Nanchang Mineral Systems Skid-Mounted Crushing Plant: Dual Iron Ore & Limestone Lines Commissioned in Zambia

Nanchang Mineral Systems Skid-Mounted Modular Crushing & Screening Plant: Dual-Line Iron Ore & Limestone Production Goes Live in Zambia

Nanchang Mineral Systems is proud to announce the successful commissioning of a complete skid-mounted modular crushing and screening plant at a major iron and steel raw materials integration project in Zambia. Delivered as a full EPC turnkey solution, the plant features two parallel processing lines — one dedicated to iron ore crushing and the other to metallurgical-grade limestone production — both now operating at full capacity.

Project Background — Africa's Integrated Steel Raw Materials Hub

The Zambian project represents a landmark investment in Africa's steel supply chain, aiming to establish a self-sufficient raw materials processing hub for integrated iron and steel production. The client required a crushing and screening system capable of simultaneously producing two distinct product streams: high-grade iron ore feedstock for direct reduction ironmaking and flux-grade limestone for blast furnace operations. The remote location and aggressive project timeline demanded a solution that minimized civil works, accelerated installation, and delivered reliable performance from day one.

The Solution — Skid-Mounted Modular Crushing & Screening System

Nanchang Mineral Systems designed, manufactured, and delivered a complete skid-mounted modular plant comprising three core processing stations:

Module	Model	Function	Line Assignment
Primary Crushing	MK-JC Skid-Mounted Jaw Crusher Station	Primary reduction of run-of-mine ore	Iron Ore Line
Secondary Crushing	MK-MC Skid-Mounted Cone Crusher Station	Secondary and tertiary size reduction	Iron Ore & Limestone Lines
Screening	MK-SR Skid-Mounted Screening Station	Multi-deck classification and sizing	Iron Ore & Limestone Lines

All modules are pre-assembled on heavy-duty skid bases, factory-tested, and shipped as ready-to-install units requiring no complex on-site civil works.

Key Highlights of the Zambian Installation

Dual-Line Simultaneous Production: The iron ore line processes run-of-mine material at 80 tonnes per hour with a final product size of 8 mm, delivering consistent high-grade feedstock for downstream ironmaking. In parallel, the limestone line produces metallurgical-grade flux material, ensuring the client has both critical raw materials from a single integrated facility.
Skid-Mounted Modular Design — No Complex Civil Works: All crushing and screening modules are pre-assembled on rigid steel skid bases at the factory. On-site installation requires only a compacted gravel pad and minor anchor points, eliminating the need for poured concrete foundations. This approach reduced site preparation time by over 60% compared to conventional stationary plants.
Centralized Integrated Control System: A fully networked PLC-based centralized control system orchestrates all equipment across both production lines. Operators monitor and manage the entire process — from raw material feed to final product stockpiling — through a single human-machine interface, enabling synchronized start-stop sequences, real-time load balancing, and automated fault diagnostics.
Full EPC Turnkey Delivery: Nanchang Mineral Systems provided end-to-end project execution encompassing engineering design, equipment manufacturing, factory acceptance testing, sea freight logistics, on-site installation supervision, commissioning, and operator training. This comprehensive EPC approach ensured a single point of accountability and seamless project delivery from concept to production.
Purpose-Built for African Operating Conditions: The entire system was engineered with emphasis on robust construction, simplified maintenance access, and readily available spare parts. Dust suppression systems, tropical-grade electrical enclosures, and reinforced structural components ensure long-term reliability in Zambia's challenging operating environment.

Performance Summary

Parameter	Iron Ore Line	Limestone Line
Throughput Capacity	80 t/h	Design-matched
Final Product Size	8 mm	Per specification
End Use	Ironmaking feedstock	Blast furnace flux
Control System	Centralized PLC, single-HMI operation
Installation Base	Skid-mounted, no poured concrete required
Project Model	Full EPC turnkey delivery

Conclusion — A Benchmark for African Mining Infrastructure

The successful dual-line commissioning of the skid-mounted modular crushing and screening plant in Zambia marks a significant achievement for Nanchang Mineral Systems and reinforces the company's position as a leading EPC solutions provider for the African mining sector. By combining modular skid-mounted design with centralized intelligent control, the project demonstrates how modern mineral processing technology can overcome the logistical and infrastructural challenges typical of remote mining developments. With both iron ore and limestone lines now in full production, this facility stands as a replicable model for integrated steel raw materials projects across the African continent and beyond.