High Efficiency Iron Ore Production Line

Project Overview

Located in Changning, Hengyang, Hunan Province, this 500TPH gangue sand and gravel aggregate production line was commissioned in February 2015. The project processes coal gangue into sand and gravel aggregates of various specifications, meeting diverse construction and infrastructure demands. Both crushing and screening operations are housed within a fully closed workshop to contain dust emission and minimize environmental impact. The entire layout is designed in accordance with the natural terrain elevation, adopting a step-type arrangement that provides large raw material storage capacity and streamlined finished product distribution.

Process Flow

Raw gangue is uniformly and continuously fed from the feeding hopper into the heavy hammer crusher via the vibrating feeder. After primary crushing, the crushed material is conveyed to the vibrating screen for size classification. Qualified aggregates of target specifications are transported directly to the finished product stockpile by belt conveyors, while oversized materials retained on the top-layer screen are returned to the heavy hammer crusher for re-crushing. This closed-circuit screening loop ensures consistent product grading, reduces waste, and maximizes overall yield. The step-type layout, following the natural slope of the terrain, allows gravity-assisted material flow between stages, lowering conveying energy consumption and simplifying the plant structure.

EPC Service Content

Zhongyu Dingli delivers a full EPC turnkey solution for gangue aggregate projects, covering site survey and geological analysis, process design tailored to gangue material characteristics, equipment manufacturing and supply, civil engineering and workshop construction, installation and commissioning, operator training, and long-term after-sales support. From individual standalone equipment to complete production lines, all crushing, sand making, screening, feeding, and conveying systems are integrated under a single contract, ensuring schedule control, cost optimization, and consistent quality throughout the project lifecycle.

Project Cases and Data

• Location: Changning, Hengyang, Hunan Province
• Material: Coal gangue
• Capacity: 500 TPH
• Commissioned: February 2015
• Workshop Design: Fully closed for both crushing and screening, achieving effective dust containment
• Layout: Step-type arrangement following terrain elevation, enabling gravity-assisted material transfer and large raw material storage
• Process Circuit: Closed-circuit screening with top-layer oversize return for re-crushing
• Product Range: Sand and gravel aggregates of multiple specifications

FAQ

Q1: Why is a closed workshop design essential for gangue crushing?

Coal gangue generates significant fine dust during crushing and screening due to its brittle and friable nature. A fully closed workshop encloses all emission points, preventing dust from escaping into the surrounding environment and ensuring compliance with strict environmental regulations.

Q2: What advantage does a step-type layout provide for aggregate production?

By arranging equipment along the natural terrain gradient, a step-type layout allows material to flow downward by gravity between processing stages. This reduces the need for inclined belt conveyors and horizontal transfers, cutting conveying energy consumption and simplifying maintenance access.

Q3: How does the closed-circuit screening loop improve gangue aggregate yield?

The closed-circuit loop returns oversized materials from the top-layer screen back to the heavy hammer crusher for re-crushing, rather than discarding them. This ensures that all raw material is progressively reduced to target sizes, maximizing finished product output and minimizing waste in gangue processing operations.