Granite Crushing Plant in Hainan: Inside a 5.3 Mt/y Project

A granite crushing plant in Danzhou, Hainan, has completed an integrated trial run under material load, bringing a project designed for 5.3 million tonnes of aggregates and manufactured sand per year into production commissioning. Leimeng Group supplied all core crushing and screening equipment, with two GC200 jaw crushers, DS and HPY cone crushers, PG double-roller sand making machines and YKJ vibrating screens.

The configuration addresses two connected requirements: reducing hard, abrasive granite through successive crushing stages and separating the processed material into saleable aggregate and sand fractions. For quarry operators planning a comparable plant, the project offers a practical example of how equipment selection connects to finished product requirements.

Project Facts: Capacity, Material and Product Sizes

The production line serves the Phase II project at the Duanmenling mining area, Xipei Farm, Danzhou. The project has passed its safety facilities completion acceptance inspection and moved from construction and installation into production commissioning.

Why Granite Crushing Requires More Than a Hardness Rating

The granite processed at this site is hard and abrasive. These properties affect different parts of the equipment decision: resistance to breakage influences the crushing duty, while abrasiveness affects wear on surfaces such as jaw plates and cone liners.

Jaw and cone crushers use compression to break rock, making them common choices for hard, abrasive materials. However, the rock name alone is insufficient for final selection. Feed size, moisture, clay content and the required product shape also matter.

For a new granite aggregate production line, representative material testing helps establish whether a proposed configuration suits the actual deposit. A plant processing weathered granite with clay contamination may need different feed preparation from one handling cleaner, fresh rock.

How the Hainan Granite Crushing Plant Is Configured

The project combines primary, secondary and tertiary crushing with a dedicated sand-making stage. Screening, washing and wastewater treatment complete the process.

Primary Crushing: Preparing Feed for the Cone Crushers

The two GC200 units handle large granite rock at the start of the line. Their role is to produce feed suitable for the next crushing stage.

When selecting a jaw crusher for granite, maximum feed size is only one consideration. The size distribution leaving the jaw crusher must also suit the receiving cone crusher. This makes the primary discharge setting part of the overall process design.

Secondary and Tertiary Crushing: Dividing the Reduction Duty

DS cone crushers handle secondary crushing, followed by HPY cone crushers for tertiary reduction.

Dividing the duty across stages provides more scope to match feed size and discharge requirements at each step. This is particularly relevant when a plant must produce smaller aggregate fractions as well as feed for sand making. Multi-stage crushing can help avoid placing an excessive reduction duty on one crusher.

For operators, cone chamber selection and the closed-side setting, or CSS, should be assessed together with feed conditions and downstream screening. A smaller setting changes the product distribution, but its effect on throughput and wear must also be considered.

Sand Making: PG Double-Roller Machines

This project uses PG double-roller sand making machines for granite manufactured sand production. Suitable feed passes between the rolls for further size reduction.

The machines feature a yielding mechanism that allows the rolls to move apart when excessively hard or uncrushable material enters, providing equipment protection.

For another granite project, the choice of a double roll sand making machine should be checked against feed size, abrasiveness, required sand yield and roll wear. The Hainan configuration is a project reference; final selection still depends on the client’s material and product requirements.

Screening and Washing Determine What Becomes a Finished Product

Crushing produces a range of particle sizes. Screening separates that material into the fractions the plant intends to sell.

In Hainan, YKJ vibrating screens work with the washing and wastewater treatment systems to support aggregate classification, cleaning and fine sand recovery. This matters because the project targets three coarse aggregate fractions and one manufactured sand fraction.

Screen Opening Is Only Part of the Decision

Screening performance also depends on how material reaches and moves across the screen. Uneven feeding, excessive bed depth and blocked openings can reduce effective separation.

Where a plant uses a closed circuit, poor separation can send material that is already small enough back through a crusher, adding unnecessary load.

Sand Quality Requires More Than a Size Range

The planned 0.075–5 mm sand fraction describes a particle-size range. It does not, by itself, establish compliance with a construction specification.

Gradation, fines content, clay contamination, particle shape and moisture should be assessed against the intended application. Washing and fine sand recovery must therefore be considered alongside the sand-making equipment when setting product quality targets.

What the Integrated Trial Run Demonstrated

During the trial run, equipment operating parameters remained stable, and the automation controls responded promptly. The connected process operated from crushing and sand making through screening, washing, finished product discharge and wastewater treatment.

During construction and commissioning, Leimeng’s project team followed equipment installation and testing, worked with the project owner to adjust operating parameters and crushing-screening configurations, and helped refine the control system.

What to Check When Planning a Similar Granite Plant

The Hainan project provides a useful equipment reference, but copying its model list would leave several design questions unanswered.

Wear cost should also be tracked against saleable output. Jaw plates, cone liners, roll surfaces and screen media contribute to operating cost, while interruptions in feeding or conveying can affect the whole line.

For that reason, hard rock crushing plant design should consider equipment access, replacement-part planning and maintenance alongside nominal capacity.

FAQ

What crusher is suitable for granite?

Jaw crushers are commonly used for primary reduction, with cone crushers handling secondary and tertiary crushing. Final selection depends on material properties, feed size, required output and finished product specifications.

Can one granite plant produce both aggregates and manufactured sand?

Yes. The Hainan project combines staged crushing, PG sand making machines, screening and washing to target three coarse aggregate fractions and a manufactured sand fraction.

Does 5.3 million tonnes per year indicate the plant’s hourly capacity?

No. Hourly capacity depends on the operating schedule and how production targets are defined.

Why include washing in a granite crushing and screening plant?

Washing can help remove adhering fines and impurities where the feed and product specifications require it. The need for washing should be assessed from material tests and the intended use of the aggregates or sand.

Discuss Your Granite Project with Leimeng Group

Leimeng Group supplied the core crushing and screening equipment and supported commissioning for this Hainan project.

To discuss a granite crushing plant, send our team your raw material information, maximum feed size, required hourly capacity and finished product sizes. If manufactured sand is part of the plan, include the target sand proportion and intended application.