"The granite sand and gravel production line built with 1.68 billion yuan has achieved a 95% particle size qualification rate with an intelligent equipment matrix, an ultra-low energy consumption of 2.8kWh/ton, and an annual output value of over 1 billion yuan, becoming a technological benchmark for the green building materials industry cluster."

In the wave of local industrial upgrading, a granite sand and gravel production line with a total investment of 1.68 billion yuan and a designed annual production capacity of 5 million tons, supported by a set of equipment independently developed by Shibang Group, has created a modern sand and gravel production line that integrates high efficiency, intelligence, and green through the innovation of the clean production system, injecting strong momentum into the improvement of regional sand and gravel supply capacity and the development of the green building materials industry cluster.

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Hard-core equipment matrix: a process tool covering the entire process

The production line is designed with the concept of "full model coverage and multi-equipment coordination" to build a full-process equipment system from coarse crushing to sand making. Two C6X jaw crushers are used as the primary crushing core at the front end. Their unique deep-cavity crushing structure and large eccentricity design enable the feed particle size to exceed the 1200mm limit, achieving a stable throughput of 1200 tons per hour when processing large pieces of granite. Two HST single-cylinder hydraulic cone crushers and four HPT multi-cylinder hydraulic cone crushers are configured in the middle crushing stage to form a gradient crushing matrix. The former achieves efficient medium crushing through the principle of laminated crushing, while the latter achieves precise particle size control with the help of a multi-cylinder hydraulic system. The two work together to increase the product particle size qualification rate to more than 95%.

In the sand making and shaping stage, four VSI6X1040 vertical shaft impact crushers constitute the core process unit. The equipment adopts a composite crushing cavity type of "stone hitting stone" and "stone hitting iron". By adjusting the rotor speed and material flow direction, it can simultaneously achieve the dual functions of machine-made sand production and aggregate shaping. After testing, the 0-5mm fine sand and gravel aggregates produced by it have rounded particles, continuous grading, and the needle-like content is controlled within 5%, which fully meets the standards for high-performance concrete sand. The 12 S5X series circular vibrating screens use dual-motor self-synchronization technology, and achieve accurate grading of four specifications of products of 0-5mm, 5-10mm, 10-16mm, and 16-33mm through a multi-layer screen combination. The screening efficiency is more than 90%, effectively avoiding the phenomenon of over-crushing of materials.

Clean production revolution: process innovation drives green transformation

The production line breaks through the traditional sand and gravel production model and builds a full-chain clean production system covering "source reduction-process control-end optimization". In the pretreatment stage, the innovative "pre-screening + multi-stage crushing" process is adopted. By configuring a heavy-duty vibration screening system, some soil impurities are separated before the material enters the crushing stage, which not only reduces equipment wear but also reduces sewage treatment costs. The intelligent storage system of the transfer warehouse uses laser radar and Internet of Things technology to monitor the particle size distribution of materials in real time.

In terms of energy consumption management, the production line deeply integrates the peak-valley electricity price strategy and develops a production scheduling system based on machine learning. By analyzing historical electricity consumption data and real-time electricity price information, the system prioritizes the startup of high-energy consumption equipment during the valley period, reducing the unit product power consumption to 2.8kWh/ton. The matching pulse dust removal system adopts a new type of coated filter material, combined with negative pressure dust collection technology, and the dust emission concentration is lower than the national environmental protection standard.

Industrial synergy effect: a demonstration sample of cluster development

The completion and commissioning of this production line not only achieves an annual output value of more than 1 billion yuan in economic benefits, but also gives birth to a complete industrial chain of "ore mining-crushing and screening-commercial concrete mixing-PC components". On this modern production line full of technology, every piece of granite is undergoing a transformation from rough ore to fine aggregate. It is not only a vivid footnote to the upgrading of local industries, but also a microcosm of China's manufacturing industry's transformation to green and intelligent. With the application of more innovative technologies and the deepening of industrial collaboration, this production line will continue to release development momentum and provide solid material guarantees for the construction of new urbanization.