipment can be perfectly matched with all models of Jaw Crushers and Impact Crushers.
Vibrating Screen (Core Equipment for Accurate Classification and Quality Improvement)
Vibrating Screen is mainly responsible for accurate classification of crushed materials. Through multi-layer screening systems, crushed stone and manufactured sand of different sizes can be classified to achieve standardization of product output.MP's circular vibrating screens and linear vibrating screens are characterized by reinforced welded frame and highly wear-resistant manganese steel screen mesh. Excellent tensile strength, wear resistance, screening accuracy and large capacity of processing are guaranteed through the equipment. It is possible to use 2-4 layer screening systems with multiple specifications of output in accordance with different capacities of production line. It helps build up an efficient closed loop production process and improves greatly the quality of finished products and the utilization of raw material.
Standardized Crushing Solutions for Different Large Rock Processing Conditions
According to MP's experience in completing thousands of crushing projects, there are three standardized solutions of crushing configuration based on different production capacities, working conditions and material characteristics. These solutions can help customers make wise choices of equipment and reduce unnecessary investment to ensure effective production.
Small Construction Site / Scattered Crushing Application: Small Jaw Crusher + Simple Feeder
This configuration features small volume, mobile convenience and simple operation. No need of building complex infrastructures and it is suitable for scattered large rocks crushing, construction waste crushing and landscape stone crushing.With low investment and short period of pay back, it is the best choice for small scale construction projects and self-use crushing application.
Medium Size Aggregate Plant / Commercial Production Application: Jaw Crusher + Impact Crusher + Vibrating Feeder + Multi-layer Vibrating Screen (Complete Production Line)
This complete closed circuit production line is suitable for processing general materials including limestone, medium-hard stone, quarry rocks.It ensures stable production capacity and high quality of finished product with continuous supply capacity of producing standardized construction aggregates. It can satisfy the long term requirements of material supply of concrete mixing plant and construction project.
Large Mining Operation / Hard Rock Application: Heavy-duty Large Jaw Crusher + High Wear Resistance Screening Production Line
This configuration is specially designed for extremely hard materials including granite, basalt and iron ore.Excellent wear resistance, powerful load-bearing ability and high durability guarantee the 24 hour continuous operation, large production capacity and low failure rate of the equipment. It is the best choice for large scale mining crushing operation.
Advantages of Cooperation with MP Mining equipment
As the direct manufacturer of crushing equipment, MP Mining Equipment possesses complete abilities including independent design, research and development, forging, assembly and quality check of equipment.Based on 15 years industry experience, controllable product quality and perfect after-sale service system, MP provides reliable crushing solutions for customers around the world. Based on experience in manufacturing of crushing equipment, MP owns standardized large scale production facilities which has successfully provided thousands of stone crushing production lines in different regions around the world.We know well the difference of rock hardness, material characteristics and working conditions in different markets. Based on practical project experience, we are able to identify the problems of crushing process and provide the customized production solutions with higher efficiency and lower cost.
Professional Product Technology Expertise
All MP equipment are independently designed and developed. Through the constant optimization of crushing chamber structure, wear-resistant materials and operational parameters, every machine can operate reliably under tough working conditions.Before delivery, each piece of equipment will go through many inspection processes including no-load test, load test, wear resistance test and pressure resistance test. With mature manufacturing technology and professional engineering ability, the performance of our equipment surpasses common industry standards.
Reliable Factory Authorization and Industry Recognition
MP is the direct factory supplier without third party brand and middleman. We provide complete technical documentation including specification of equipment, manufacturing authorization, references of projects and professional technical instruction.Customers are welcome to visit factory and test the equipment. With proved industry recognition and reliable manufacturing ability, MP provides trustable equipment solutions directly from the factory.
Genuine Customer Reputation and Long Term Reliability
The MP crushing equipment has been widely exported to international market and provided long term service for mining company, infrastructure contractor and aggregate processing enterprise. With stable performance of equipment, low failure rate, quick spare parts supply and active after-sales service, we have built the good relationship with many long-term customers.We also provide all-round one stop services including equipment selection consulting, project planing, equipment installation and commissioning, lifetime operation and maintenance service to ensure customers can enjoy the production protection throughout the whole project period.
The key to efficient and compliant large rock crushing is following the scientific process of "primary crushing for size reduction, secondary crushing for shaping, and screening for closed loop classification".With proper selection of professional crushing equipment including Jaw Crusher, Impact Crusher, Feeder and Screen according to rock hardness, feed size and production requirement, customers can avoid improper equipment selection and inefficient construction process.A properly designed crushing system can largely improve the quality and production capacity of aggregate while effectively reducing the wear of equipment, energy consumption and maintenance cost.As the professional direct manufacturer of crushing equipment, MP provides comprehensive solutions including: Customized equipment selection;Tailor-made crushing production line design;Complete crushing equipment supply;Original spare parts support;Professional installation guide;Long term after sale maintenance services.
