How is Granite Processed: Granite Crushing & Grinding Plant

Анхдагч бутлах: Where the Real Work Starts

Those multi-ton blocks need breaking fast and reliably. This is brute force territory:

• Хацарт бутлуур Rule Here: That simple “chomp” motion handles irregular chunks better than anything else. Feed size? We’ve seen jaws take 60-inch monsters down to 6-inch minus. Key is manganese jaw chemistry – don’t cheap out. Expect to swap liners every 6-12 months in hard granite.
• Гиратор бутлуур Option: Only makes sense for massive primary throughput (бодох 5,000+ цагдаа). Expensive upfront, but lower cost per ton at scale. Maintenance complexity scares off smaller ops.

Table 1: Choosing Your Primary Weapon (Боржин чулуу)

Secondary/Tertiary Crushing: Shaping the Profit

Primary output is still useless rubble. Now we shape and size it:

• Конусан бутлуур: Non-negotiable here. That mantle/concave action crushes granite multiple times on the way down. Want cubical aggregate for premium pricing? Cone CSS settings are your golden knob. Үл үзэгдэгд: Run slightly wider CSS than you think – better throughput and less recirculation than chasing the last 5% spec.
• Tertiary Stage Reality: Needed only if making chip seal or ultra-fine feed for grinding. HPGRs gain traction here – lower energy, less dust, but sensitive to feed variation. Screen between stages religiously; recirculating fines kills cone efficiency.

Screening: The Unsung Profit Center

Screens make or break your gradation specs. In granite processed plant:

• Inclined Vibrating Screens: Only real choice for primary/secondary circuits. Deck count depends on product splits needed. Mesh blinding? Guaranteed with wet granite. Use polyurethane or rubber mats on top decks. Actual operator gripe: “Maintenance never lubes the vibrators!”
• Scalping: Do it early. Pulling fines before primary crushing reduces wear and boosts jaw capacity 10-15%. Simple grizzly screens pay for themselves fast.

Conveying Granite: No Room for Weak Links

Abrasives belts fail spectacularly. Key learnings:

• Feeders: Apron feeders for primary discharge – they shrug off impacts that wreck belts. Vibrating pan feeders work fine for screened fractions.
• Конвейер: Minimum 3-ply belts, 25mm top covers. Impact beds at loading points aren’t optional – they’re insurance. Dust? Contain it at transfer points or face cleanup costs that dwarf the baghouse investment.

Grinding Granite: Where Efficiency Matters

Turning granite into powder burns cash if you get it wrong. Reality check:

• VRMs Dominate: Vertical Roller Mills are the only sane choice for serious granite powder production. Why? That roller-on-table action crushes efficiently while hot air dries. Energy savings vs ball mills? 30-40% isn’t unusual. Grinder’s maxim: “Your kWh/ton decides if you eat steak or ramen.”
• Ball Mills? Only if you inherit one or grind very coarse. Prepare for liner changes every 3 months and energy bills that hurt.

Table 2: Granite Grinding – Technology Tradeoffs

Classification: Hitting the Number

Grind size specs are contracts. Miss them, lose customers.

• VRM Integrated Classifiers: The elegant solution. Adjust rotor speed, change fineness instantly. Just keep bearings maintained – a seized classifier stops the whole plant.
• External Air Separators: Necessary with ball mills. More moving parts, more dust points. Efficiency drops if fan blades wear unevenly. Lab tech warning: “Sample every shift. Classifier drift sneaks up.”

Dust Control: It’s About Survival

Granite silica dust isn’t a nuisance – it’s a lethal hazard and a regulator’s dream citation. Non-negotiables:

• Baghouses: Pulse-jet design. Size generously – undersized filters blow through or blind constantly. Filter media? PTFE membrane for granite. Expensive, but lasts.
• Enclosure Philosophy: Seal every transfer point. Hood crusher discharges. Run negative pressure in grinding buildings. Safety manager’s mantra: “If you see dust escaping, the system failed hours ago.”

Product Handling: Don’t Lose What You Made

Granite powder flows like concrete if handled poorly:

• Pneumatic Conveying: Use dense phase systems. Gentle handling prevents particle degradation. Airlocks must be robust – granite wears rotary valves fast.
• Silos: Mass flow design mandatory. Cone angles >70 degrees. Fluidizing pads prevent bridging. Level indicators? Radar, not mechanical probes. Storage horror story: “One clogged silo cost us 3 days of production. Never again.”