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4 - 6 mm
6 10 mm
0 20 mm
10 14 mm
14 20 mm
These aggregates are meant not only for sales but will also be used as raw materials for
the other plants.
The stone crushing plant will itself be fed with boulders extracted from the rock quarry
which will be exploited within the same project area. This approach eliminates the need
for the boulder transportation to be effected along public roads, which would have
otherwise contributed to an increase in road traffic in the region surrounding the project
site, and adversely affected traffic patterns on the nearby roads, including the M1
motorway.
The General Arrangement of the stone crushing plant is enclosed at Annex 4B, at the
end of Section 4.
4.3 PROCESS DESCRIPTION
The overall stone crushing process will involve, as is the standard case, the following
processing units:
Boulder Feed
Dumper trucks, of average carrying capacity of 25 tonnes, will deliver boulders to the
stone crusher by an internal road network within the site, distinct from other usual
traffic routes which will be used by visitors, buyers, staff, etc. The boulder transport
internal route leads up to the feed ramp upstream of the crushing area.
The trucks will unload into a delivery hopper of a capacity of 80 tonnes which will in
turn feed a vibrating grizzly feeder of dimension 450 x 1500 mm (labelled F1 on the
flow diagram enclosed at Annex 4C).
The primary crushing process will be carried out by a jaw crusher.
The jaw crusher will be enclosed on all of its sides, so as to contain dust emission and
noise generation arising during the loading of boulders in the crusher.
A water-mister station will be situated at the mouth of the crusher to abate any dust
emission. Thus the dust generation will be reduced at source, and will not therefore
affect the surrounding.
4.4.2
48 x 60 DT
48 x 60
Capacity (t/h)
500
190
<90
4.4.3
4.4.4
4.6.2
4.6.3
200 - 250
Less than 75
Motorpower (kW)
200
<90
4.7.1
Conveyor C10
20 - 75
Motorpower (kW)
200
<90
4 -20
0-4
Motorpower (kW)
200
<90
Selector Screen
A three-deck selector screen will be supplied with aggregates of size 75mm from the
secondary crushers and oversized aggregates re-injected from the tertiary crusher. The
selector screen will consist of three different sized meshes on each deck.
The size of the mesh on each deck is as follows:
20 mm
14 mm
10 mm
Product Screens
Aggregates from the quaternary crusher are sieved on the product screens where
finished products are separated with respect to their sizes, i.e. 0 4mm, 4 - 6mm and 6 10mm and directed to their respective stockpile.
A portion of the 0 4 mm sized sand is washed in a washing unit labelled DU1 on the
flow chart enclosed at Annex 4C for the production of washed rocksand.
4.11 STOCKPILES
In a stone crushing process, it is inevitable to have recourse to stockpiles. In this
particular case, they will be as described below:
4.11.1
Spalls Stockpile
Spalls produced from the primary stone crusher jaw crusher will be stock piled before
being fed to the secondary crushers through the conveyors. Spalls from the primary
crusher will be conveyed via the conveyor belt labelled C1 to the primary stockpile at
an average throughout capacity of 500 tonnes per hour.
The boulders stockpile will of a maximum height of 15 metres giving a holding capacity
of about 15,000 tonnes.
This stockpile will be fitted with water misters/sprinklers which will keep the stockpiles
in a wetted condition at all times. The wetting of the spalls in the stockpile normally
induces the fine particles on the surface of the stockpile to cling to the spalls surface so
that they are not blown away by wind action to produce dust emission and pluming
which evidently constitute an environmental hazard. Thus the wetting of the stockpile
will eliminate the environmental impacts associated with dust emissions.
4.11.2
Product Stockpiles
Product stockpiles for each type of the finished materials (aggregates), as listed at subsection 4.2 above, will be established downstream of the product screens. It is
inevitable that these stockpiles shall be open to the atmosphere for the simple reason
that loaders are required to move from one point of the stockpile to the other for the
loading of the materials onto the transporting lorries. Thus loaders will be utilized to
load lorries with the intended type of material from the individually dedicated
stockpiles.
Dust emissions from the finished product stockpiles will be suppressed by the same type
of dust suppression system, namely water-misters and water sprinklers, in the same way
as for the spalls stockpiles.
The product stockpiles are positioned as shown on the general layout plan of the plants
enclosed at Annex 4A at the end of Section 4.
Office
Workers Mess
Toilet
Bathrooms
Workshop