Started in 1980s, Zhengzhou Unique Industrial Equipment Co., Ltd (Unique Group) is already a famous manufacturer & developer of mining equipment like stone crushing & screening equipment and ore processing equipment in China. Our products scope mainly includes cone crusher, jaw crusher, impact crusher, sand making machine, vibrating screen, vibrating feeder, belt conveyor, stationary & mobile stone crushing plant, ball mill, magnetic separator and cement production line etc.
Stone crushing plants inevitably generate waste (e.g., stone powder, scraps, non-compliant aggregates), which increases costs, occupies space, and harms the environment. Efficient waste reduction is critical for improving profitability and sustainability. Below are proven strategies combining process optimization, equipment upgrades, recycling, and management practices to achieve green production.
1.1 Precision Process Design
Multi-Stage Crushing Strategy: Adopt “coarse → medium → fine crushing → screening” stages tailored to material hardness and product requirements. Example: For hard rocks (e.g., granite), increase coarse crushing ratios to reduce fine-stage loads, limiting stone powder generation to 5–8%.
Closed-Loop Recycling System: Integrate return belts to reprocess oversized or needle-shaped aggregates, cutting waste by 15–20%.
1.2 Upgrade Equipment for Lower Waste
Low-Loss Crushers:
Jaw Crushers: Use deep-chamber models (e.g., PE-600×900) to minimize blockages and energy waste.
Impact Crushers: Deploy VSI “stone-on-stone” sand makers to reduce wear by 30% and fine powder output.
High-Efficiency Screens: High-frequency screens (e.g., 3YK1860) achieve >95% screening accuracy, preventing material misclassification.
Maintenance Protocols: Monthly checks for crusher gaps (e.g., jaw plate spacing) and quarterly screen calibration to maintain performance.
2.1 Pre-Treatment & Grading
Impurity Removal: Install magnetic separators (e.g., RCYD series) and manual sorting at feed points to eliminate metal, soil, and vegetation.
Hardness-Based Stockpiling: Separate raw materials by hardness (e.g., limestone vs. basalt) to reduce over-crushing by 10%.
2.2 Real-Time Monitoring
IoT Sensors & Automation: Track feed rates (200–300 tons/hour), particle distribution (0–5mm, 5–10mm), and equipment load (70–85% of rated current) via PLC systems.
Waste Tracking: Use weigh sensors at waste outlets to maintain waste rates below 3% of total output. Trigger alerts for 3-day exceedances.
3.1 Stone Powder Utilization
Artificial Sand Production: Blend stone powder (<0.075mm) with aggregates (8–10% moisture) to meet GB/T 14684 standards, cutting costs by ¥20/ton.
Industrial Fillers: Process ultrafine limestone powder (>90% CaCO₃) into coatings/plastic fillers using Raymond mills (e.g., 4R3216), boosting value 3–5x.
3.2 Reprocess Non-Compliant Aggregates
Secondary Crushing: Convert needle-shaped aggregates (>15%) into 5–10mm road base materials via cone crushers (e.g., HPT300).
Construction Waste Recycling: Crush concrete/mortar waste into ≤40mm recycled aggregates (GB/T 25177 compliant) for roadbeds (50%+ replacement rate).
3.3 Metal & Water/Dust Recovery
Metal Recycling: Collect worn crusher parts (e.g., jaw plates) for smelting (¥500–800/ton).
Water & Dust Systems: Use sedimentation tanks + filter presses for 85% water reuse and bag dust collectors (e.g., DMC-120) for >99% dust recovery.
4.1 Performance Incentives
Link team bonuses to waste targets (≤3% rate), with penalties for non-compliance.
Reward employee suggestions (e.g., process tweaks) with ¥500–2000 for viable ideas.
4.2 Skill Development
Quarterly training on “uniform feeding” and “start-stop sequences” to prevent operational waste.
Competitions to test parameter adjustments (e.g., crusher discharge settings) and waste sorting skills.
5.1 Leverage Green Incentives
Apply for tax rebates (50% VAT refund) and subsidies (10–30% equipment funding) under “resource recycling” certifications.
5.2 Industry-Academia Collaboration
Develop low-energy tech (e.g., ultrasonic crushing) to cut waste rates (e.g., 4.5% → 2.8%) and energy use by 12%.
Partner with concrete plants to customize aggregate specs, reducing off-spec production.
By integrating process optimization, equipment upgrades, recycling, and employee engagement, stone crushing plants can reduce costs by ¥0.5–2/ton while enhancing sustainability. Future trends like AI sorting and IoT monitoring will further drive waste reduction, aligning with global green building policies for long-term profitability.
