Three-Stage Closed-Circuit + Shaping and Recycled Material Process Flowchart
Stage 1: Coarse Crushing – Jaw Crusher Opens the Way, Large Pieces Subdue
• Raw Material: 50-500mm river pebbles, evenly fed by a vibrating feeder
• Equipment: C-Series Jaw Crusher
• Discharge Particle Size: ≤120mm
Note: The C-Series jaw crusher adopts deep-cavity crushing and a large eccentricity design, resulting in strong single-machine processing capacity. River pebbles are crushed to below 120mm in a single pass, paving the way for efficient operation of the subsequent cone crusher.
Section 2: Closed-Circuit Crushing & Screening – Main Zone of Cone Crusher
Equipment 1: Simons Cone Crusher (Standard Type)
• Feed Size: ≤120mm
• Discharge Size: ≤40mm
Operating Instructions:
• Coarse crushed material is conveyed to Vibrating Screen #1 via belt conveyor;
• Oversize material (>40mm) is returned to the Simons Cone Crusher (Standard Type) for further crushing;
• Undersize material (≤40mm) enters the next stage buffer bin.
This section forms the first closed-circuit cycle, ensuring uniform particle size of the material entering the fine crushing section and significantly reducing the load on the fine crushing cone crusher.
Section 3: Fine Crushing & Main Screen Classification – Finished Product Separation
Equipment 2: Simons Cone Crusher (Short-Head Type)
• Feed Size: ≤40mm
• Discharge Size: ≤25mm
Operating Instructions:
• Undersize material from the medium crushing screen enters the short-head cone crusher for fine crushing;
• The crushed material is fed into two vibrating screens (parallel/series configuration) for precision classification;
Screen Configuration: 20mm / 10mm / 5mm three-layer mesh.
Detailed Classification Path of Two Vibrating Screens:
① Above 20mm → Return to short-head cone crusher (closed-loop circulation)
② 10-20mm → Finished product stockpile (coarse aggregate)
③ 5-10mm → Finished product stockpile (fine aggregate)
④ 0-5mm → Enter the sand making machine shaping area
Section 4: Sand Making and Shaping – Particle Shape Optimization, High-Quality Manufactured Sand
Equipment: Vertical Shaft Impact Sand Making Machine
Feed: 0-5mm undersize fine material
Work Objectives:
• Improve the particle morphology of 0-5mm material, remove sharp edges, and improve roundness;
• Adjust the fineness modulus (controlled between 2.4-3.0, adjustable);
• Produce an additional portion of ultrafine powder (depending on market demand).
Finished Product Destination: After being sorted or screened by a small sieve, the 0-5mm high-quality manufactured sand from the sand making machine is stored separately.
