Technological Process
Crushing & Screening Plant Technological Process
In order to realize the large-scale production and processing of various minerals, a crushing and screening production system composed of different modules such as feeding, crushing, conveying, screening, storage, and electrical came into being. We combine industry-leading crushing, screening solutions and bulk ore sorting technology to provide customers with overall open pit mining solutions that can minimize mine operating costs and increase productivity.
Feeding and primary crushing
The materials are directly unloaded into the hopper by dump trucks, or unloaded into the hopper by bulldozers or loaders, and then evenly transported to the primary mineral sizer by apron feeder, which crushes the large materials(800mm-1500mm) into medium sizes(250mm-500mm).
Screening and secondary crushing
After being crushed by the primary mineral sizer, the medium sized materials are conveyed to the banana screen or roller screen through the belt conveyor for screening.
After screening, the finished products that meet the requirements are directly conveyed to the storage yard or other downstream equipments by the main belt conveyor. The medium sized materials will flow directly into the secondary mineral sizer through the chute to be crushed to the finished product(30-100mm)that meet the requirements, and then conveyed to the storage yard or other downstream equipments by the main belt conveyor.
The materials are directly unloaded into the hopper by dump trucks, or unloaded into the hopper by bulldozers or loaders, and then evenly transported to the primary mineral sizer by apron feeder, which crushes the large materials(800mm-1500mm) into medium sizes(250mm-500mm).
Screening and secondary crushing
After being crushed by the primary mineral sizer, the medium sized materials are conveyed to the banana screen or roller screen through the belt conveyor for screening.
After screening, the finished products that meet the requirements are directly conveyed to the storage yard or other downstream equipments by the main belt conveyor. The medium sized materials will flow directly into the secondary mineral sizer through the chute to be crushed to the finished product(30-100mm)that meet the requirements, and then conveyed to the storage yard or other downstream equipments by the main belt conveyor.
360 Display
Crushing & Screening Plant 360 Display
The open-pit mine crushing and screening plant consists of crushing part, screening part and conveying part.
Apron Feeder
Apron Feeder
Apron Feeders are a reliable feeding method used to feed a wide variety of applications. It is suitable for heavy loads and high impact materials and delivers the material at a uniform rate to achieve optimal feeding of downstream equipment.
Apron feeders are suitable for conveying lumpy, abrasive, heavy, high temperature materials such as mining, quarrying, coal, cement and other mineral processing applications.
Apron feeders are suitable for conveying lumpy, abrasive, heavy, high temperature materials such as mining, quarrying, coal, cement and other mineral processing applications.
Primary Mineral Sizer
Primary Mineral Sizer
Mineral sizer is a modern approach to crushing that uses shear force and tensile force between the toothed rollers to crush materials, which is the best choice for handling hard, wet, sticky materials.
The feeding granularity of primary mineral sizer is less than or equal to 1500mm and the discharging granularity is less than 300mm. The unique tooth alloy formulation is sufficient to breaker materials ranging from soft coal (30mpa) to hard granite (250MPa).
The feeding granularity of primary mineral sizer is less than or equal to 1500mm and the discharging granularity is less than 300mm. The unique tooth alloy formulation is sufficient to breaker materials ranging from soft coal (30mpa) to hard granite (250MPa).
Banana Screen
Banana Screen
Banana screen is called multi-angle screen or multi-slope screen, adopts banana-shaped multi-section screen deck technology, each layer of the scree has a relatively large throughput, which can achieve special throughput in a relatively small screening area.
It can be designed as single, double and triple deck structure according to the demand, and there are also a variety of screen panels available to meet the screening needs of different customers.
Banana screen with high screening efficiency and high throughput, which is mainly used in coal, mining operations, aggregate production, metallurgy, transportation, and electric power industries, for classification, dewatering, desliming and screen medium of various medium and fine materials.
It can be designed as single, double and triple deck structure according to the demand, and there are also a variety of screen panels available to meet the screening needs of different customers.
Banana screen with high screening efficiency and high throughput, which is mainly used in coal, mining operations, aggregate production, metallurgy, transportation, and electric power industries, for classification, dewatering, desliming and screen medium of various medium and fine materials.
Roller Screen
Roller Screen
Roller screens, also known as wobble feeders and disc screens, are very suitable for bulk materials that are difficult to screen, including wet and sticky materials.
Compared to traditional vibrating screens, roller screens are less prone to clogging and can guarantee both throughput and screening results. With its outstanding advantages, our roller screen is widely used in coal, mining, metallurgy, chemical industry, sand aggregate and other industries.
Compared to traditional vibrating screens, roller screens are less prone to clogging and can guarantee both throughput and screening results. With its outstanding advantages, our roller screen is widely used in coal, mining, metallurgy, chemical industry, sand aggregate and other industries.
Secondary Mineral Sizer
Secondary Mineral Sizer
Mineral sizer is a modern approach to crushing that uses shear force and tensile force between the toothed rollers to crush materials, which is the best choice for handling hard, wet, sticky materials.
The feeding granularity of primary mineral sizer is less than or equal to 1500mm and the discharging granularity is less than 300mm. The unique tooth alloy formulation is sufficient to breaker materials ranging from soft coal (30mpa) to hard granite (250MPa).
The feeding granularity of primary mineral sizer is less than or equal to 1500mm and the discharging granularity is less than 300mm. The unique tooth alloy formulation is sufficient to breaker materials ranging from soft coal (30mpa) to hard granite (250MPa).
Belt Conveyor
Belt Conveyor
The belt conveyor is one of the best options for bulk materials handling equipment .It can continuously transport materials from one place to another place.
Belt conveyors form the backbone of many operations and are used in the mining, mineral processing, metallurgy, port, cement, grain, chemical and power generation industries to receive/unload, store, recycle and transport various material types within the plant.
Belt conveyors form the backbone of many operations and are used in the mining, mineral processing, metallurgy, port, cement, grain, chemical and power generation industries to receive/unload, store, recycle and transport various material types within the plant.
Features and Benefits
Crushing & Screening Plant Features
We provide customized crushing, screening and conveying solutions to open pit mines around the world, improving resource availability, productivity and energy efficiency in mining operations.
Tailored Design
EXCT provides customizable open pit crushing and screening solutions to meet your operational needs.
We can customize the most scientific, reasonable and economical crushing and screening station integrated solutions for customers based on comprehensive considerations such as material characteristics, production capacity requirements, working conditions and other factors.
The feeding module can choose a heavy-duty apron feeder or a heavy-duty chain feeder. The crushing module can be a Mineral Sizer or a Feeder Breaker. The screening module can choose Banana Screen, Roller Screen or Inclined Screen.
The feeding module can choose a heavy-duty apron feeder or a heavy-duty chain feeder. The crushing module can be a Mineral Sizer or a Feeder Breaker. The screening module can choose Banana Screen, Roller Screen or Inclined Screen.
Reliable Performance Components
Each piece of equipment that makes up the crushing and screening station has high reliability and durable quality.
Each of our equipment has undergone scientific selection, careful design, high-precision processing, and is equipped with high-quality components from internationally well-known brands such as Siemens and SEW, ensuring the high reliability of the equipment. It can ensure the normal function of the equipment under the harshest conditions, avoid maintenance downtime, and ensure long-term stable operation.
Simple Construction
A single piece of equipment is delivered to the site in the form of complete machine, which can be assembled and debugging faster, shortening the construction cycle.
Each equipment of our Open-pit mine crushing and screening station is delivered to the site in the form of complete machine equipment, which can be assembled and Commissioning faster and more convenient, which can shorten the construction time and reduce the construction cost, and put the project into operation as soon as possible.
The design of the crushing and screening station is scientific and reasonable, and the characteristics of the equipment are fully considered, which makes the connection between the various equipment contained in the crushing station simpler and the overall efficiency higher.
The design of the crushing and screening station is scientific and reasonable, and the characteristics of the equipment are fully considered, which makes the connection between the various equipment contained in the crushing station simpler and the overall efficiency higher.
High Degree of Automation
Through the intelligent control system and a variety of equipment to achieve the interlocking function, ensure the optimal overall performance of the crushing and screening station.
The feeding module adopts frequency conversion adjustment to accurately control the feeding speed. The crushing and screening station is equipped with a complete intelligent electrical system, remote monitoring system, etc., which can monitor the production status and fault hazards of each equipment in real time, realize unattended production during the production process, and achieve targeted and precise maintenance during daily maintenance, thereby improving efficiency and significantly reducing worker labor intensity.
Easy to Inspect and Maintain
Each machine has high reliability and excellent maintainability, ensuring normal operation of the operation.
The overall total of the crushing and screening station is reasonable, and the layout of various auxiliary facilities is reasonable, making it convenient for maintenance personnel to carry out inspection and maintenance.
The modular design facilitates timely and rapid replacement of parts, reducing downtime and maintenance costs.
The modular design facilitates timely and rapid replacement of parts, reducing downtime and maintenance costs.
Environmental Friendly
The entire crushing and screening station adopts a closed design to avoid material leakage and improve overall economic benefits.
The crushing and screening station is equipped with a dust removal system, which is arranged in the crushing chamber where dust is easily generated and at key nodes for material transfer. It can effectively prevent dust pollution, reduce the impact on the environment, and meet the requirements of green construction.
Talk with our Technical Engineer
Submit your requirements and Talk with one of our Technical Engineer about your project.
Service Process
Crushing & Screening Plant Service Process
From customers' project requirements to project operation, we tailor a full range of services for your project to maintain efficient operation of the project and achieve maximum economic benefits.
Specifications Configuration
Crushing & Screening Plant Specifications Configuration
We are customized for each application material to provide the best configuration and meet all your requirements.
Notes: Configuration information is typical values for reference. Please contact our technical engineers for more assistance with equipment selection.
800t/h Coal Crushing Station
1000t/h Coal Crushing Station
1200t/h Coal Crushing Station
1500t/h Coal Crushing Station
2000t/h Coal Crushing Station
2500t/h Coal Crushing Station
3000t/h Coal Crushing Station
800t/h Coal Crushing Station | |||
Item | Equipment Name | Specification | Value |
1 | Hopper | Volume | 100m³ |
Length x Width x Height | 6m*6m*5.8m | ||
2 | Apron Feeder | Equipment Model | BL1400-9M |
Max. Allowed Feed Size | 750mm | ||
C/C Distance | 9000mm | ||
Pan Width | 1400mm | ||
Chain Speed | 0.25m/s | ||
Power | 75kw | ||
3 | Primary Mineral Sizer | Equipment Model | 2PLF100200 |
Crusher Roller Diameter | 1000mm | ||
Crusher Roller Length | 2000mm | ||
Feed Size | ≤750mm | ||
Discharge Size | ≤250mm | ||
Roller Rotate Speed | 54r/min | ||
Equipment Power | 132kw*2 | ||
4 | Secondary Mineral Sizer | Equipment Model | 2PLF100250 |
Crusher Roller Diameter | 1000mm | ||
Crusher Roller Length | 2500mm | ||
Feed Size | ≤250mm | ||
Discharge Size | ≤50mm | ||
Roller Rotate Speed | 66r/min | ||
Equipment Power | 132kw*2 | ||
5 | Belt Conveyor | Model | B1200-45m |
Handling Capacity | 800t/h | ||
Belt Width | 1200mm | ||
Belt Speed | 1.6m/s | ||
Belt Conveyor Length | 45m | ||
6 | Banana Screen | Model | ZXF2461 |
Screen Surface Width | 2400mm | ||
Screen Surface Length | 6100mm | ||
Layer | 2 | ||
Mesh Open Size | 150/50 | ||
Power | 37kw |
1000t/h Coal Crushing Station | |||
Item | Equipment Name | Specification | Value |
1 | Hopper | Volume | 120m³ |
Length x Width x Height | 6m*7m*6m | ||
2 | Apron Feeder | Equipment Model | BL1600-10M |
Max. Allowed Feed Size | 800mm | ||
C/C Distance | 10000mm | ||
Pan Width | 1600mm | ||
Chain Speed | 0.25m/s | ||
Power | 90kw | ||
3 | Primary Mineral Sizer | Equipment Model | 2PLF120200 |
Crusher Roller Diameter | 1200mm | ||
Crusher Roller Length | 2000mm | ||
Feed Size | ≤800mm | ||
Discharge Size | ≤300mm | ||
Roller Rotate Speed | 66r/min | ||
Equipment Power | 160kw*2 | ||
4 | Secondary Mineral Sizer | Equipment Model | 2PLF100300 |
Crusher Roller Diameter | 1000mm | ||
Crusher Roller Length | 3000mm | ||
Feed Size | ≤300mm | ||
Discharge Size | ≤50mm | ||
Roller Rotate Speed | 74r/min | ||
Equipment Power | 160kw*2 | ||
5 | Belt Conveyor | Model | B1400-55m |
Handling Capacity | 1000t/h | ||
Belt Width | 1400mm | ||
Belt Speed | 1.6m/s | ||
Belt Conveyor Length | 55m | ||
6 | Banana Screen | Model | ZXF3061 |
Screen Surface Width | 3000mm | ||
Screen Surface Length | 6100mm | ||
Layer | 2 | ||
Mesh Open Size | 150/50 | ||
Power | 55kw |
1200t/h Coal Crushing Station | |||
Item | Equipment Name | Specification | Value |
1 | Hopper | Volume | 150m³ |
Length x Width x Height | 8m*8m*6m | ||
2 | Apron Feeder | Equipment Model | BL1800-12M |
Max. Allowed Feed Size | 950mm | ||
C/C Distance | 12000mm | ||
Pan Width | 1800mm | ||
Chain Speed | 0.25m/s | ||
Power | 110kw | ||
3 | Primary Mineral Sizer | Equipment Model | 2PLF120250 |
Crusher Roller Diameter | 1200mm | ||
Crusher Roller Length | 2500mm | ||
Feed Size | ≤950mm | ||
Discharge Size | ≤300mm | ||
Roller Rotate Speed | 74r/min | ||
Equipment Power | 200kw*2 | ||
4 | Secondary Mineral Sizer | Equipment Model | 2PLF100350 |
Crusher Roller Diameter | 1000mm | ||
Crusher Roller Length | 3500mm | ||
Feed Size | ≤300mm | ||
Discharge Size | ≤75mm | ||
Roller Rotate Speed | 66r/min | ||
Equipment Power | 160kw*2 | ||
5 | Belt Conveyor | Model | B1400-55m |
Handling Capacity | 1200t/h | ||
Belt Width | 1400mm | ||
Belt Speed | 2m/s | ||
Belt Conveyor Length | 55m | ||
6 | Banana Screen | Model | ZXF3673 |
Screen Surface Width | 3600mm | ||
Screen Surface Length | 7300mm | ||
Layer | 2 | ||
Mesh Open Size | 150/75 | ||
Power | 75kw |
1500t/h Coal Crushing Station | |||
Item | Equipment Name | Specification | Value |
1 | Hopper | Volume | 200m³ |
Length x Width x Height | 9m*8m*6m | ||
2 | Apron Feeder | Equipment Model | BL2000-12M |
Max. Allowed Feed Size | 1000mm | ||
C/C Distance | 12000mm | ||
Pan Width | 2000mm | ||
Chain Speed | 0.25m/s | ||
Power | 160kw | ||
3 | Primary Mineral Sizer | Equipment Model | 2PLF120300 |
Crusher Roller Diameter | 1200mm | ||
Crusher Roller Length | 3000mm | ||
Feed Size | ≤1000mm | ||
Discharge Size | ≤300mm | ||
Roller Rotate Speed | 66r/min | ||
Equipment Power | 250kw*2 | ||
4 | Secondary Mineral Sizer | Equipment Model | 2PLF120300 |
Crusher Roller Diameter | 1200mm | ||
Crusher Roller Length | 3000mm | ||
Feed Size | ≤300mm | ||
Discharge Size | ≤100mm | ||
Roller Rotate Speed | 66r/min | ||
Equipment Power | 200kw*2 | ||
5 | Belt Conveyor | Model | B1600-75m |
Handling Capacity | 1500t/h | ||
Belt Width | 1600mm | ||
Belt Speed | 1.6m/s | ||
Belt Conveyor Length | 75m | ||
6 | Roller Screen | Model | GZS1618 |
Screen Surface Width | 1600 | ||
Screen Shaft Quantity | 18 | ||
Mesh Open Size(space) | 50 | ||
Power | 15KW*4 |
2000t/h Coal Crushing Station | |||
Item | Equipment Name | Specification | Value |
1 | Hopper | Volume | 300m³ |
Length x Width x Height | 9m*9m*6.5m | ||
2 | Apron Feeder | Equipment Model | BL2200-14M |
Max. Allowed Feed Size | 1200mm | ||
C/C Distance | 14000mm | ||
Pan Width | 2200mm | ||
Chain Speed | 0.28m/s | ||
Power | 110kw*2 | ||
3 | Primary Mineral Sizer | Equipment Model | 2PLF120350 |
Crusher Roller Diameter | 1200mm | ||
Crusher Roller Length | 3500mm | ||
Feed Size | ≤1200mm | ||
Discharge Size | ≤350mm | ||
Roller Rotate Speed | 74r/min | ||
Equipment Power | 315kw*2 | ||
4 | Secondary Mineral Sizer | Equipment Model | 2PLF120400 |
Crusher Roller Diameter | 1200mm | ||
Crusher Roller Length | 4000mm | ||
Feed Size | ≤350mm | ||
Discharge Size | ≤75mm | ||
Roller Rotate Speed | 66r/min | ||
Equipment Power | 315kw*2 | ||
5 | Belt Conveyor | Model | B1800-75m |
Handling Capacity | 2000t/h | ||
Belt Width | 1800mm | ||
Belt Speed | 2m/s | ||
Belt Conveyor Length | 75m | ||
6 | Roller Screen | Model | GZS2024 |
Screen Surface Width | 2000 | ||
Screen Shaft Quantity | 24 | ||
Mesh Open Size(space) | 50 | ||
Power | 22KW*4 |
2500t/h Coal Crushing Station | |||
Item | Equipment Name | Specification | Value |
1 | Hopper | Volume | 300m³ |
Length x Width x Height | 9m*9m*6.5m | ||
2 | Apron Feeder | Equipment Model | BL2400-14M |
Max. Allowed Feed Size | 1500mm | ||
C/C Distance | 14000mm | ||
Pan Width | 2400mm | ||
Chain Speed | 0.28m/s | ||
Power | 132kw*2 | ||
3 | Primary Mineral Sizer | Equipment Model | 2PLF150300 |
Crusher Roller Diameter | 1500mm | ||
Crusher Roller Length | 3000mm | ||
Feed Size | ≤1500mm | ||
Discharge Size | ≤350mm | ||
Roller Rotate Speed | 74r/min | ||
Equipment Power | 400kw*2 | ||
4 | Secondary Mineral Sizer | Equipment Model | 2PLF150300 |
Crusher Roller Diameter | 1500mm | ||
Crusher Roller Length | 3000mm | ||
Feed Size | ≤350mm | ||
Discharge Size | ≤75mm | ||
Roller Rotate Speed | 66r/min | ||
Equipment Power | 400kw*2 | ||
5 | Belt Conveyor | Model | B2000-75m |
Handling Capacity | 2500t/h | ||
Belt Width | 2000mm | ||
Belt Speed | 2m/s | ||
Belt Conveyor Length | 75m | ||
6 | Roller Screen | Model | GZS2224 |
Screen Surface Width | 2200 | ||
Screen Shaft Quantity | 24 | ||
Mesh Open Size(space) | 75 | ||
Power | 30KW*4 |
3000t/h Coal Crushing Station | |||
Item | Equipment Name | Specification | Value |
1 | Hopper | Volume | 400m³ |
Length x Width x Height | 12m*12m*6.5m | ||
2 | Apron Feeder | Equipment Model | BL2800-18M |
Max. Allowed Feed Size | 1500mm | ||
C/C Distance | 18000mm | ||
Pan Width | 2800mm | ||
Chain Speed | 0.28m/s | ||
Power | 160kw*2 | ||
3 | Primary Mineral Sizer | Equipment Model | 2PLF150400 |
Crusher Roller Diameter | 1500mm | ||
Crusher Roller Length | 4000mm | ||
Feed Size | ≤1500mm | ||
Discharge Size | ≤350mm | ||
Roller Rotate Speed | 74r/min | ||
Equipment Power | 500kw*2 | ||
4 | Secondary Mineral Sizer | Equipment Model | 2PLF150400 |
Crusher Roller Diameter | 1500mm | ||
Crusher Roller Length | 4000mm | ||
Feed Size | ≤350mm | ||
Discharge Size | ≤75mm | ||
Roller Rotate Speed | 66r/min | ||
Equipment Power | 500kw*2 | ||
5 | Belt Conveyor | Model | B2000-75m |
Handling Capacity | 3000t/h | ||
Belt Width | 2000mm | ||
Belt Speed | 2.5m/s | ||
Belt Conveyor Length | 75m | ||
6 | Roller Screen | Model | GZS2824 |
Screen Surface Width | 2800 | ||
Screen Shaft Quantity | 24 | ||
Mesh Open Size(space) | 75 | ||
Power | 37KW*4 |
Major Equipment
Crushing & Screening Plant Major Equipment
EXCT provides customizable open pit mine Crushing & Screening Plant to meet your operational needs. We offer industry-leading crushing, screening and material handling equipment.
Brochures
Crushing & Screening Plant Related Brochure Download
Here are some of our brochures about EXCT Crushing & Screening Plant and project cases for you.
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Spare Parts
Crushing & Screening Plant Auxiliary Equipment
We provide crushing and screening equipment for open pit mines, but we are also able to provide other auxiliary equipment depending on the application.
Cases
Crushing & Screening Plant Successfull Case
With high quality and perfect service, EXCT has won the support and trust of many customers at home and abroad.
Yiwu Guanghui Energy Development Co., Ltd Eastern Mining Area 1,200TPH Crushing Stations Project
Customer Name:Yiwu Guanghui Energy Development Co., Ltd
Equipment Name:Mineral Sizer, Apron Feeder, Inclined Screen, Belt Conveyor
Equipment Model:2PLF120/200, 2PLF90/300, BSJ1600*100000mm, B1400,B1200, B1400, 2YKH-3060
Handling Material:Coal
Handling Capacity:1,200tph
Input Size: ≤1300mm
Output Size:≤300mm, ≤50-150mm
Changji Xinlian Coal Chemical Industry and Trade Co., LTD 1,000TPH Coal Crusher Station Project
Customer Name:Urumqi Qi Hangyuan Trade Co., LTD
Equipment Name:Mineral Sizer, Apron Feeder, Inclined Screen, Belt Conveyor
Equipment Model:2PLF100/350, ZBWJ2400×16000, 2YKH-3061
Handling Material:Coal
Handling Capacity:1,000t/h
Input Size: ≤400mm
Output Size: ≤150mm
Xinjiang Jinneng Mining Co., LTD. Judong Coal Qitai County Heishan Coal Mine Phase I Feeder Project
Customer Name:Xinjiang Jinneng Mining Co., LTD
Equipment Name: Apron feeder
Equipment Model:ZBWJ2400*13500
Handling Material:Coal
Handling Capacity:2,000tph
Material Sizer: ≤1000mm
Fushun Mining Group Co.,Ltd 1500TPH Crushing Project of Oil Shale At West Coal Open Pit
Customer Name:Fushun Mining Group Co.,Ltd
Equipment Name:Primary Mineral Sizer
Equipment Model:2PLF120/200, 2PLF100/300
Handling Material:Oil Shale
Handling Capacity:1,500tph
Input Size: ≤1500mm
Output Size: ≤60mm
Xingsheng Open-pit Coal Mine 4500TPH Crushing Station Project
Customer Name:Xinjiang Jiangna Mining Industry Co.,Ltd
Equipment Name:Mineral Sizer, Apron Feeder, Roller Screen, Belt Conveyor
Equipment Model:2PLF150/300, ZBWJ2500*16000, GZS2500*5, B1800*21
Handling Material:Coal
Input Size: ≤1500mm
Output Size: <300mm
Northern Weijiamao Coal power Co., LTD. Open pit coal mine 4000TPH Coal Feeder System Project
Customer Name: Northern Weijiamao Coal power Co., LTD
Equipment Name: Apron Feeder
Equipment Model: ZBWJ2500*14000
Handling Material: Coal
Material Sizer: ≤1800mm
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