Multi-cylinder Cone Crusher

Project Scale: Annual production capacity of approximately 2.4 million metric tons per line, covering an area of 80 mu and including a 50,000-metric-ton storage silo. Modular pre-assembly and on-site installation take only 4 months, reducing construction time by 30% compared to traditional methods.

Application Scenarios: Aggregate supply for high-speed rail projects; capacity expansion and upgrades for large quarries; construction of 10-million-metric-ton-scale aggregate export bases; and smart upgrades and renovations of mining areas.

Core Challenges: Traditional assembly lines suffer from high failure rates, complex maintenance, and labor-intensive operations; segmented procurement results in significant markups and high investment costs; failure to meet environmental emission standards leads to rectification orders and production halts; and lengthy production line commissioning cycles cause missed market opportunities.

Solution Highlights: AI-powered Industrial Internet of Things (IIoT) provides real-time monitoring of 68 pieces of equipment, with a 97% accuracy rate for fault predictions; DCS intelligent central control enables one-button start/stop and scheduled lubrication, requiring only one operator; a three-tier environmental protection design (enclosed walkways + pulse dust collection + source-level spraying) keeps dust levels ≤10 mg/m³ and noise levels ≤75 dB; EPC costs reduced by 20%, energy consumption lowered to 65% of conventional production lines, with annual electricity savings exceeding 6 million yuan; 3 overseas bases with over 200 bilingual engineers available to arrive on-site within 48 hours.

Raw material intake - Intelligent feeding (AI real-time frequency adjustment) - Single-step crushing - High-efficiency vibrating screening - Three-tier environmental protection system (enclosed corridor + pulse dust collection + source spraying) - Finished Product Storage - Unattended Weighing and Discharge

Key Features: The AI-powered industrial internet adjusts the crushing frequency in real time based on raw material hardness; the single-step crushing process simplifies production by 40% and ensures a high finished product yield; the three-tier environmental protection system achieves dust levels ≤10 mg/m³ and noise levels ≤75 dB; the DCS central control system enables one-click start/stop and scheduled lubrication, with real-time monitoring of production capacity and energy consumption data via remote mobile devices; The unmanned weighing system ensures 100% data accuracy.

 

Solution Design: Raw material analysis + production capacity planning; provides a comprehensive smart configuration plan for the entire line, DCS control room layout diagrams, production capacity estimates, and ROI analysis, delivered within ≤5 business days.

Equipment Manufacturing: Integrated manufacturing of all line equipment, including the DCS control room and three-tier environmental protection facilities; shipped as modular, pre-assembled units; 100% full-unit testing.

Installation and Commissioning: On-site installation takes only 4 months thanks to modular pre-assembly; on-site engineer commissioning + DCS integration testing, along with operator training.

O&M Management: Global coverage by over 200 bilingual engineers; on-site repair within 48 hours, spare parts delivery within 72 hours; remote intelligent diagnostics + regular technical inspections.

Zambia·Lusaka Quarry Smart Upgrade Project

The client, Zambia Aggregates Ltd., is the designated aggregate supplier for Zambia’s national infrastructure projects. The existing traditional assembly line suffered from frequent breakdowns, with an OEE of only 65%, and dust emissions exceeded standards, putting the company at risk of environmental penalties. By adopting Zhongyu Dingli’s 800-metric-ton EPC turnkey solution-featuring DCS intelligent central control, a three-tier environmental protection design, and an Africa-specific enhanced sand and dust prevention configuration-the installation, upgrade, and commissioning were completed in 4 months. Since commissioning, the facility has operated continuously and stably: OEE has increased to over 88%, and the failure rate has decreased by 70% compared to the old line; measured dust emissions are ≤9 mg/m³, meeting both Zambia Environmental Authority and CE EN 1889 certification standards; the DCS control room requires only one operator for one-button start/stop, reducing labor costs by 75% compared to the old line; The single-step crushing process has simplified operations, reducing energy consumption to 65% of the old line’s level; the unmanned weighing system ensures 100% data accuracy with zero measurement loss.

Customer Feedback: “The upgrade-from a constantly failing, outdated production line to a smart system with one-button start/stop-has exceeded our expectations. Single-person operation and zero environmental risks allow us to focus all our energy on market expansion.”

Sand Gravel Aggregate Line FAQ