Dolomite Portable Crushing Plant in Malaysia

Summary：This article delves into the details of this project, including the characteristics of Malaysian dolomite, the challenges of on-site crushing, the configuration and technical advantages of the NK portable crusher plant, and the practical benefits brought by the integrated solution.

Dolomite, a carbonate mineral composed of calcium magnesium carbonate (CaMg(CO₃)₂), is a versatile raw material widely used in construction, agriculture, glass manufacturing, and metallurgy industries. Malaysia, endowed with abundant dolomite reserves, has witnessed a surging demand for high-quality dolomite aggregates amid the rapid development of its infrastructure sector, including highway construction, urban rail transit, and real estate projects.

To meet the market’s stringent requirements for dolomite aggregate quality and production efficiency, a leading Malaysian mining company partnered with SBM to deploy an advanced mobile dolomite crushing production line. This turnkey solution has achieved remarkable success in optimizing dolomite processing, reducing operational costs, and enhancing environmental sustainability. This article delves into the details of this project, including the characteristics of Malaysian dolomite, the challenges of on-site crushing, the configuration and technical advantages of the NK portable crusher plant, and the practical benefits brought by the integrated solution.

1. Project Background: Dolomite Resources and Market Demand in Malaysia

Malaysia boasts significant dolomite deposits, primarily distributed in states such as Perak, Selangor, and Johor. The dolomite in these regions is characterized by high purity (CaO content 30-35%, MgO content 20-25%), dense structure, and hardness ranging from 3 to 4 on the Mohs scale, making it an ideal raw material for producing high-strength concrete aggregates, road base materials, and flux in steelmaking. With the Malaysian government’s continuous investment in infrastructure development under the 12th Malaysia Plan (2021-2025), the demand for high-quality dolomite aggregates has increased exponentially. Traditional fixed crushing plants, however, face insurmountable challenges in meeting this demand, including high upfront investment, long construction cycles, difficulty in adapting to scattered dolomite mining sites, and high transportation costs of raw ore.

The client, a well-established Malaysian mining enterprise specializing in dolomite extraction and processing, was confronted with these pain points. Its existing fixed crushing line had low production efficiency, high energy consumption, and poor mobility, making it unable to efficiently utilize scattered dolomite resources. Moreover, the uneven particle size of the final aggregates failed to meet the quality standards for high-grade construction projects. To address these issues, the client sought a flexible, efficient, and cost-effective crushing solution. After in-depth market research and technical communication, SBM's NK portable crusher plant stood out due to its superior mobility, high crushing efficiency, and intelligent control system, ultimately becoming the core equipment for the client’s new dolomite crushing line.

2. Key Challenges in Dolomite On-Site Crushing in Malaysia

The on-site crushing of dolomite in Malaysia posed several unique challenges that required a tailored technical solution. Firstly, the dolomite mining sites are widely scattered across mountainous and hilly areas, with complex terrain and poor road conditions. This demanded that the crushing equipment have excellent mobility to be easily transported and deployed to different sites without extensive infrastructure modifications. Secondly, the Malaysian climate is hot and humid, with frequent rainfall, which places high requirements on the waterproof, dustproof, and corrosion-resistant performance of the equipment. Thirdly, the client required the final dolomite aggregates to meet strict quality standards, including uniform particle size (0-5mm, 5-10mm, 10-20mm), low needle-flake content (≤10%), and high compressive strength (≥30MPa). Finally, in response to Malaysia’s increasingly stringent environmental protection regulations, the crushing line needed to minimize dust and noise pollution.

Against this backdrop, fixed crushing plants were deemed impractical due to their poor mobility and high environmental impact. In contrast, SBM’s NK portable crusher plant, with its modular design, robust structure, and advanced environmental protection systems, was well-equipped to overcome these challenges, providing a reliable solution for efficient and eco-friendly dolomite crushing.

3. Core Equipment Configuration: NK Portable Crusher Plant and Integrated System

SBM customized a comprehensive mobile crushing line for the client based on the characteristics of Malaysian dolomite and the client’s specific requirements. The core equipment is the NK series portable crusher plant, which integrates feeding, crushing, screening, and conveying functions into a single modular unit. The entire line consists of three key components: the portable jaw crusher plant, the portable cone crusher plant, and the vibrating screen portable plant, forming a two-stage crushing and one-stage screening process. This configuration ensures high crushing efficiency, stable product quality, and flexible operation.

3.1 Portable Jaw Crusher Plant (Primary Crushing)

As the primary crushing equipment, the jaw crusher plant is responsible for breaking large dolomite raw ore (with a maximum feed size of 600mm) into smaller particles (50-100mm) suitable for secondary crushing. This plant is equipped with a high-performance jaw crusher, which features a large crushing chamber, high crushing ratio (up to 6:1), and strong crushing capacity. The jaw plate is made of high-chromium alloy steel, which has excellent wear resistance and a long service life, adapting to the hard and abrasive nature of dolomite.

The modular design of the plant enables quick assembly and disassembly, with the entire unit capable of being deployed and put into operation within 24 hours of arriving at the site. Additionally, the plant is equipped with an intelligent control system that monitors key parameters such as feed rate, crushing pressure, and motor load in real-time, ensuring stable and efficient operation.

3.2 Portable Cone Crusher Plant (Secondary Crushing)

The secondary crushing stage is crucial for ensuring the particle size and shape of the final dolomite aggregates. The portable cone crusher plant is adopts a hydraulic adjustment system and a multi-cylinder structure, enabling precise control of the discharge particle size. The cone crusher features a unique crushing cavity design (standard cavity for medium crushing), which ensures uniform particle size of the crushed products and low needle-flake content, meeting the high-quality requirements of construction aggregates.

It is equipped with a dust suppression system, including a water spray device and a dust cover, which effectively reduces dust emissions during the crushing process. The intelligent control system of the cone crusher plant is seamlessly connected with that of the jaw crusher, enabling coordinated operation between the primary and secondary crushing stages. Operators can adjust the feed rate and discharge particle size of both plants through a centralized control panel, improving operational efficiency and reducing labor intensity.

3.3 Portable Screen Plant (Screening and Classification)

After secondary crushing, the dolomite particles are sent to the vibrating screen for screening and classification. This plant is equipped with a 3-layer circular vibrating screen with a screen area of 18㎡ (1800×6000mm), which can efficiently separate the crushed products into three specifications: 0-5mm (fine aggregate), 5-10mm (medium aggregate), and 10-20mm (coarse aggregate). The vibrating screen adopts a high-frequency vibration motor, which has strong screening capacity and high screening efficiency (≥95%), ensuring that the final products meet the required particle size standards.

The screen mesh is made of high-wear-resistant polyurethane material, which has a long service life and is easy to replace. The plant is also equipped with a conveyor belt system that transports the classified aggregates to the corresponding product stockpiles. The entire screening and conveying process is fully automated, reducing manual intervention and improving production efficiency.

3.4 Auxiliary Equipment and Systems

To ensure the smooth operation of the entire mobile crushing line, SBM also provided a series of auxiliary equipment and systems, including a vibrating feeder (to ensure uniform feeding of raw ore), a belt conveyor (for material transportation between different plants), a diesel generator set (for emergency power supply), and an integrated control room (for centralized monitoring and operation of the entire line). Additionally, the line is equipped with a comprehensive environmental protection system, including dust suppression (water spray + dust collector), noise reduction (sound insulation cover for motors), and wastewater treatment (sedimentation tank for recycling water), fully complying with Malaysia’s environmental protection regulations.

4. Technical Advantages of the NK Portable Crusher Plant in Dolomite Crushing

The NK portable crusher plant deployed in the Malaysian dolomite project boasts several core technical advantages that distinguish it from traditional crushing equipment and competitors’ products, ensuring efficient, stable, and eco-friendly operation.

4.1 Superior Mobility and Flexibility

NK mobile crushers can adapt to various complex terrains, including mountainous areas, muddy roads, and uneven ground. The self-propelled function allows the plant to move freely between different mining sites without the need for cranes or other heavy equipment, significantly reducing the time and cost of equipment transportation and deployment. For the client’s scattered dolomite mining sites, this mobility means that the crushing line can be quickly relocated to utilize raw ore resources in different areas, maximizing resource utilization and reducing transportation costs of raw ore.

4.2 High Crushing Efficiency and Stable Performance

The NK series portable crusher plants are equipped with high-performance crushing equipment (jaw crusher and cone crusher) with optimized structures and strong power systems. The primary crushing plant has a maximum production capacity of 200t/h, while the secondary crushing plant can process up to 150t/h. The entire line’s designed production capacity is 120-150t/h, which is 30% higher than the client’s previous fixed crushing line. The hydraulic adjustment system of the cone crusher ensures precise control of the discharge particle size, with a deviation of ≤2mm, ensuring uniform product quality. Moreover, the equipment is made of high-strength steel and wear-resistant materials, which can withstand the harsh operating conditions of hot and humid climates in Malaysia, ensuring long-term stable operation with a low failure rate (average failure rate ≤2% per month).

4.3 Intelligent Control and Easy Operation

The entire mobile crushing line adopts an advanced intelligent control system, which integrates PLC control, touch screen operation, and remote monitoring functions. Operators can monitor key parameters such as feed rate, crushing pressure, motor temperature, and discharge particle size in real-time through the centralized control panel. The system also has automatic fault diagnosis and alarm functions, which can promptly detect equipment malfunctions and notify maintenance personnel, reducing downtime. Additionally, the system supports remote operation and monitoring, allowing managers to keep track of production status and equipment operation from the office, improving management efficiency. The user-friendly interface of the control system makes it easy for operators to learn and operate, reducing the requirement for professional skills and lowering labor costs.

4.4 Excellent Environmental Protection Performance

In response to Malaysia’s strict environmental protection regulations, the NK portable crusher plant is equipped with a comprehensive environmental protection system. The dust suppression system, consisting of water spray devices installed at the feed port, discharge port, and conveyor belt, effectively reduces dust emissions by more than 90%. For fine dust that cannot be completely removed by water spray, a bag-type dust collector is installed, ensuring that the dust concentration at the work site is ≤10mg/m³, which is far below Malaysia’s national standard of 50mg/m³. The noise reduction system, including sound insulation covers for motors and crushers, reduces the noise level at the work site to ≤75dB(A), protecting the health of operators. The wastewater treatment system collects and treats the water used for dust suppression, with the treated water reused for dust suppression, realizing zero discharge of wastewater and saving water resources.

4.5 Cost-Effective and High Return on Investment

Compared with traditional fixed crushing plants, the NK portable crusher plant has significant cost advantages. Firstly, the upfront investment of the mobile crushing line is 40% lower than that of a fixed plant of the same capacity, as it does not require extensive civil engineering such as foundation construction. Secondly, the mobile line’s mobility reduces the transportation cost of raw ore by 50%, as the equipment can be deployed directly at the mining site, eliminating the need to transport large raw ore to a fixed plant. Thirdly, the intelligent control system and high equipment reliability reduce labor costs by 30% and maintenance costs by 25%, respectively.

5. Project Operation Results and Client Benefits

Since its commissioning, the dolomite crushing line equipped with NK portable crusher plants has maintained stable operation for a long period, bringing significant economic and social benefits to the client. The key operation results are summarized as follows:

• Production Efficiency: The actual production capacity of the line is significantly higher than the client’s previous fixed crushing equipment, enabling the client to achieve high annual output of high-quality dolomite aggregates and fully meet the supply needs of major local construction projects.
• Product Quality: The final dolomite aggregates feature uniform particle size and excellent physical properties, fully complying with the quality standards for high-grade concrete and road base materials. The product qualification rate has been greatly improved, helping the client gain a distinct competitive advantage in the market, boost product sales and increase product value.
• Operational Costs: The line effectively reduces unit energy consumption, labor costs and maintenance costs. The significant annual cost savings have greatly improved the client’s profitability.
• Environmental Performance: The dust and noise levels at the operation site are well-controlled, fully meeting local environmental protection regulations. The client successfully passed environmental inspections with excellent results, avoiding potential environmental risks and enhancing its corporate image in terms of environmental responsibility.
• Mobility and Flexibility: The mobile crushing line can be quickly relocated to different mining sites, significantly improving the utilization rate of raw ore resources. It also enables the client to develop new mining areas that were previously inaccessible with fixed crushing equipment, further expanding its business scope and market share.

The client’s project manager commented: “SBM’s NK portable crusher plant has comprehensively optimized our dolomite processing operations. Its outstanding mobility, operational efficiency and environmental performance have exceeded our expectations. The high-quality aggregates produced by the line have helped us secure contracts for multiple key infrastructure projects, and the cost savings have effectively enhanced our profitability. We are very satisfied with this cooperation and look forward to further collaboration with SBM on future projects.”

6. Application Prospects of NK Portable Crusher Plant in Malaysia’s Mining Industry

Malaysia’s mining industry, including dolomite, limestone, granite, and iron ore mining, is poised for significant growth driven by the country’s infrastructure development and industrialization. The challenges of scattered mining sites, complex terrain, and strict environmental regulations make mobile crushing solutions an ideal choice for Malaysian mining enterprises. SBM’s NK portable crusher plant, with its superior performance and tailored solutions, has broad application prospects in Malaysia’s mining industry.

In addition to dolomite, the NK portable crusher plant can also be used for crushing other minerals such as limestone, granite, and basalt, as well as construction waste recycling. Its modular design allows for flexible configuration according to different mineral characteristics and production requirements, providing customized solutions for various applications. With the continuous advancement of intelligent and environmental protection technologies, SBM will continue to optimize the NK series portable crusher plants, enhancing their performance, reducing energy consumption, and improving user experience, to better serve the needs of the Malaysian mining industry and contribute to the country’s sustainable development.