Process flow and equipment configuration of basalt sand production line

In the construction of buildings, roads, bridges and other infrastructure, high-quality sand and gravel aggregate is an indispensable basic material. Basalt has become an ideal raw material for sand making because of its excellent characteristics such as high hardness, wear resistance and corrosion resistance. Through scientific and reasonable technological process and advanced equipment configuration, the basalt sand production line can process basalt into high-quality sand and gravel products that meet various specifications and meet the market demand for high-quality sand and gravel aggregates.​

1. The process flow of basalt sand production line​

Feeding​

Raw material preparation: The mined basalt ore is first transported to the raw material storage site of the sand production line. These ores vary in size and need to be initially screened and sorted for subsequent processing.​

Feeding equipment work: The commonly used feeding equipment is a vibrating feeder. The vibrating feeder drives the eccentric block through the motor to generate excitation force, so that the material is thrown on the feed chute, so as to evenly and continuously transport the basalt ore to the next process - crushing. The vibrating feeder has the advantages of adjustable feeding speed, large conveying capacity and stable operation, which can ensure the uniformity of the feeding of the whole production line and avoid problems such as idling or blockage of the crusher due to insufficient or excessive feeding.​

Crushing link​

Coarse crushing: Coarse crushing usually uses a jaw crusher. The jaw crusher uses the relative motion between the moving jaw and the static jaw to extrude, split and bend the basalt ore entering the crushing cavity. Its large crushing ratio can crush large pieces of basalt ore (the maximum feed particle size can reach about 1200mm) to a smaller particle size (generally the discharge particle size is between 100 - 350mm), laying the foundation for the subsequent medium and fine crushing process. The jaw crusher has the characteristics of simple structure, sturdy and durable, and convenient maintenance, and is the preferred equipment for the coarse crushing process in the basalt sand production line.​

Secondary crushing and fine crushing: After coarse crushing, basalt materials enter the secondary crushing and fine crushing links, and the commonly used equipment is cone crusher and impact crusher. The cone crusher extrudes the material by moving from the mortar wall to the crushing wall, so that the material is continuously crushed by extrusion, bending and shearing in the crushing chamber. It is suitable for medium and fine crushing of ores of various hardnesses, and has the advantages of high crushing efficiency, uniform product particle size and low energy consumption. The impact crusher uses the plate hammer on the rotor that rotates at high speed to hit and crush the material entering the crushing chamber, and make the material repeatedly hit between the impact plate and the rotor for further crushing. The products crushed by the impact crusher are in the shape of a cube with a low content of needle flakes, which is suitable for occasions with high requirements for the shape of sand and gravel aggregates. In actual production, according to the hardness of basalt, feed particle size and product particle size requirements, etc., the appropriate medium and fine crushing equipment or a combination of the two can be selected.​

Sand making link​

Sand making machine selection: The particle size of the basalt material after crushing has basically met the requirements of sand making, and it needs to be further processed into sand granular products through the sand making machine. Commonly used sand making machines are impact sand making machines (such as VSI sand making machine, 5X sand making machine, etc.). The impact sand making machine adopts two crushing principles, "stone to stone" and "stone to iron", the material is accelerated in the high-speed rotating impeller, and then thrown out from the impeller, and the high-speed collision and friction with the counterattack block and liner in the crushing cavity occurs, so as to be crushed into fine sand particles. This sand making machine has the advantages of high sand making efficiency, good sand grain shape (mostly cube), low energy consumption, etc., and can produce high-quality machine-made sand.​

Sand making process: After the material enters the sand making machine, it is first accelerated to a very high speed in the impeller, and then ejected at high speed, colliding with other materials in the crushing chamber or impact blocks, liners, etc. During the collision process, the material is not only broken into smaller particle sizes, but also has a smoother, rounder surface and more regular shape due to the friction and grinding action between each other. At the same time, the air circulation system inside the sand making machine can discharge the dust generated in the crushing process in time, ensuring the cleanliness and efficiency of the sand making process.​

Sieving process​

Screening equipment work: The materials after sand making need to be graded and screened by the screening equipment to obtain sand and gravel products with different particle size specifications. The commonly used screening equipment has a vibrating screen, the vibrating screen drives the screen box to do high-frequency vibration through the motor, so that the material does a leaping forward movement on the screen surface, the material smaller than the size of the screen hole becomes the product under the screen through the screen, and the material larger than the size of the screen hole is left on the screen surface to continue to move forward, and finally discharged from the other end of the screen to become the product on the screen. The vibrating screen has the characteristics of high screening efficiency, large processing capacity and high screening accuracy, and can accurately classify sand and gravel materials according to different particle sizes according to production needs.​

Screening process: Under normal circumstances, the sand making production line will be set up with multi-layer vibrating screens for multiple screenings. For example, the material with larger particles can be screened out through a coarse screen and returned to the sand making machine or crusher for reprocessing; The middle layer screen is used to screen out the sand and gravel products that meet the target particle size requirements and output them as finished products; The lowest screen is used to screen out the finer sand and dust. Through this multi-stage screening method, the quality and yield of sand and gravel products can be maximized, and the diverse needs of different users for sand and gravel particle size can be met.​

Sand washing​

Necessity of sand washing: After screening, sand and gravel products are often mixed with some soil, dust and other impurities, which will affect the quality and performance of sand and gravel, and reduce its use effect in construction and other fields. Therefore, the sand needs to be cleaned to remove these impurities.​

Sand washing equipment and working principle: Commonly used sand washing equipment includes spiral sand washing machine and wheel bucket sand washing machine. The spiral sand washing machine stirs and cleans the sand and gravel materials in the sink through the rotation of the spiral blades, and the impurities are discharged from one end of the sink with the water flow, and the clean sand and gravel are transported to the other end of the sink by the spiral blades for discharge. The wheel bucket sand washing machine uses the rotation of the wheel bucket to roll and clean the sand and gravel materials in the sand washing tank, and at the same time flushes the materials through the high-pressure water gun to separate the impurities from the sand and gravel, and finally the clean sand and gravel is lifted from the wheel bucket to the discharge port. Sand washing equipment can effectively remove soil, dust and other impurities in sand and gravel, improve the cleanliness and quality of sand and gravel, and make it better meet the strict requirements of construction, road and other projects for sand and gravel aggregates.​

2. Equipment configuration of basalt sand production line​

Feeding equipment​

Vibratory feeder: The model is selected according to the size of the production line and the demand for feed volume, such as the common GZD series vibratory feeder, whose feeding capacity ranges from tens to hundreds of tons per hour. For example, the GZD960×3800 vibrating feeder, with a feed size of up to 500mm and a feeding capacity of 80 - 400t/h, is suitable for medium-sized basalt sand production lines.​

Crushing equipment​

Jaw crusher: The jaw crusher for primary crushing can choose PE series, such as PE600×750 jaw crusher, with a feed particle size of up to 500mm and a processing capacity of 80 - 240t/h, which is suitable for processing basalt raw materials of medium hardness.​

Cone crusher: The common models of cone crusher for medium and primary crushing include PYB series standard cone crusher and PYZ series medium cone crusher. Taking the PYB1750 cone crusher as an example, it has a maximum feed size of 215mm, an adjustment range of 25 - 50 mm of discharge opening, and a processing capacity of 120 - 380 t/h, which can further crush the basalt after coarse crushing.​

Impact crusher: The impact crusher can choose PF series, such as PF1214 impact crusher, with a maximum feed size of 300mm and a processing capacity of 70 - 130t/h, which can effectively crush basalt into products with uniform particle size and good shape, which is suitable for production scenarios with high requirements for the shape of sand and gravel aggregates.​

Sand making equipment​

Impact sand making machine: For example, the VSI6X1140 impact sand making machine has a maximum feed size of 50mm and a throughput of 200 - 580t/h, which has the characteristics of high speed, large crushing ratio and low energy consumption, and can efficiently produce high-quality basalt machine-made sand.​

Screening equipment​

Vibrating screen: The commonly used vibrating screen has 2YK1860 type, etc., the screen area of this type of vibrating screen is 10.8 square meters, the screening particle size range is 0.5 - 50mm, and the processing capacity is 10 - 150t/h, which can accurately screen the basalt materials after sand making according to the production needs.​

Sand washing equipment​

Spiral sand washer: XL-914 spiral sand washer, with a processing capacity of 15 - 40t/h, can effectively clean impurities in sand and gravel and improve the quality of sand and gravel.​

Wheel bucket sand washing machine: 2LXT1520 wheel bucket sand washing machine, with a processing capacity of 30 - 80t/h, is suitable for large-scale cleaning of basalt sand and gravel to ensure the cleanliness of the finished sand.In the construction of buildings, roads, bridges and other infrastructure, high-quality sand and gravel aggregate is an indispensable basic material. Basalt has become an ideal raw material for sand making because of its excellent characteristics such as high hardness, wear resistance and corrosion resistance. Through scientific and reasonable technological process and advanced equipment configuration, the basalt sand production line can process basalt into high-quality sand and gravel products that meet various specifications and meet the market demand for high-quality sand and gravel aggregates.​

1. The process flow of basalt sand production line​

Feeding​

Raw material preparation: The mined basalt ore is first transported to the raw material storage site of the sand production line. These ores vary in size and need to be initially screened and sorted for subsequent processing.​

Feeding equipment work: The commonly used feeding equipment is a vibrating feeder. The vibrating feeder drives the eccentric block through the motor to generate excitation force, so that the material is thrown on the feed chute, so as to evenly and continuously transport the basalt ore to the next process - crushing. The vibrating feeder has the advantages of adjustable feeding speed, large conveying capacity and stable operation, which can ensure the uniformity of the feeding of the whole production line and avoid problems such as idling or blockage of the crusher due to insufficient or excessive feeding.​

Crushing link​

Coarse crushing: Coarse crushing usually uses a jaw crusher. The jaw crusher uses the relative motion between the moving jaw and the static jaw to extrude, split and bend the basalt ore entering the crushing cavity. Its large crushing ratio can crush large pieces of basalt ore (the maximum feed particle size can reach about 1200mm) to a smaller particle size (generally the discharge particle size is between 100 - 350mm), laying the foundation for the subsequent medium and fine crushing process. The jaw crusher has the characteristics of simple structure, sturdy and durable, and convenient maintenance, and is the preferred equipment for the coarse crushing process in the basalt sand production line.​

Secondary crushing and fine crushing: After coarse crushing, basalt materials enter the secondary crushing and fine crushing links, and the commonly used equipment is cone crusher and impact crusher. The cone crusher extrudes the material by moving from the mortar wall to the crushing wall, so that the material is continuously crushed by extrusion, bending and shearing in the crushing chamber. It is suitable for medium and fine crushing of ores of various hardnesses, and has the advantages of high crushing efficiency, uniform product particle size and low energy consumption. The impact crusher uses the plate hammer on the rotor that rotates at high speed to hit and crush the material entering the crushing chamber, and make the material repeatedly hit between the impact plate and the rotor for further crushing. The products crushed by the impact crusher are in the shape of a cube with a low content of needle flakes, which is suitable for occasions with high requirements for the shape of sand and gravel aggregates. In actual production, according to the hardness of basalt, feed particle size and product particle size requirements, etc., the appropriate medium and fine crushing equipment or a combination of the two can be selected.​

Sand making link​

Sand making machine selection: The particle size of the basalt material after crushing has basically met the requirements of sand making, and it needs to be further processed into sand granular products through the sand making machine. Commonly used sand making machines are impact sand making machines (such as VSI sand making machine, 5X sand making machine, etc.). The impact sand making machine adopts two crushing principles, "stone to stone" and "stone to iron", the material is accelerated in the high-speed rotating impeller, and then thrown out from the impeller, and the high-speed collision and friction with the counterattack block and liner in the crushing cavity occurs, so as to be crushed into fine sand particles. This sand making machine has the advantages of high sand making efficiency, good sand grain shape (mostly cube), low energy consumption, etc., and can produce high-quality machine-made sand.​

Sand making process: After the material enters the sand making machine, it is first accelerated to a very high speed in the impeller, and then ejected at high speed, colliding with other materials in the crushing chamber or impact blocks, liners, etc. During the collision process, the material is not only broken into smaller particle sizes, but also has a smoother, rounder surface and more regular shape due to the friction and grinding action between each other. At the same time, the air circulation system inside the sand making machine can discharge the dust generated in the crushing process in time, ensuring the cleanliness and efficiency of the sand making process.​

Sieving process​

Screening equipment work: The materials after sand making need to be graded and screened by the screening equipment to obtain sand and gravel products with different particle size specifications. The commonly used screening equipment has a vibrating screen, the vibrating screen drives the screen box to do high-frequency vibration through the motor, so that the material does a leaping forward movement on the screen surface, the material smaller than the size of the screen hole becomes the product under the screen through the screen, and the material larger than the size of the screen hole is left on the screen surface to continue to move forward, and finally discharged from the other end of the screen to become the product on the screen. The vibrating screen has the characteristics of high screening efficiency, large processing capacity and high screening accuracy, and can accurately classify sand and gravel materials according to different particle sizes according to production needs.​

Screening process: Under normal circumstances, the sand making production line will be set up with multi-layer vibrating screens for multiple screenings. For example, the material with larger particles can be screened out through a coarse screen and returned to the sand making machine or crusher for reprocessing; The middle layer screen is used to screen out the sand and gravel products that meet the target particle size requirements and output them as finished products; The lowest screen is used to screen out the finer sand and dust. Through this multi-stage screening method, the quality and yield of sand and gravel products can be maximized, and the diverse needs of different users for sand and gravel particle size can be met.​

Sand washing​

Necessity of sand washing: After screening, sand and gravel products are often mixed with some soil, dust and other impurities, which will affect the quality and performance of sand and gravel, and reduce its use effect in construction and other fields. Therefore, the sand needs to be cleaned to remove these impurities.​

Sand washing equipment and working principle: Commonly used sand washing equipment includes spiral sand washing machine and wheel bucket sand washing machine. The spiral sand washing machine stirs and cleans the sand and gravel materials in the sink through the rotation of the spiral blades, and the impurities are discharged from one end of the sink with the water flow, and the clean sand and gravel are transported to the other end of the sink by the spiral blades for discharge. The wheel bucket sand washing machine uses the rotation of the wheel bucket to roll and clean the sand and gravel materials in the sand washing tank, and at the same time flushes the materials through the high-pressure water gun to separate the impurities from the sand and gravel, and finally the clean sand and gravel is lifted from the wheel bucket to the discharge port. Sand washing equipment can effectively remove soil, dust and other impurities in sand and gravel, improve the cleanliness and quality of sand and gravel, and make it better meet the strict requirements of construction, road and other projects for sand and gravel aggregates.​

3. Equipment configuration of basalt sand production line​

Feeding equipment​

Vibratory feeder: The model is selected according to the size of the production line and the demand for feed volume, such as the common GZD series vibratory feeder, whose feeding capacity ranges from tens to hundreds of tons per hour. For example, the GZD960×3800 vibrating feeder, with a feed size of up to 500mm and a feeding capacity of 80 - 400t/h, is suitable for medium-sized basalt sand production lines.​

Crushing equipment​

Jaw crusher: The jaw crusher for primary crushing can choose PE series, such as PE600×750 jaw crusher, with a feed particle size of up to 500mm and a processing capacity of 80 - 240t/h, which is suitable for processing basalt raw materials of medium hardness.​

Cone crusher: The common models of cone crusher for medium and primary crushing include PYB series standard cone crusher and PYZ series medium cone crusher. Taking the PYB1750 cone crusher as an example, it has a maximum feed size of 215mm, an adjustment range of 25 - 50 mm of discharge opening, and a processing capacity of 120 - 380 t/h, which can further crush the basalt after coarse crushing.​

Impact crusher: The impact crusher can choose PF series, such as PF1214 impact crusher, with a maximum feed size of 300mm and a processing capacity of 70 - 130t/h, which can effectively crush basalt into products with uniform particle size and good shape, which is suitable for production scenarios with high requirements for the shape of sand and gravel aggregates.​

Sand making equipment​

Impact sand making machine: For example, the VSI6X1140 impact sand making machine has a maximum feed size of 50mm and a throughput of 200 - 580t/h, which has the characteristics of high speed, large crushing ratio and low energy consumption, and can efficiently produce high-quality basalt machine-made sand.​

Screening equipment​

Vibrating screen: The commonly used vibrating screen has 2YK1860 type, etc., the screen area of this type of vibrating screen is 10.8 square meters, the screening particle size range is 0.5 - 50mm, and the processing capacity is 10 - 150t/h, which can accurately screen the basalt materials after sand making according to the production needs.​

Sand washing equipment​

Spiral sand washer: XL-914 spiral sand washer, with a processing capacity of 15 - 40t/h, can effectively clean impurities in sand and gravel and improve the quality of sand and gravel.​

Wheel bucket sand washing machine: 2LXT1520 wheel bucket sand washing machine, with a processing capacity of 30 - 80t/h, is suitable for large-scale cleaning of basalt sand and gravel to ensure the cleanliness of the finished sand.