Case Study: Modular Crushing Plant Boosts Efficiency for China-Kyrgyzstan-Uzbekistan Railway Construction
Project Overview
Location: Tashkent Region, Uzbekistan
Application: Aggregate production for China-Kyrgyzstan-Uzbekistan Railway (0-5mm sand, 5-10mm, 10-20mm, 20-31.5mm ballast).
Equipment Supplied:
· Feeding & Primary Crushing: 9638 Vibrating Grizzly Feeder + PE600×900 Jaw Crusher (0-500mm → 0-150mm).
· Secondary Crushing: PF1214 Impact Crusher Module (adjustable output: 0-40mm).
· Screening: 3YK1860 Vibrating Screen (3-deck, high-precision classification).
· Conveying & Dust Control: Enclosed belt conveyors + pulse dust collectors.
Challenges & Solutions
1. Strict Aggregate Specifications for Railway Ballast
Requirement: 20-31.5mm basalt aggregates (flakiness <10%), 0-5mm manufactured sand (fineness modulus 2.6-3.0).
Solution:
· PE600×900 Jaw Crusher ensured uniform primary crushing with <75mm discharge setting.
· PF1214 Impact Crusher with hydraulic adjustment produced cubical-shaped aggregates ideal for rail ballast.
· 3YK1860 Screen achieved 98% screening efficiency via polyurethane mesh panels.
2. Rapid Deployment in Remote Site
Challenge: 30-day installation deadline due to tight railway construction schedule.
Solution:
· Pre-assembled modular stations reduced on-site work by 60% (commissioned in 18 days).
· Plug-and-play electrical system with IP65 protection for desert dust resistance.
3. Dust & Noise Compliance
Regulation: Uzbekistan GOST R 12.3.047-2020 (dust <10mg/m³, noise <75dB).
Measures:
· Dust Control: Water spray nozzles at transfer points + baghouse filters.
· Noise Reduction: Soundproof enclosures for PF1214 impact crusher.
Performance Results
Metric | Outcome |
Capacity | 120-150 TPH (basalt) |
Final Products | 0-5mm (28%), 5-10mm (22%), 10-20mm (30%), 20-31.5mm (20%) |
Dust Emission | 8.2mg/m³ (compliant) |
Downtime | <2% (remote monitoring via IoT sensors) |
Project ROI | Achieved in 5 months due to high-demand aggregates |
"The modular design allowed us to start production 12 days ahead of schedule. The PF1214's ability to switch between railway ballast and concrete aggregates saved us $220,000 in equipment leasing costs."
— Mr. Alimov, Site Manager, Uzbekistan Rail Project
Why This Configuration Works
1. PE600×900 Jaw Crusher: High crushing ratio (6:1) for hard basalt.
2. PF1214 Impact Crusher: Adjustable grate gap (10-40mm) for multi-size output.
3. 3YK1860 Screen: 18m² screening area with 3-layer precision separation.
Diagram:
[Raw Material] → 9638 Feeder → PE600×900 → PF1214 → 3YK1860 → [4 Finished Products]
Project Photos & Videos
(Attach: Crushing plant site layout, PF1214 in operation, screened aggregates stockpile)