This newly constructed limestone aggregate facility, with a daily production capacity of 10,000 metric tons, employs a two-stage crushing process consisting of coarse crushing and shaping using a DLPCZ1620 heavy-duty hammer crusher, followed by fine control and recirculation of feed material via a DLPC1216 shaping machine. The system is equipped with a ZGC2050 heavy-duty feeder, as well as two 3YKZ3070 and two 2YKZ3070 large circular vibrating screens, producing premium aggregates in various specifications, including “mi stone,” 0.5–1 mm, 1–2 mm, and 1–3 mm. The entire line is a newly constructed green mine featuring high production capacity, excellent particle shape, and an extremely low over-crushing rate.

Core Challenges: At 10,000-metric-ton-scale mines, single-unit capacity bottlenecks force multiple machines to operate in parallel, complicating operation and maintenance; large-scale crushing results in high over-crushing rates, generating significant waste; and improper equipment selection for new mines leads to redundant investment.

Solution Highlights: The DLPCZ1620 heavy-duty hammer crusher integrates crushing and shaping functions into a single unit; its large feed opening ensures high adaptability, producing sand and gravel with uniform particle shape in a single pass; the DLPC1216 shaping machine performs secondary fine shaping only on oversized return material, preventing over-crushing of the entire batch and increasing the yield rate to over 92%; The 3YKZ3070 + 2YKZ3070 dual large-scale vibrating screens ensure precise grading, producing four different specifications in a single pass.

Raw limestone → ZGC2050 heavy-duty feeder for uniform feeding → DLPCZ1620 heavy-duty hammer crusher (integrated crushing and shaping) Single-pass shaping → The crushed mixture enters the 3YKZ3070 three-layer circular vibrating screen for primary classification → Oversize material from the oversize fraction is returned for re-screening after secondary fine crushing by the DLPC1216 shaping machine → Secondary screening and fine classification via the 2YKZ3070 double-layer circular vibrating screen → Four finished product specifications—Mishi, 0.5–1 mm, 1–2 mm, and 1–3 mm—are stored separately. The dual-screen interlocking control system combined with the shaping machine processes only returned material, ensuring a controllable over-crushing rate and a waste rate below 8%.

Solution Design: Mine resource assessment, comprehensive ore analysis, 10,000-metric-ton-scale master plan layout, equipment selection and matching, and green mine environmental impact assessment plan. Equipment Manufacturing: ZGC2050 feeder, DLPCZ1620 heavy-duty hammer crusher, DLPC1216 shaping machine, 3YKZ3070 and 2YKZ3070 large circular vibrating screens, conveying system, dust collection and power distribution systems, and centralized control systems—all manufactured in-house and certified to CE/ISO standards. Installation and Commissioning: 25–35 days for the installation of complete production lines at large-scale mines, including integrated commissioning until full-capacity production and compliance with standards. Operations and Maintenance Management: Systematic training for operators, a 1-year warranty on core equipment, a dedicated spare parts inventory, regular inspections, and remote diagnostics.

Riyadh Aggregate Plant Project, Saudi Arabia: Daily production of 10,000 metric tons of limestone at a newly constructed green mine. The system features a DLPCZ1620 heavy-duty hammer crusher combined with a DLPC1216 shaping machine for precision-controlled recirculation, along with a dual-screen system (3YKZ/2YKZ3070) under integrated control, producing premium-grade aggregate in metric stone and three-grade gradation. The shaping machine processes only 15% of the oversize return material, with an over-crushing rate below 8% and a product yield of 93%. The plant has been operating at full capacity continuously for two and a half years since commissioning.

Customer Feedback: "The dual crusher setup with the DLPC1216 shaping only the oversize is brilliant—we get over 93% product yield with almost no waste. The 3YKZ3070 and 2YKZ3070 screens handle 10,000 metric tons daily without any bottlenecks. A world-class limestone plant delivered on time.”

Q: Why is a separate shaping machine needed instead of shaping the entire feed?

A: The DLPCZ1620 heavy-duty hammer crusher itself combines crushing and shaping functions; approximately 85% of the material meets particle size specifications in a single pass. Custom Made Complete Sets of Equipment for Premium Aggregate Production Mines The DLPC1216 shaping machine only refines the 15% of oversize material returned from the screen, avoiding over-crushing and wasted energy consumption caused by full-volume shaping. Turnkey Services for Large Scale Quarries Producing Aggregates with Excellent Grain Shape This increases the product yield to over 93% and reduces energy consumption by approximately 20% compared to a full-volume shaping solution.

Q: What is the footprint of a production line with a daily capacity of 10,000 metric tons?

A: The core process section (crushing + screening + finished product stockpile) requires approximately 300 × 150 meters, with a total area of about 45,000 square meters. Complete Set of Equipment for a New Limestone Mine EPC Turnkey Project Linear, L-shaped, or U-shaped layouts can be customized based on the mine site's topography; the specific design is subject to the 3D master plan.

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