PLANT LAYOUTOnce the plant is in operation, there is seldom timeavailable to stop operations to remodel; therefore, thelayout and erection of the crusher unit should be givenadequate time to ensure an efficient facility is built.Equipment ConfigurationSpecial attention should be given to creating alogical flow of material from the point where trucksenter the plant with raw material to the point wheretrucks depart from the crusher with crushed aggregateproducts. You should evaluate the physicalenvironmental requirements of each piece ofequipment, such as foundation requirements, waterrequirements, and power requirements, to ensure theyare included during the construction stage.DrainageAdequate drainage charnels should be constructedduring the initial earthworking stage of construction andconstantly improved as the plant is built. This issignificant because most of the rock crushing plantshave electrical components inherent to their operation.Prevailing WindsEquipment should be oriented in such a manner thatprevailing winds carry the rock dust generated by thecrusher away from the facility. Support equipment, suchas generators and water pumps, and permanentfacilities, such as latrines, offices, and maintenanceshops, should be located out of the path of windscarrying the rock dust.DO NOT FORGET THE DEPARTMENT OFENVIRONMENT’AL QUALITY (DEQ) REQUIRE-MENTS FOR DUST CONTROL. The DEQ works forthe Environmental Projection Agency (EPA). The EPAhas established standards for controlling the amount ofrock dust that can be admitted into the air.The COMSECOND/COMTHIRDNCB EquipmentOffices work closely with the DEQ to ensure the plantsin the NCF abide by the rules of the DEQ. Sprinklersystems have been installed on rock crushers in the NCFto control the rock dust produced from crushingoperations to meet the requirements of one rule. As thecrusher supervisor, you are responsible to make surethese systems remain operational.Organization of SpaceThe crusher design should include adequate spacearound the equipment. This space is required to provideaccess areas for maintenance personnel to performrepairs, space to move cranes in and out to lift out andreplace or rotate worn jaw plates and roll shells, spacefor the fuel truck to refuel the equipment, and space toremove and replace components of the crusher unit.Material Handling and StorageT h e p l a ntshouldincludeadequatematerial-handling devices to expedite the flow ofmaterial through the plant and eliminate doublehandling of the material.A headwall ramp should be constructed to allowhaul units or loaders to back up to or approach the apronfeeder of the primary unit and discharge their loads. Ifa problem with oversized rock is anticipated, you shouldhave a prescreening grizzly built in the quarry or overthe apron feeder to remove the oversized rock.When possible, store quality product size aggregatein bins, rather than in open stockpiles. This is mostimportant when the aggregate is crushed tospecifications sizes or has been washed. Openstockpiling of aggregate can be contaminated bywindblown sand, fines, and trash.When bins are not available for aggregate storage,headwalls should be constructed for stockpiles to ensureseparation of different sizes of aggregate beingprocessed. The area separating headwalls should belarge enough to stockpile a large supply of aggregate andhave adequate space on the front side for loadingvehicles without causing congested traffic areas.Aggregate stockpiles are loaded by loaders orclamshells. These machines are most efficient forloading vehicles with clean aggregate off the top ofstockpiles. The aggregates at the bottom of stockpilesbecome embedded in the ground and tend to becomecontaminated. This layer is lost for use.StockpilingStockpiling is most efficiently accomplished onhard, flat, clear areas. The location of the stockpilesshould be convenient to the quarry, the crusher, and thehauling unit. When available space is large comparedwith the bulk of material to be stored, trucks may dumppiles as closely as possible to each other.6-13
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