Here’s a process flow chart for a typical stone crusher plant, along with a step-by-step explanation of the crushing process:
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Stone Crusher Process Flow Chart
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1. Feeding → 2. Primary Crushing → 3. Secondary Crushing → 4. Screening → 5. Conveying → 6. Final Product Storage
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# Step-by-Step Explanation:
1. Feeding (Raw Material Intake)
– Large rocks (raw material) are loaded into the crusher plant using a vibrating feeder or an excavator.
– A grizzly screen may remove very fine material before crushing.
2. Primary Crushing (Jaw Crusher / Gyratory Crusher)
– The first stage reduces large rocks (up to 1-2 meters) into smaller pieces (~150-300 mm).
– Common machines:
– Jaw Crusher (for hard, abrasive stones)
– Gyratory Crusher (for high-capacity primary crushing)
3. Secondary Crushing (Cone Crusher / Impact Crusher)
– Further reduces the size (~20-70 mm) for better shaping and gradation.
– Common machines:
– Cone Crusher (produces finer, well-shaped aggregates)
– Impact Crusher (for softer stones, produces cubical output)
4. Screening (Vibrating Screen)
– Crushed material is separated into different sizes using screens.
– Oversized material is sent back for re-crushing (closed-circuit system).
5. Conveying (Belt Conveyors)
– Screened aggregates are transported to storage or further processing.
6. Final Product Storage & Dispatch
– Aggregates are stockpiled in different size categories:
– Coarse aggregates (e.g., 20–40 mm)
– Fine aggregates (e.g., sand, 0–5 mm)
– Ready for sale or use in construction.
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Additional Processes (Optional):
– Tertiary Crushing: For ultra-fine output (<10 mm).
– Washing: Removes dust/clay using a sand washer.
– Dust Contr
Water sprays or bag filters minimize dust pollution.
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Diagram Example:
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[Raw Stone] → [V