Sand and Gravel Aggregate Production Line

Africa Cobblestone Sand Making Line 10Mtpa Turnkey Solution High Wear Optimization EPC Delivery

1. Project Overview

10 Million Tons Per Annum Cobblestone Sand Making Line for Africa

Designed for the unique challenges of cobblestone processing in African mining environments, Zhongyu Dingli delivers a fully integrated 10Mt/a sand making solution. Cobblestone's high hardness (Mohs 7) and silica content cause rapid equipment wear, poor particle shape, and unstable output at large capacity — this line eliminates all three pain points in a single closed-loop system.

Project Scale

• Annual Output: 10Mt/a (1,250–1,300 TPH continuous operation)
• Capacity Fluctuation: ≤4%, supporting 24/7 high-intensity operation
• Comprehensive Power Consumption: 2.0–2.5 kWh/t (15% below industry average)

Application Scenario Large-scale cobblestone quarries, aggregate plants, commercial concrete mixing stations, and infrastructure projects across Africa — where hard-rock processing, dust control, and water conservation are critical operational requirements.

Core Pain Points Solved

Solution Highlights

• Cobblestone-specific three-stage process: Primary Crushing → Fine Crushing → Impact Sand Making & Shaping
• Closed-loop zero-waste design with intelligent PLC control
• Dust collection ≥99%, emission <20mg/m³; water recycling ≥90%
• Full EPC turnkey delivery with local African after-sales support

2. Process Flow

Customized Cobblestone Three-Stage Crushing & Sand Making Process

Raw cobblestone is fed through heavy-duty Vibrating Feeders into Jaw Crushers for primary reduction, then processed by Hydraulic Cone Crushers for secondary fine crushing. Classified by multi-deck Vibrating Screens into 0–5mm, 5–10mm, and 10–20mm fractions, the fine material enters VSI Sand Makers for impact shaping, while oversized material returns automatically to crushers for reprocessing. Finished sand undergoes final screening and optional washing before output — forming a fully closed-loop, zero-waste production circuit.

3. EPC Service Content

From Site Survey to Full Operation — Single-Source Responsibility

① Solution Design

• Raw material grading analysis & cobblestone hardness testing
• Process flowchart & plant layout optimization for African site conditions
• Environmental compliance assessment for local mining regulations

② Equipment Manufacturing

• Complete equipment package: Jaw Crushers ×2, Cone Crushers ×3, VSI Sand Makers ×4, Vibrating Feeders ×4, Vibrating Screens ×6, plus conveyor and optional Mobile Crusher
• ISO-certified manufacturing with factory acceptance testing before shipment

③ Installation & Commissioning

• On-site installation supervision by certified engineers
• Trial run with raw cobblestone; performance guarantee testing
• Operator training program (on-site, 5–7 days)

④ Operations & Maintenance Support

• Spare parts warehouse setup on-site
• Annual maintenance contracts available
• Local service partner network across major African mining regions

4. Project Cases & Data

Real-World Performance — Africa Cobblestone Sand Making Plant

Project: 10Mt/a Cobblestone Sand Making Line — East Africa Customer Profile: Regional aggregate supplier serving national road construction and urban development Completion: Full EPC delivery, commissioned within 10 months

Production Data (Post-Commissioning)

Customer Feedback

"The wear-resistant linings lasted far longer than our previous equipment. We achieved stable 1,300 TPH output from month one, and the cubic-shaped sand directly meets national infrastructure grade standards without further processing." — Operations Director, East Africa Aggregate Group

5. FAQ

Q1: How does this line handle cobblestone's extreme hardness (Mohs 7) and high silica wear issues? The line is cobblestone-specific from design to wear parts. Heavy-duty Jaw Crushers and Cone Crushers are equipped with Zhongyu Dingli's proprietary NM500 wear-resistant linings and reinforced rotors, extending wear part life by 2.5×. The VSI Sand Makers adopt dual "stone-on-stone" and "stone-on-iron" technology, which both optimizes particle shape and distributes impact forces to reduce rotor wear — specifically engineered for high-silica, hard-rock materials.

Q2: Can the line maintain stable 10Mt/a output in Africa's remote, high-temperature environments? Yes. The configuration is sized with headroom for harsh conditions — total power 1,800–2,000 kW with optimized energy efficiency at 2.0–2.5 kWh/t. The closed-loop design with 4 large-capacity feeders and 6 multi-deck screens ensures continuous uniform material flow. The PLC intelligent control system supports real-time load monitoring and fault self-diagnosis, enabling 24/7 operation even in remote locations with limited on-site technical staff.

Q3: What environmental and after-sales support is available for African projects? The line meets global environmental standards: pulse dust collectors achieve ≥99% collection with emission <20mg/m³, and the circulating water system achieves ≥90% reuse. Zhongyu Dingli maintains local service partnerships across major African mining regions, providing on-site response, spare parts supply, and annual maintenance contracts. Remote IoT monitoring is also available for sites with limited technical personnel.