Complete Limestone Sand Making Plant Process

Limestone sand making plant is a production facility used to process limestone into sand for various construction and industrial applications. The limestone sand production line follows a systematic three-stage crushing + screening + washing process, ensuring gradual size reduction and uniform product quality. Here’s the detailed workflow: 

Process Flow of Limestone Sand Production Line

Stage 1: Raw Material Preparation & Pretreatment

First, limestone raw materials (mixed with clay, max feed size ≤600mm, clay content ≤15%) are excavated from the raw material yard (1KM away from the production site) and transported to the main hopper via dump trucks. A grizzly feeder (bar spacing: 100mm) under the hopper separates oversize materials (>100mm) for primary crushing, while undersize materials () are directly conveyed to merge with the primary crushing output—this pretreatment avoids overload of crushers and improves processing efficiency.

Stage 2: Three-Stage Crushing (Size Reduction)

•Primary Crushing: The PE600X900 jaw crusher processes >100mm limestone into particles ≤120mm (closed side setting: 120mm; spindle speed: 250rpm; capacity: 120TPH). This stage breaks large raw materials into manageable sizes for subsequent processing.
•Secondary Crushing: Two PEX250X1200 jaw crushers (CSS: 40mm; spindle speed: 330rpm; 37KW/unit) further reduce the ≤120mm material to ≤40mm. With a combined capacity of 120TPH, this stage ensures consistent particle size for sand making.
•Tertiary Sand Making: Two vertical shaft impactors (VSIs) with a linear speed of 50m/s (160KW/unit) perform the final crushing. Small vibrating feeders above the VSIs ensure uniform feeding, promoting even rotor wear and cubic particle formation. The output meets strict size requirements: 70% ≤5mm, 90% ≤10mm, and 100% ≤16mm.

Stage 3: Screening & Sand Washing

Materials from the VSI sand making machines are sent to a double-layer vibrating screen (mesh sizes: 5mm and 10mm) for classification. Three product grades are separated: 0-5mm (finished sand), 5-10mm (fine aggregate), and 10-16mm (coarse aggregate). The 0-5mm sand is fed into a screw sand washer (mud removal rate ≥95%) to eliminate clay, dust, and impurities, reducing the final clay content to ≤1%. All equipment is connected by 800mm-wide belt conveyors for continuous material transfer.

2. Quality Control Measures

To ensure the finished sand meets industrial and construction standards (GB/T 14684-2011 Grade Ⅱ), the production line implements comprehensive quality control throughout the process:

(1) Raw Material Quality Control

•Conduct pre-inspection of limestone: Test clay content (must be ≤15%) and compressive strength (≥80MPa) before feeding. If clay content exceeds 15%, add a pre-washing machine to remove excess clay and avoid affecting product purity.
•Control raw material particle size: Reject limestone blocks >600mm to prevent damage to crushers and ensure stable operation.

(2) In-Process Quality Monitoring

•Crushing Parameter Control: Real-time monitor the closed side setting (CSS) of jaw crushers and linear speed of VSIs. Adjust CSS within ±5mm based on particle size tests to maintain consistent output granularity.
•Feeding Uniformity: Use vibrating feeders to control feeding rate (match crusher capacity) and avoid uneven wear of crushing components, which could lead to irregular particle shapes.
•Screening Efficiency Check: Regularly inspect the vibrating screen mesh for blockages or damage; replace worn meshes promptly to ensure accurate classification (error margin ≤2% for particle size grading).

(3) Finished Product Quality Inspection

•Physical & Chemical Tests: Conduct daily tests on finished sand, including particle size distribution (using a sieve shaker), clay content (via washing method), and compressive strength (using a pressure tester). Ensure 0-5mm sand accounts for ≥70% of total output.
•Particle Shape Evaluation: Use a digital image analyzer to check the cubicity of sand particles (elongation coefficient ≤1.2). Re-adjust VSI rotor speed if irregular shapes (e.g., needle-like particles) exceed 5%.
•Environmental Impurity Control: Monitor the sand washer’s water quality and mud removal efficiency; recycle wash water (after sedimentation) to reduce environmental impact and ensure sand cleanliness.

(4) Equipment & System Maintenance

•Regular Equipment Calibration: Calibrate PLC control panels and monitoring systems monthly to ensure accurate data collection (e.g., capacity, power consumption, particle size).
•Wear Part Management: Replace VSI rotors, jaw crusher liners, and screen meshes according to maintenance schedules (VSI rotor service life ≥8000 hours) to avoid product quality degradation due to worn components.
•Continuous Operation Monitoring: The PLC system provides real-time alerts for equipment malfunctions (e.g., overload, abnormal temperature), enabling timely troubleshooting to prevent defective product production.
 

Key Plant Features

•High Efficiency: Three-stage crushing ensures step-by-step size reduction, 70% of output is direct sand (0-5mm).
•Quality Output: Cubic-shaped sand (elongation coefficient ≤1.2) with low impurity (clay content ≤1%), sells at 15-20% higher price than natural sand.
•Automatic Operation: PLC control + real-time monitoring reduces labor (only 2-3 operators needed).
•Cost-Effective: Economical investment with low maintenance (VSI rotor service life ≥8000 hours).
•EPC Turnkey Service: One-stop solution from site selection, design, installation, to training.

Why Choose Baichy Machinery?

Henan Baichy Machinery Equipment Co., Ltd. is a mining machinery manufacturer integrating R&D, production and sales. Stone crusher is one of its core production equipment. It has mature technology and processes, complete models and configurations, and technical engineers can tailor production line configuration plans for you. If you are interested in the stone crusher, please click on the online consultation to get solution and price now. Baichy Machinery is dedicated to serving you 24 hours a day!

• Experience & Authority (Trust Signals)
• 20+ Years of Expertise: Baichy Machinery (established 2003) has completed 500+ EPC sand making projects worldwide.
• Certifications: ISO 9001 Quality Management System, CE Certification, China Sand and Stone Association Member.
• Patented Technology: VSI hydraulic opening device (Patent No.: ZL202021876543.1) for easy maintenance.
• Case Study: Highway construction project in Indonesia (2023) – 120TPH limestone sand plant, running 24/7 with 98% operational rate.
• Third-Party Test Report: Certified by National Building Materials Quality Supervision and Inspection Center (Report No.: 2024-SM-0896).

Contact Baichy Machinery

Get your customized limestone sand making plant solution! We offer:
•Free site survey and process design
•Detailed quotation within 24 hours
•On-site training for operators
•Spare parts supply (global logistics)
Email: vip@baichy.com | Website: www.baichy.com
 

People Also Frequently Asked Questions (FAQ)

1.What’s the investment budget for this plant?

Total cost: 350,000-450,000 (EPC turnkey, including equipment, installation, and training).

2.Can it handle limestone with high clay content?

Yes, if clay content >15%, we add a pre-washing machine (optional) to ensure output quality.

3.What’s the warranty period?

1-year warranty for main equipment; lifetime technical support + 48-hour on-site service response.

4.Is the plant environmentally friendly?

Equipped with dust collectors (emission ≤10mg/m³) and noise reduction covers (≤85dB); wash water can be recycled.