Stone Crusher License

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There are various types of stone crushers in India. The type and size of a stone crusher depends on the location of the crusher, the demand for crushed products, distance to urban areas, type of raw material available and the local availability of plant and machinery. The stone crushers are generally categorized as small, medium and large sized crushers.

Small Stone Crushers

The small stone crushers have a stone crushing capacity of 3-25 tones per hour. These crushers have one jaw and one or two rotary screens.
These stone crushers have manual breaking, feeding, retrieving and stocking operations with one jaw and one rotary screen.
This type of stone crushers has manual breaking and manual or gravity feeding belt conveyors having single jaw & single rotary screen.
These stone crushers have a mechanical or Gravity feeding with single jaw having vibratory type screens with belt conveyors.
This type of small stone crushers has a single Jaw Bucket Elevator with Elevated vibratory screen having storage bunkers type compact units

Medium Size Stone Crushers

The medium size stone crushers have a stone crushing capacity of 25 to 100 tones per hour. They have one primary and one secondary crusher or one primary and two secondary crushers with more than one vibratory screens. The mined stones are transported by trucks to the elevated stone wells, which are then gravity fed to primary stone crusher. The crushed stone is moved to vibratory screens using conveyer belts and are stockpiled into various sizes of crushed stones. The oversized stones are again fed into the secondary crusher and back to vibratory screen using a conveyor belt.

Large size stone crushers

The stone crushers having a production capacity between 100 to 200 tones per hour are categorized as large stone crushers. These crushers have two or more than two primary, secondary & tertiary type crushers with at least 2 or more vibratory screens and having mechanized loading, unloading and conveying operations. The large stone crushers are generally owned by large construction companies for their own large construction projects having their own leased open - cast mines and a fleet of mechanical mining equipment, trucks and dumpers and loaders.

The different types of stone crushers are as following:

Jaw Crushers

Single toggle Jaw crusher
Double Toggle Crusher
Impact Jaw Crushers

Gyratory (Cone) Crushers

Primary Gyratory Crusher
Cone Crusher

Roller Crushers

Single-Roll Crusher
Double Roll Crusher

Hammer Crusher

Impactor/Impact Breakers

Rotopoctor

The stone crushing unit must be located 1 Km away from a Class A and above cities, towns, villages and approved habitations.
It needs to be situated at 5 Km away from a Wild Life Sanctuary or the buffer zone declared for the same.
The stone crushing unit should be located 200 meters away from the boundary of a National Highway and the boundary of a railway line and from a river, canal or a lake.
It is mandated to be located at minimum 500 meters away from a sensitive area such as educational institute or a religious place.
The stone crusher should be situated at a 1 Km distance from a place of historical importance.

Every stone crushing unit is required to install adequate pollution control measures such as erection of G.I. Sheets cover and the sprinklers prior to the commencement of operations.
A dust doom should be provided in the unit.
All stone crushers are to be covered and water sprinkling system should be installed to suppress the dust generated due to material handling, loading and unloading activity.
The vibratory screens need to be properly covered by G.I. Sheets to prevent the emission into
the atmosphere due to screening and grading activity.
All the conveyor belts are required to be covered by G.I or M.S. sheets.
Wetting of roads is to be carried out at frequent intervals to suppress the ground level dust within the premises to control the air borne dust emission due to wind velocity.
All the approach roads and ramps are to be metlled.
A Curtain or wall is needed surrounding the stone crusher unit.
A display board should be erected at the entrance of stone crusher displaying the survey no, name and address of owner and the unit.
Fine dust generated during screening, crushing and grading should be disposed off into abandoned mines.

Fixed Costs

1.   Crusher & Screen
I.   Jaw Crusher (20 x 12) Rs.2.5 Lakh
II.   Jaw Crusher (16 x 9) Rs. 2.0 Lakh
III.   Vibratory Screen Rs. 1.20 Lakh
IV.   Handling Material Equipment:
a)   Belt Conveyors (tyre) Rs.0.25 Lakh
b)   Motors Rs.0.30 Lakh
c)   Structural Rs.1.50 Lakh
d)   Miscellaneous electricals, starters Rs.1.0 Lakh
e)   Miscellaneous Structural, chutes etc Rs.2.0 Lakh
f)   Lab & office equipment Rs.1.25 Lakh
2.   Transportation vehicles
I.   2 Tractors Rs.4 Lakh
II.   2 Dumpers Rs.9 Lakh
3.   DG set 62 KVA (Captive Power Generation) Rs. 3 Lakh
4.   Civil work
I.   Ramp, stone well etc Rs.3 Lakh
II.   Office sheds Rs. 3 Lakh
Total Capital Investment Rs.34 Lakh
Cost of dust control System Rs. 1 Lakh
(enclosures, tank, pump, pipes, nozzles etc)

Annual Operating Cost/year

Electricity Rs 7 lakh
Man power Rs Rs 12 lakh
Royalty Rs 2 Lakh
Transportation Rs 1 lakh
Misc. Costs Rs. 5 Lakh
Total operating cost per year - Rs.32 Lakh

The documents required for the State Pollution Control Board permission for a stone crusher are as following:

Details of the applicant such as Name of the Authorized Signatory, Company Name, GST Certificate etc
Mining Lease certificate issued by the Geology and Mines Unit
Copy of Khasra of the site issued by the Revenue Department
Project Report approved by Authorised and Empaneled Consultants
Layout Plan of the site

Introduction

The Stone Crushing Industry is a very important industrial sector in India, producing crushed stones of different sizes as per the demand of the raw materials in construction of Roads, Highways, Bridges and residential and commercial buildings. As per the latest estimates, there are more than 12,000 registered stone crusher units in India. This number is expected to increase further as the demand for development of infrastructure such as roads, buildings etc is also expected to rise. The annual turnover of the Stone Crushing Industry is approximately Rs. 5000 crores. This sector is offering direct employment to more than 500,000 people, who are employed in various operations of the stone crushing units such as mining, stone crushing, transportation of mined stones and crushed products etc. This sector assumes even greater significance as the majority of this work force employed in these stone crushers come from rural and economically backward areas where employment opportunities are anyway scarce. It acts as a good source of earning for uneducated and unskilled poor population of the rural India.

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