Analysis Before Building a Aggregate Sand Production Line

As the sand and gravel aggregate industry pivots towards high-quality development, it faces operational challenges in new production lines that often fail to meet investor expectations. This is primarily due to inconsistencies in design quality, impacted by varying expertise across design units. Below is an analysis of the main issues encountered in new sand and gravel production lines, along with suggested countermeasures to promote sustainable and high-quality development within the industry.

1. Capacity and Product Variety Issues and Countermeasures

The diverse demand for aggregate products, influenced by local environmental and resource conditions, calls for customization in product variety and production capacity. While typical production lines categorize aggregates into three standard sizes (15–30mm, 5–15mm, and 0–5mm), some regions may require finer granularity due to environmental factors. Therefore, production lines in these areas may need to classify aggregates into five categories (20–30mm, 10–20mm, 5–10mm, 3–5mm, and 0–3mm).

Countermeasure: Production standards for new sand and gravel lines should be adjusted to match specific market demands and resource availability. This involves rationally planning product types and annual output capacity by considering the geological characteristics of local resources and market demand.

2. Equipment Selection Issues and Countermeasures

Choosing the right equipment is crucial for determining the quality and capacity of production lines. Some investors compromise on equipment selection, opting for less robust options to reduce costs, which can lead to issues such as reduced efficiency and poor product quality, especially when processing hard stones like basalt or granite.

mobile aggregate production line

Countermeasure: Engage professional geological survey and design agencies for scientifically grounded equipment selection. This includes evaluating the physical properties of raw materials, like hardness and abrasiveness, to ensure that the chosen equipment is compatible with the production requirements, thus enhancing efficiency and durability. You should choose the right mobile crushers to process raw rocks.

3. Material Storage and Bin Issues and Countermeasures

Material storage bins, such as those for stone powder and coarse feed, are prone to issues like caking in high humidity, which hinders material discharge, and dead zones in rectangular bin designs that impede smooth feeding.

Countermeasure: Install air cannons beneath stone powder storage tanks to prevent caking and maintain material flow. For coarse feed bins, adopting a trapezoidal or "inverted eight" design for side discharge outlets can eliminate dead zones and improve feeding efficiency. Additionally, using a reinforced foundation can mitigate deformation risks in storage bins.

mobile aggregate production line

4. Material Transfer Drop Issues and Countermeasures

Large drops between equipment, particularly from coarse crushers to conveyors, can damage belts and rollers, causing operational interruptions and maintenance challenges.

Countermeasure: Replace impact rollers with impact beds to cushion material transfer. Additionally, early-stage design modifications to chute structures can help reduce the impact force on subsequent equipment, thus prolonging the lifespan of conveyors and other components. This also suit for mobile conveyors in mobile aggregate production line.

The successful development of new sand and gravel aggregate production lines requires a comprehensive approach to design, equipment selection, and operational efficiency. By analyzing and addressing these specific issues, the sand and gravel aggregate industry can achieve its goals of high quality, eco-friendliness, and sustainability.