Basalt Aggregate Production Line Solutions By Capacity
ZME 80-100 TPH Basalt Aggregate Production Line Solution. Integrating advanced Vibrating Grizzly Feeder and Hydraulic Cone Crusher technologies.
Hard rock (such as basalt, granite, diorite, etc.) exhibits extremely high uniaxial compressive strength under saturated conditions. This type of material is highly abrasive to wear parts. Therefore, when designing this production line, ZME’s primary objective is to balance the initial investment (CAPEX) while significantly lowering operational expenses (OPEX) through optimized equipment configuration.
For hard basalt rock, the crushing circuit design must be scientifically engineered; it should not only chase production capacity but also reduce the frequency of spare part replacement by utilizing the “Laminated Crushing” principle.
Basic Process Flow of Basalt Crushing Production Line
Primary Feeding & Pre-Screening: Rock material is uniformly fed by the ZME Vibrating Grizzly Feeder (VGF) into the primary jaw crusher. The VGF is equipped with adjustable grizzly bars to screen out soil and fine materials before entering the crusher, effectively reducing the machine’s workload.
Primary Crushing (Stage One): The coarsely crushed material is transferred via a belt conveyor to the secondary crushing stage.
Secondary & Fine Crushing (Solution Optimization): Given the highly abrasive nature of basalt, ZME recommends using a Hydraulic Cone Crusher. Unlike Impact Crushers, Cone Crushers utilize a compression (squeezing) principle, which can extend the lifespan of wear parts several times over.
Screening & Closed-Circuit Layout: Material enters the ZME Vibrating Screen. Products that meet specifications are transferred to the finished product stockpiles, while out-of-spec materials are returned to the Cone Crusher for reprocessing (closed-circuit system).
Finished Product Washing: For 0–5 mm manufactured sand, a ZME Screw Sand Washer is utilized. Through uniform spiral agitation, dust and impurities are removed while simultaneously initiating the material dehydration (natural dewatering) process.
Equipment Configuration List (Capacity: 80–100 TPH)
The following is the technical translation into Indonesian, tailored to meet the requirements of project proposals or mining product catalogs in Indonesia:
| No. | Peralatan | Model | Jumlah | Daya | Fungsi |
|---|---|---|---|---|---|
| 1 | Vibrating Grizzly Feeder (VGF) | ZSW380×95 | 1 Unit | 11 kW | Mengatur pengumpanan material secara merata dan melakukan pra-penyaringan tanah melalui batang grizzly untuk melindungi mesin penghancur berikutnya. |
| 2 | Mesin Penghancur Rahang (Jaw Crusher) | PE600×900 | 1 Unit | 75 kW | Penghancuran primer (tahap pertama), dirancang khusus untuk menghancurkan bongkahan besar batu basalt yang keras. |
| 3 | Mesin Penghancur Kerucut Hidrolik (Hydraulic Cone Crusher) | HP200 / GP100 (Sebagai pengganti Impact Crusher) | 1 Unit | 132–160 kW | Penghancuran sekunder (tahap menengah/halus). Dirancang untuk material dengan tingkat kekerasan tinggi seperti basalt guna meminimalkan frekuensi penggantian suku cadang (wear parts). |
| 4 | Layar Getar Sirkular (Circular Vibrating Screen) | 4YK1860 | 1 Unit | 22 kW | Memiliki 4 lapis saringan untuk memisahkan material secara presisi menjadi ukuran produk jadi: 0–5mm, 5–10mm, 10–20mm, dan 20–30mm. |
| 5 | Mesin Pencuci Pasir Spiral (Screw Sand Washer) | XL915 | 1 Unit | 11 kW | Mencuci debu dan kotoran dari pasir hasil produksi untuk meningkatkan kualitas gradasi agregat. |
| 6 | Konveyor Sabuk (Belt Conveyor) | B500 / B650 / B800 | 1 Set | Disesuaikan | Menghubungkan antar-peralatan untuk menciptakan alur distribusi material secara otomatis. |
| 7 | Sistem Kontrol Listrik (Electric Control System) | Panel Kontrol Terpusat PLC | 1 Set | — | Memungkinkan pengoperasian lini produksi dengan sistem satu tombol (one-key start/stop), pemantauan arus listrik, serta sistem alarm jika terjadi gangguan. |
Performance Advantages of ZME Solutions
- High Automation & Operational Stability: ZME production lines feature a high level of automation alongside low operational costs. The combination of the VGF’s pre-screening capabilities and the Cone Crusher’s laminated crushing technology ensures long-term production stability.
- Maintenance Cost Efficiency (“Compression Over Impact”): By replacing traditional Impact Crushers with a Cone Crusher, rapid wear issues on blow bars caused by hard rock are eliminated. This not only extends maintenance intervals (reducing downtime) but also significantly lowers spare part consumption costs per ton of product.
- Superior Finished Product Quality: The final product features a uniform grain size and a cubical shape (well-rounded and non-flaky). Supported by our Screw Sand Washer unit, the cleanliness of the manufactured sand fully complies with Indonesian National Standards (SNI) for construction-grade sand.
- Environmental Adaptability & Customization: ZME provides comprehensive process flow solutions and technical support. Based on varying mine site conditions, we can design non-standard auxiliary components to guarantee maximum performance even in extreme environments.
Summary: This solution is a proven, turn-key package from ZME specifically engineered for hard rock quarries. Through the efficient pre-screening of the VGF and the precise washing of the Screw Sand Washer, this production line not only delivers high-quality aggregates but also sets a new industry standard for equipment durability in the mining sector.