Project Overview

Solution design - installation and commissioning

The production line has run for less than 3 years. The equipment was purchased from other domestic manufacturers. Unfortunately, the equipment cannot meet the customer’s demand on capacity while the maintenance cost was quite high. What’s worse, within 3 years most of facilities were broken and must be replaced. In December, 2015, the customer bought from SBM 2 sets of HST315 single cylinder hydraulic cone crusher and a PE900*1200 Jaw Crusher. The cone crusher adopts advanced intelligent control method. After installation and commissioning, the production line has been put into use for 3 months. The aggregate produced was characterized by good granularity and quality, so when the aggregate was put on the market, it won favors and had a higher price. Therefore, the customer spoke highly of SBM’s products and services.

Project Background

  • Influenced by "The Belt and Road", "13th Five-Year" plan, China increases investment in infrastructure. "The Belt and Road" initiative involves more than 60 countries and total investment amounts to $6 trillion. China Railway Corporation plans to complete 800 billion yuan of investment in 2016. During "12th Five-Year", fixed assets investment on railway will achieve 3.58 trillion yuan while railway as long as 30.5 thousand kilometers will be put in operation, increasing by47.3% and 109% respectively compared with "11th Five-Year". Railway, highway and other infrastructure projects need a large number of aggregate, so high-quality sand aggregate production becomes a craze for many enterprises.

  • After many years of quarrying, the natural sand is reducing sharply so the quarrying cost is getting higher and higher. Because natural sand belongs to non-renewable resources, many areas start to make regulations to strictly prohibit the exploitation of natural river sand, in order to maintain the natural landscape, protect dyke dam and the ecological balance. Under the influence of policy and environmental factors, machine-made sand production is promoted for protecting ecological environment.

  • Basalt has the advantages of high compressive strength, low crushing value, strong corrosion resistance, good adhesion, etc. It has been recognized as the best material in the construction of highway, railway and airport runway in the world. Not only that, basalt is also widely used in lightweight concrete for high buildings because it is porous but hard. It can make concrete lighter with the admixture in concrete. Besides, it has advantages of sound insulation and heat insulation so it is popular at major building materials markets.

Design Scheme

Material: Basalt

Input Size: >750mm

Moh’s Hardness: 7

Output Size: 0-5mm、5-12mm、12-24mm、24-31mm、31-40mm

Capacity: 450-500TPH

Application: Mixing station, road construction, high-speed rail construction

Equipment Configuration

According to the requirements of customers, the finished materials have five kinds with different finenesses. Therefore, as for the configuration of production line, SBM engineers replaced coarse and fine crushing equipment with low capacity and efficiency and installed a multi-level screen which is equipped with PLC intelligent control and dust removal system, which ensures that the whole production line is highly efficient and environmental protection.

The production line includes PE900 * 1200 jaw crusher, two sets of HST315 single cylinder hydraulic cone crusher, one ZSW420 * 110 vibrating feeders, five sets of 3Y2160 circular vibrating screen, one transfer bin, one dust removal system and ten sets of belt conveyor.

Equipment Quantity Use Operation mode
PE900×1200 jaw crusher 1 unit Coarse crushing Manual
HST315 hydraulic cone crusher 2 unit Medium and fine crushing PLC intelligent control
ZSW420×110 feeder 1 unit Coarse feeding Manual
3Y2160 circular vibrating screen 5 unit Medium and fine screening Manual
Transit storage bin 1 unit Storage bin Manual
Dust removal system 1 set Remove dust Manual

Process analysis

20-750mm of basalt after separation is given into primary jaw crusher PE900 * 1200 by ZSW420*110 vibrating feeder where the basalt is crushed to 0-300mm of fine aggregate which is then transmitted to transfer bin through belt conveyor. Transfer bin is arranged below the hydraulic valve and small vibrating feeder. Passing the transfer bin, the material is then sent into two sets of HST315 single cylinder hydraulic cone crusher for secondary crushing. The broken material then enters the two sets of 3Y2160 circular vibrating screen which brings material above 40mm back to transfer bin which fine material is sieved out as finished product.

  • HST hydraulic cone crusher

  • Process flow chart

Salute to "Industry 4.0": HST315 single cylinder hydraulic cone crusher

  1. The main equipment is HST315 single cylinder hydraulic cone crusher. Apart from high efficiency, low cost and long service life, the intelligent electronic control system of the cone crusher is also a major highlight of the production line. Intelligent electronic control system can provide multiple control modes including manual control, constant feed control and constant power control mode. Users can continuously monitor actual internal load and the device can be adjusted automatically so as to optimize the utilization rate of crusher, which can make crusher play best performance at any time. Besides, intelligent electronic control system can automatically monitor and display various operating parameters to record real-time operation situation and give alarm if necessary. For example, when the lining board is too worn to be used continuously, it will automatically display and alarm in the control panel.

  2. 1. Central control system: It is designed for large crushing line or for customers having centralized control requirements. The whole system takes industrial computer as the core part. Through a variety of communication technologies, the PLC (programmable controller) is read and the status of equipment is collected. Then according to equipment status, computer furthermore sends commands to control the equipment on site, so as to realize the remote control, information record and analysis. The central control system can realize the automation, intelligence and concentration of the production line, which can meet the requirements of the customers and achieve the decentralized management, centralized control:

    1). centralized control equipment, remote control, remote parameter setting.

    2).data records, historical inquiry, data printing, boot time recording, automatic storage run time.

    3).flexible system, convenient operation, powerful function, share resource, high safety performance.

    4). the powerful communication, the system expansion, the remote control of the Internet of things, user can view equipment status at any time.

    5). high degree of automation and fuzzy control. Greatly save labor and material costs.

    6). realize the monitoring visualization and individual start and stop, a key to start and stop, single control and interlock switch, automatic determination operation fault, automatic stop when in fault condition.

    7). rapidly complete upgrading based on the optimization of the production process latter.

  3. 2. Remote monitoring and control system (IOT): This system allows all devices to be integrated into network. Wherever we are, customers will be able to view machine's availability and historical records as long as there is a device that has access to internet. The remote monitoring control system, what's more, can also provide instant warning service. Furthermore, when grinding mill is in trouble, we will promptly notify the relevant personnel and provide remote guidance service, conveniently and quickly.

Manufacturers’ PK: How to Get Orders

This cooperation is a victory of SBM when competing with other manufacturers. The old basalt crushing line has run for 2-3 years. The customer used other manufacturer's equipment before. As a result, the capacity was unsatisfying and maintenance cost was quite high. Within 2 years the customer changed 3-4 sets of main equipment. Eventually, they chose SBM by purchasing a series of crushing equipment.

1. Company strength: SBM is a leading manufacturer of crushers and mills in the world. Our machines are widely used in mining and metallurgy, municipal engineering, high-speed railway, highway, bridges, ports, airports, water (nuclear) power plant around the world. In addition, SBM’s excellent quality and perfect service are best-known all over the world.

2. Product quality: It is a key for SBM to win customers in the 30 years of development. As for this case, SBM provided HST single cylinder cone crusher for customers according to the hardness of basalt. Product quality was excellent and the final output was totally out of customer expectation.

3. Quick production: Due to the fact that the line was being in production, to avoid economic losses caused by production disruption, SBM made preparations in advance to make production as usual. The installation engineer worked overtime in 6 days on site and installed two units and solved other issues completely to let the production line keep normal production.

4. After-sale service: In the development of more than 30 years, the company's services have always had a good reputation. Under the premise of standardized service, SBM will continue to improve the service system to create a more experienced service team.

Customer Feedback

We used equipment produced by small domestic factory before. The poor quality made us crazy and we replaced the host device again within two years. Maintenance cost a lot. Then by accident we learned that SBM does well in mine crushing after the market investigation, so we bought two sets of HST single cylinder cone crusher and one jaw crusher. The whole process spent less than a month. SBM impressed me deeply by good quality and service efficiency. We will continue to cooperate with SBM later.


Customer site

Extended Reading

General layout of crushing line is as follows: (raw material bin) - feeder-jaw crusher-transit bin-cone crusher(impact crusher) - vibrating screen-storage bin. But the layout of actual production line is made in terms of scale, material property, input and output size, discharging method and other special requirements.

1. The scale of production line: The scale directly determines equipment selection, which further determines the investment of equipment. For example, as for 200t/h production line, HJ98 high-energy jaw crusher and HPT300 multi cylinder hydraulic cone crusher would be recommended; for 300t/h production line, it is better to configure PEW860 European jaw crusher, HST160 single cylinder hydraulic cone crusher and HPT300 multi-cylinder hydraulic cone crusher, etc.; for another 500t/h production line, It is a good choice to configure HJ125 high energy jaw crusher, HST250 single cylinder hydraulic cone crusher, HST315 single cylinder hydraulic cone crusher, etc.

2. Material features: The selection of equipment is decided by hardness of materials. Very often, processing of hard materials like granite, basalt, pebble can adopt cone crusher while soft materials like limestone and dolomite can use impact crusher for middle crushing.

3. Input and output size:

(1) Input size: PE600X900 jaw crusher is recommended for materials about 500mm while PE750X1060 is recommended for materials around 600mm.

(2) Output size: Different output sizes bring different capacities.

Granite Crushing:

Output Size   CSB160   HPT300

25mm   150t/h   200t/h

40mm   200t/h   250t/h

4. Discharge method: Two-layer sieve: two kinds of finished product and one kind of returning material; three-layer sieve: three kinds of finished product and one kind of returning material.

5. Special requirements: It is necessary to make different configurations according to actual crushing needs such as installation of de-ironing separator if there is iron briquette in the raw materials; installation of the dust remover if there is a strict requirement on environment; installation of sand-washer if there is a need for sand purity and installation of electric generator if there is no electricity supply.