1. Project Overview & Site Execution
To meet the high demand for concrete aggregates in Rio de Janeiro, this 450TPH production line utilizes an advanced "Jaw + Cone + VSI" configuration specifically optimized for High-Abrasion Basalt. By implementing a choke feeding strategy in the VSI5X-1145 Sand Maker, the system creates a stable "rock-on-rock" crushing environment, effectively reducing wear parts consumption by 35% while producing high-quality cubical sand and aggregates that meet strict construction standards.
LOCATION
Rio de Janeiro, Brazil
CAPACITY
450 TPH
MATERIAL
Basalt
PRODUCTS
0-5mm, 5-10mm, 10-20mm, 20-31.5mm
Project Site Snapshot & Execution Summary
This photo captures the primary crushing stage installation, utilizing a modular steel structure design which dramatically reduced on-site installation time and complexity.
"The deep rotor VSI design is a game changer. Our wear costs dropped by 35% compared to the old impact crusher line, and the sand shape is perfect for high-grade concrete."
2. Detailed Process Flow & Design Rationale
Due to the extreme hardness and abrasiveness of local basalt in Rio, a traditional impact crushing circuit would result in excessive wear costs. Therefore, we designed a "Jaw + Cone + VSI" multi-stage configuration:
- Primary Crushing: Large basalt rocks are fed into the PE Series Jaw Crusher for coarse crushing.
- Secondary Crushing: The material is conveyed to the HPT Multi-cylinder Hydraulic Cone Crusher. Its lamination crushing principle effectively handles hard rocks while minimizing liner wear.
- Tertiary Shaping (Critical Step): The crushed stone enters the Deep Rotor VSI Sand Maker. We utilized a "stone-beating-stone" principle with choke feeding. This forms a protective material lining inside the chamber, preventing the basalt from directly impacting the metal body.
- Screening: A 4-deck S5X Vibrating Screen separates the final aggregates into 0-5mm (manufactured sand) and various gravel sizes.
3. Key Equipment Configuration List
We selected market-leading, durable models to ensure stable 24/7 operation and low maintenance costs.
4. Project Highlights & Value Creation
35% Lower Wear Costs
By utilizing the VSI's "rock-on-rock" principle and choke feeding, direct metal contact is minimized, significantly extending liner life.
Superior Particle Shape
The impact crushing action produces cubical aggregates and sand with excellent gradation, meeting Brazil's strict concrete standards.
Hydraulic Maintenance
Both the HPT Cone and VSI5X feature hydraulic lifting covers, reducing maintenance downtime by over 40%.
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