Basalt Crushing Solutions

Basalt crushing and sand making solution – Basalt is a kind of basaltic ejecta rock, its chemical composition is similar to gabbro or gabbro, basalt is faced with fast wear and tear of equipment, poor granularity of finished products, high energy consumption and other challenges in the process of crushing and sand making due to its high hardness (Moh’s hardness of 6-7), high compressive strength (up to 300MPa), and high abrasion resistance. Challenges.

Combined with the industry practice and technology optimization, the following is a set of high-efficiency and low-consumption crushing and sand making equipment configuration plan:

Core equipment selection and configuration

Coarse crushing stage: Jaw Crusher

Jaw Crusher

Function: Handle the size of large basalt ≤ 1200mm, crushing to the medium size of 100-300mm.

Selection points: the use of compound swing jaw crusher, equipped with high manganese steel liner, liner life of 1,500-2,000 hours, need to add iron removal device to prevent damage to metal foreign objects.

Middle and fine crushing stage: Cone Crusher

Cone Crusher

Function: to further crush the coarse crushed material to ≤50mm, reduce the subsequent sand load.

Selection points: Priority is given to multi-cylinder hydraulic cone crusher, which adopts laminated crushing technology, with a liner life of up to 3,000 hours, and a low tonne power consumption of 1.1kWh/t, which significantly improves the efficiency. For super-hard basalt, fine crushing can be added (such as single-cylinder + multi-cylinder combination).

Sand making and shaping stage: Roll Crusher

Roll Crusher

Function: Process the medium crushed material into 0-5mm mechanism sand, and optimise the particle size.

Selection points: simple structure, modular design of key components, easy to replace after wear and tear, the roll body adopts high-strength alloy steel, the service life can be more than one year, especially for long-term crushing of high hardness materials.

Auxiliary equipment

high-frequency vibrating screen

Screening: high-frequency vibrating screen (polyurethane screen mesh, opening rate ≥35%), to achieve multi-level screening such as 0-3mm, 3-5mm.

Wheel bucket sand washer

Sand washing: Wheel bucket sand washer (with spraying system) to deal with raw materials with mud content >5%, or screw sand washer to improve the cleanliness. Dedusting: pulse bag filter (efficiency ≥99%), focusing on covering crushing and screening.

Process flow design

According to the capacity demand and finished product specifications, the following two mainstream solutions are recommended:

Conventional solution (100-500 tonnes per hour)

Flow: Jaw Crusher (coarse crushing) → Multi-cylinder Cone Crusher (medium and fine crushing) → Roll Crusher (sand making) → Vibrating Screen (closed-circuit recycling) → Sand Washer.

Advantage: moderate investment in equipment, suitable for medium-sized projects, finished sand fineness modulus 2.6-3.0, needle flake content ≤ 10%.

High output programme (800t/h and above)

Flow: Jaw Crusher  →  Single Cylinder Cone Crusher (medium crushing)  →  Multi Cylinder Cone Crusher (fine crushing)  →  Roll Crusher  →  Vibrating Screen + Micro Mist Dust Suppression System.

Advantages: three-stage crushing to improve efficiency, dry production combined with intelligent control (PLC system), dust emissions ≤ 20mg/m³, tonne power consumption reduced by 15%.

Cost control and optimisation

Wear-resistant material upgrading: adopting tungsten carbide composite liner (life span extended by 3 times) and high chromium cast iron impeller, reducing the frequency of downtime maintenance. Time-sharing production: utilising low tariff hours to run energy-intensive equipment (e.g. cone breakers) to reduce electricity costs. Resource recycling: the stone powder after screening can be recycled for building material filler, and the sand washing wastewater is recycled after treatment in the sedimentation tank.