Stage 1: Jaw Crusher
This is the first stage of crushing which reduces the boulders from Quarry to Aggregates. A Jaw Crusher reduces large size rocks or ore by placing the rock into compression. A fixed jaw, mounted in a "V" alignment is the stationary breaking surface, while the movable jaw exerts a force on the rock by forcing it against the stationary plate. The space at the bottom of the "V" aligned jaw plates is the crusher product size gap or the size of the crushed product from the jaw crusher. The rock remains in the jaws until it is broken small enough to pass through the gap at the bottom of the jaws.
Stage 2: Cone crusher
Here the cone segregates the materials into 90 mm, 40 mm & 0 to 20 mm. The crushing action is caused by the closing of the gap between the mantle line (movable) mounted on the central vertical spindle and the concave liners (fixed) mounted on the main frame of the crusher.
Stage 3: VSIC Vertical Shaft Impact Crusher
V.S.I.C means 'Vertical Shaft Impactor Crusher', in which shaft and crushing chamber are in a vertical position which is a latest crushing technology. The stone or material fed at the center of the rotor, which is rotating at high R.P.M. accelerate the material and material is thrown out from the rotor with a vigorous velocity of 300 ft. per sec. The main advantage of this process is material breaks at the minimum surface area, which makes the particle of cubical/spherical shape and brings consistency in size.
Stage 4: Screening
Screens and feeders are essential components in an efficient crushing operation. Screens are used for scalping and classifying materials into required sizes.
Stage 5: Dry / Wet Classification
Heaviest particle mainly + 150 microns - 5 mm not ascending will fall to the bottom of the inner cone and on to a chute and stockpiled on the ground through a conveyor belt, which is classified Sand conforming to the standards prescribed in IS 383.
The dry feed material 0-5mm from the crushing plant and water is added into the fabricated tank equipped with a slow-moving screw where decantation takes place with low turbulence flow. Water with (-) 150 microns will be carried away by the flowing water moves in the opposite side and collected in the weir and discharged outside.