crushing and screening plant

Project Scale: Single-line capacity from 50 to 300 tons/hour, finished product size adjustable from 0 to 31.5mm, supporting simultaneous three-way output of coarse aggregate, fine aggregate, and manufactured sand. Fully integrated modular process combining jaw crusher + cone crusher + impact sand maker + vibrating screen.

Application Scenarios: High-performance asphalt concrete aggregate for highways and airport runways; railway ballast; bridge concrete aggregates; cast stone and process stone raw materials for construction; specialty industrial diabase powder raw materials (chemical bonding powder, melt-spun fibers).

Core Pain Points: Diabase with Mohs hardness of 6-7 causes extreme wear on conventional crushers, resulting in high downtime and replacement costs; traditional single-stage crushing has low efficiency, poor finished particle shape, and high flakiness index, failing to capture the premium value of high-end aggregates; discontinuous aggregate gradation fails to meet highway/airport runway mix design requirements; dust and waste treatment non-compliance poses environmental rectification risks.

Solution Highlights: Lamination crushing + rock-on-rock shaping process improves efficiency by 35%-55% over traditional equipment, producing well-rounded particles with continuous gradation and qualification rate ≥95%; jaw + cone + impact three-stage combination specifically designed for high-hardness diabase, offering large reduction ratio and low wear; coarse/fine aggregate and manufactured sand three-way output meets multi-scenario raw material needs for highways, railways, and building materials in one line; closed-circuit process minimizes dust and waste spillage, meeting green mining environmental standards.

Blasting feed → surge bin uniform feeding → jaw primary crushing (large diabase lumps primary reduction) → vibrating pre-screening → cone secondary/fine crushing (oversize material >40mm recirculated for re-crushing) → impact sand maker shaping (material <40mm enters shaping stage) → finished product vibrating screening (0-5mm/5-10mm/10-20mm/20-31.5mm classification) → optional washing stage (producing clean aggregate) → compartment storage and discharge

Node Descriptions: Lamination crushing principle is applied at both jaw and cone crushing stages, enabling inter-particle breakage and reducing metal wear; impact sand maker with rock-on-rock shaping ensures well-rounded finished particles with significantly reduced flakiness index; >40mm oversize material automatically returns to cone crusher for re-crushing, eliminating under-crushed waste; closed-circuit design prevents dust and waste spillage for full compliance; washing stage is optional, meeting strict clay content requirements for concrete and pavement aggregate standards.

 

Scheme Design: Based on diabase hardness parameters, target size requirements, and capacity scale, provide full-line configuration plans including jaw + cone + impact, process flow diagrams, and finished product gradation analysis reports, delivered within ≤5 working days.

Equipment Manufacturing: Full-line modular manufacturing, with crushing chambers and wear parts reinforced for high-hardness diabase conditions; 100% full-machine testing before delivery to ensure component matching under high-hardness operating conditions.

Installation & Commissioning: Resident engineers for full on-site installation and commissioning, including three-stage closed-circuit system integration, vibrating screen parameter calibration, and operation training, ensuring finished product size qualification rate is achieved on first commissioning.

Operation & Maintenance Outsourcing: Remote real-time data monitoring, online fault alerts, quarterly technical inspections; wear parts for high-hardness conditions are prioritized for rapid replenishment, minimizing unplanned downtime impact on aggregate supply chains.

Ethiopia · Addis Ababa Highway Diabase Aggregate Project (2024)

Client Addis Infrastructure Group is a major highway infrastructure general contractor in Ethiopia, undertaking the Addis Ababa–Dire Dawa highway project. The project specifications required high-performance asphalt concrete aggregates, with diabase raw material sourced from a local quarry (Mohs hardness 6.5). The existing single-stage crushing line produced finished product with flakiness index exceeding 20%, failing to meet highway mix design requirements. Adopted Zhongyu Dingli's EPC turnkey solution with jaw + cone + impact shaping, completing delivery in 22 days and installation/commissioning in 20 days. Since commissioning, it has been running continuously and stably: finished aggregate qualification rate of 96.8%, flakiness index ≤5%, passing both Ethiopian Ministry of Transport and ASTM international aggregate standards; rock-on-rock shaping produced well-rounded diabase aggregate, with the asphalt concrete mix design passing acceptance on first submission; closed-circuit process dust emissions passed local environmental inspections; diabase fine powder simultaneously recovered for subgrade stabilization fill, achieving waste utilization rate over 90%.

Client Feedback: "Diabase is too hard – our previous crushers just couldn't handle it. Switching to the three-stage combination with shaping machine, the particle shape fully meets highway requirements, and the dust control also helped us pass environmental inspections smoothly."

 

Q1: With diabase being so hard, how is crusher wear controlled?

Jaw plates and cone mantle liners are made of high-manganese wear-resistant alloy specifically for high-hardness diabase conditions; impact crusher blow bars use composite wear-resistant materials. Wear life is extended by approximately 40% compared to standard configurations, with spare parts supply within ≤7 days.

Q2: Can the finished product size of 0-31.5mm be adjusted to meet different project requirements?

Screen specifications are flexibly configurable, covering 0-5mm/5-10mm/10-20mm/20-31.5mm multiple size fractions diabase crushing production line. Screen gradation combinations are customized during the scheme design phase based on target project mix design standards.

Q3: Can the diabase aggregate line simultaneously meet both highway aggregate and railway ballast specifications?

The three-way separate storage system can simultaneously produce size fractions required for both highway aggregate and railway ballast by adjusting vibrating screen combinations, eliminating the need for two separate lines.

Q4: Is the washing stage mandatory?

The washing stage is optional. It is recommended for high-end concrete aggregates with clay content requirements ≤0.5% diabase sand making machine. For standard highway aggregate and railway ballast, the washing stage can be omitted to reduce overall investment.

Q5: How is diabase waste (stone powder) handled?

Diabase stone powder can be recovered for subgrade stabilization fill, chemical bonding powder raw materials, high efficiency diabase processing or melt-spun diabase fiber production. Comprehensive waste utilization rate can exceed 90%, achieving zero off-site waste disposal and reducing treatment costs.

 

Need a dedicated aggregate crushing solution for your diabase mine? Tell us your raw material hardness parameters, finished product size requirements, and target capacity, and we will provide customized configuration recommendations and ROI analysis within 24 hours.