Steel Structure Sand and Aggregate Production Line

1. Project Overview

Zhongyu Dingli 7Mt/a High-Calcium Limestone Crushing Production Line — EPC Turnkey for Ultra-Large-Scale Aggregate Output

This 7 million tons per annum sand and gravel processing line is a full EPC turnkey project delivered by Zhongyu Dingli, with a total investment of 230 million RMB. Designed specifically for high-calcium limestone — a material widely used in construction, cement, and chemical industries — the line achieves 1,500–1,900 TPH hourly output and 7Mt/a annual production of multi-spec aggregates, combining Jaw Crusher and Hammer Crusher in an integrated, compact layout.

Project Scale

• Annual Output: 7Mt/a (7 million tons per annum)
• Hourly Output: 1,500–1,900 TPH
• Total Investment: 230 million RMB
• Processing Material: High-Calcium Limestone
• End Products: Sand and gravel aggregates of various specifications

Application Scenario High-calcium limestone quarries, ultra-large aggregate plants, cement raw material supply bases, and chemical-grade calcium powder production — where massive continuous output, product diversity, and strict environmental compliance are simultaneously required.

Core Pain Points Solved

Solution Highlights

• Jaw Crusher + Hammer Crusher integrated scheme — dual crushing in a compact structure
• Complete intelligent control system: 6 subsystems from procurement to cloud monitoring
• Full green operation: closed workshops, dust removal, atomizing sprinklers, noise reduction
• 230 million RMB total EPC investment — single-source responsibility from design to commissioning

2. Process Flow

Jaw-Hammer Integrated Crushing with Closed-Loop Multi-Spec Screening

Raw high-calcium limestone is fed into a Jaw Crusher for primary coarse reduction, then directed to a Hammer Crusher for secondary fine crushing and shaping in a single pass. The integrated Jaw-Hammer design eliminates redundant intermediate crushing stages, producing a compact production line with rational layout. Crushed material enters multi-deck Vibrating Screens for precision grading into various sand and gravel aggregate specifications. Unqualified oversized material is automatically returned to the Hammer Crusher for reprocessing, forming a closed-loop circuit that ensures zero waste and stable 1,500–1,900 TPH output.

3. EPC Service Content

230 Million RMB EPC Turnkey — From Blueprint to Full Operation

① Solution Design

• Raw material chemical analysis (CaCO₃ content, hardness, impurity profile)
• Jaw-Hammer integrated process optimization for high-calcium limestone characteristics
• Compact plant layout design with rational equipment positioning
• Environmental compliance blueprint for closed workshop and dust removal systems

② Equipment Manufacturing

• Core package: Jaw Crusher, Hammer Crusher, Vibrating Screens, Feeders, Conveyor Systems
• Intelligent control system package: Purchase & Sales Management System, Automatic Loading System, Automatic Material Receiving System, Mining Production Management System, Cloud Monitoring System, Low-Voltage Distribution System
• Full closed workshop construction materials and dust removal equipment
• ISO-certified manufacturing with factory acceptance testing

③ Installation & Commissioning

• Complete plant installation including civil works, equipment, electrical, and intelligent systems
• Closed workshop construction and environmental system setup
• Cloud monitoring platform deployment and system integration testing
• Full-line trial run with raw limestone; performance guarantee at 7Mt/a
• Comprehensive operator and management team training

④ Operations & Maintenance Support

• Cloud-based remote monitoring for real-time production oversight
• Intelligent system software updates and maintenance
• Spare parts supply and annual maintenance contracts
• Long-term O&M service available for mega-scale operations

4. Project Cases & Data

Real-World Performance — 7Mt/a High-Calcium Limestone EPC Project

Project: 7Mt/a High-Calcium Limestone Sand & Gravel Processing Line Delivery Model: Full EPC turnkey by Zhongyu Dingli Total Investment: 230 million RMB Configuration: Jaw Crusher + Hammer Crusher integrated scheme

Production Data (Post-Commissioning)

Project Features

• Intelligentization: Fully equipped with 6 integrated intelligent subsystems — Purchase & Sales Management, Automatic Loading, Automatic Material Receiving, Mining Production Management, Cloud Monitoring, and Low-Voltage Distribution — enabling data-driven, hands-off production management.
• Green Operation: Closed workshops, dust removal equipment, atomizing sprinkler systems, and sound insulation measures fully meet environmental protection requirements for ultra-large-scale limestone operations.

Customer Feedback

"Zhongyu Dingli delivered the entire line — from civil design to cloud system deployment — under one contract. The intelligent management system transformed our operation: real-time production data, automated loading, and zero environmental compliance issues from day one." — General Manager, High-Calcium Limestone Aggregate Group

5. FAQ

Q1: What makes the Jaw-Hammer integrated design more efficient than traditional multi-stage crushing for high-calcium limestone?

High-calcium limestone is relatively soft (Mohs 3–4) and easy to crush. Traditional lines often use 3–4 separate crushing stages, increasing equipment count, floor space, and CAPEX. Our Jaw-Hammer integrated scheme uses the Jaw Crusher for primary coarse reduction and the Hammer Crusher for simultaneous fine crushing and shaping — achieving equivalent or better output quality in a single compact line. This reduces equipment investment, shortens the production line by approximately one crushing stage, and simplifies daily operation and maintenance.

Q2: How does the intelligent control system improve operations at this scale?

At 7Mt/a scale, manual management becomes impractical. The 6 intelligent subsystems cover the full operational chain: Mining Production Management schedules crusher output and screen settings; Automatic Loading controls truck dispatch and weighing without manual intervention; Automatic Material Receiving tracks inbound raw material; Purchase & Sales Management links production data to commercial transactions; Cloud Monitoring provides real-time equipment health and production metrics from any location; and Low-Voltage Distribution optimizes energy allocation across the line. Together, these systems reduce management labor by over 50% and eliminate data gaps between production and business operations.

Q3: How does the line meet environmental requirements for ultra-large-scale limestone operations?

The entire production line operates inside fully closed workshops, preventing dust and noise from escaping the plant boundary. Inside, pulse dust collectors and atomizing sprinkler systems achieve dust emission below 15mg/m³. Sound insulation measures reduce noise to ≤65dB at the workshop perimeter. All systems are designed to meet or exceed Chinese national environmental standards for mining operations, and the configuration can be adapted to comply with international standards (EU, ASEAN, etc.) for projects in other regions.