Unstable crushed stone gradation? Difficulty in controlling stone powder content?
How to Consistently Produce High-Quality Crush and Run?
In 20 years of serving aggregate manufacturers worldwide, we've found that producing qualified crush and run is relatively easy, but consistently producing high-quality crush and run is a significant challenge. The core pain point lies in the stability of particle size distribution and the precise control of stone powder content. Today, we share professional solutions from a technical perspective.
Why is your product inconsistent?
Many manufacturers report that their crush and run products have unstable performance, sometimes achieving perfect compaction, and other times feeling loose and weak. This typically stems from:
• Raw material fluctuations: Differences in parent rock hardness and soil content between different batches.
• Equipment wear: Wear and tear on the crushing chamber, liners, and screens subtly alters the output particle size.
• Rigid processes: Fixed equipment parameters prevent flexible adjustments based on raw material variations.
These factors cause the final crushed stone to stone powder ratio to deviate from the optimal range (typically 85:15 to 90:10), directly impacting the final compaction strength of the engineering base course.
Grading Control Solution: From Extensive to Precision
To solve the gradation problem, a systematic management of the crushing and screening process is essential.
First Stage: Pre-shaping of Primary Crushing
Traditional jaw crushers
Traditional jaw crushers produce a large amount of flaky material, affecting subsequent processes. We recommend using a European-style jaw crusher with a curved crushing chamber. Its layered crushing principle produces more cubic particles, providing more uniform raw materials for subsequent processes and optimizing particle morphology from the source.
Second Stage: Core Link - On-Demand Production of Stone Powder
Multi-cylinder hydraulic cone crusher
More stone powder is not necessarily better; it needs to be produced on demand. We suggest using a multi-cylinder hydraulic cone crusher as the core of secondary crushing.
Advantages: The discharge port can be easily adjusted through the hydraulic system, compensating for liner wear in real time and minimizing particle size variation.
Key Functions: Its layered crushing principle significantly increases the proportion of cubic particles in the product, and the amount of stone powder generated can be precisely influenced within a certain range by adjusting the speed and stroke. This is a key technical means to stabilize product quality.
The Third Stage: Intelligent Screening and Closed-Loop Circulation
Multi-layer heavy-duty vibrating screens are configured, and oversized particles are returned to the cone crusher for further crushing via a reflux system (closed-loop circulation). This ensures strict control over the maximum particle size of the final product and a continuous gradation curve. Intelligent screening efficiency is the last line of defense for ensuring product specifications.
Success Story: From Passive Adjustment to Proactive Early Warning
We upgraded the CR-6 production line for a Middle Eastern client. Based on the existing production line, we added an online particle size analyzer and an intelligent equipment monitoring system.
Results: The system can monitor the crusher's output particle size trend in real time. If the stone powder content deviates from the set value, it will issue an early warning and can adjust the cone crusher parameters accordingly. The client achieved a leap from post-inspection to pre- and in-process control, increasing the product qualification rate to 99.5% and winning long-term supply contracts for large-scale infrastructure projects due to its superior product stability.
Customized Equipment and Process Packages for You
We offer more than just single machines; we provide system solutions that guarantee stable output of high-quality Crush and Run Gravel.
Standard Solution: European-style jaw crusher + multi-cylinder cone crusher + closed-circuit screening system.
Upgrade Solution: Building upon the above, an intelligent control system and online monitoring are added to achieve digital production management.
Service Support: We provide specialized process debugging services to help customers find the optimal operating point for the equipment based on the characteristics of local stone materials.
FAQ: Three Questions about Production Technology
Q1: Our raw material has changed from granite to limestone. Does the production line need major modifications?
A1: Not necessarily major modifications, but process parameters must be reset. Limestone is more brittle, and the stone powder output will naturally increase. In this case, the discharge port of the multi-cylinder cone crusher should be adjusted, and the rotation speed may need to be reduced to reduce over-crushing. Our engineers can provide equipment parameter optimization solutions for different rock types.
Q2: How to choose the number of screen layers and aperture of the vibrating screen?
A2: For production standard CR-6, we recommend a three-layer screen. The top layer screens out oversized material (e.g., 1.5 inches), the middle layer obtains the main aggregate (e.g., 0.75-1.5 inches), and the bottom layer screens out fine aggregate and stone powder (<0.75 inches). The bottom screened material is the desired stone powder composition. Precise aperture matching is key to achieving ideal gradation.
Q3: How to reduce equipment wear costs during Crush and Run production?
A3: The core is to reduce equipment overwork. Ensure the primary crushing has a sufficient crushing ratio to lighten the load for secondary crushing. Simultaneously, select appropriate liner materials for the cone crusher (e.g., high-manganese steel or composite ceramics for highly abrasive rocks). Our equipment uses a modular wear parts design, allowing for faster replacement and effectively reducing downtime, significantly lowering overall operating costs in the long run.
About of Baichy Heavy Industry
Baichy Heavy Industry is a high-tech mining equipment company integrating R&D, manufacturing, sales, and after-sales service. Focusing on crushing, grinding, and mineral processing equipment, we provide professional solutions to our customers. We are ISO9001:2015 、certified, and our products include mobile crushing palnts, crawler crushing plant, construction waste crushing plants, jaw crushers, sand making machines, cone crushers, fine crushers, grinding mills, ball mills, etc., all with reliable performance to meet diverse project needs.
Our advantages:
• Professional pre-sales support: Free project design and comprehensive solutions to help you accurately select the right equipment;
• Comprehensive on-site service: Providing installation guidance and worker training to ensure smooth equipment commissioning;
• Reliable after-sales guarantee: A complete after-sales system, timely response to technical inquiries and equipment maintenance, ensuring long-term stable operation.
To protect your rights, please contact us through the following official channels for professional service:
Official Website Customer Service
WhatsApp: 0086-15093222637
Email: [email protected]
We are committed to providing high-quality equipment and full-cycle services to deliver comprehensive intelligent solutions for the global mining industry!
