Breaking it big with stationary processing.

Stationary processing plants are specially designed for many years of use in one single, fixed location. What types of crushing and screening equipment do they use for processing stones and recycling material? What advantages do they offer?

Stationary processing plants are usually operated in large rock deposits. They are typically designed for a useful life of 20 or more years. In addition to large quarries or the mining industry, stationary plants are also used in the processing of recycling materials, such as demolition waste, concrete, asphalt, incineration ash, or steel slag.

Made-to-measure design

Two questions need to be answered first of all when designing a stationary processing plant: Where will it be located, and what material will be processed? To meet with the individual requirements placed on the stationary processing plant, the entire plant is then designed and set up in accordance with prevailing local conditions. A feature that all stationary plants have in common is that several crushing and screening units co-operate, forming an integrated system.

Different crushing techniques

Crushing techniques distinguish between pressure crushing and impact crushing. Jaw crushers or cone crushers use the so-called pressure crushing technique where material is reduced in size mainly by high pressure between slow-moving wear parts. Impact crushers use the so-called impact crushing technique, in which the rock is accelerated by a massive fast-moving rotor and reduced in size by impacting against breaker walls.

Sophisticated screening technology

In materials processing, the quality of an end product is determined, among other things, by the number of crushing stages and by sufficiently dimensioned screening equipment. A basic distinction is made between pre-screening, which is important for separating the material streams prior to crushing, and grading, which separates the different final aggregate fractions.

Pre-screening screening separates material streams

Pre-screening screening is used for separating the material streams. Contaminations are also eliminated in this first processing stage. The material is separated via the screening surface, which usually consists of a slotted screen or perforated plate.

Grading for the fine range

Grading determines the screening quality, meaning the quality of the end product. Grading screens have a screening surface which consists of, for instance, a wire screen for precise separation of the medium and fine aggregate fractions. The graded final aggregate fractions are finally discharged via belt conveyors and stockpiled.

Use advantages consistently

Stationary processing plants enable large amounts of material to be crushed, and complex processes to be managed. End products of superior quality are produced, complying with the standards to be adhered to in terms of grain size and cubicity, which may differ from one market area to the next. Stationary plants play their aces in particular when it comes to flexibility in production. The crushed aggregate can be stored in several silos, enabling the most diverse aggregate mixtures to be produced right at the plant, and in accordance with the requirements of the customer or end user. Yet another advantage of stationary plants: The production can always be adapted to changing requirements in the sales markets.

Reducing the burden on the environment

Preventing the emission of dust is an important aspect of materials processing. Stationary processing plants offer two options for doing so: They either feature water spray systems for binding the dust, or special dust extraction systems. The entire plant can also be fully enclosed to protect the environment from dust and noise.