Dhaka 120t/h Construction Waste Crushing Line Project in Bangladesh: An Efficient Resource Utilization Solution Adapted to National Conditions
Against the backdrop of accelerating urbanization in Bangladesh, Dhaka generates over 8 million tons of construction waste annually, with a recycling rate of less than 5%. In 2025, the 120t/h crushing line project constructed by XINYU MACHINE was put into operation in the suburbs of Dhaka. It not only filled the gap in large-scale construction waste treatment in the local area but also achieved a win-win situation in economic and environmental benefits through customized configurations. The following details are presented from three aspects: equipment configuration, national condition adaptation, and application feedback.
Core Configuration and Technical Parameters: Balancing Production Capacity and Local Needs
Main Equipment Composition (Closed-Loop Design)
- Raw Material Pretreatment System: ZSW380×95 vibrating feeder (processing capacity 150-300t/h) equipped with a grid with 200mm aperture, which can pre-screen out clay blocks and small impurities to reduce the subsequent crushing pressure.
- Coarse Crushing Link: PE600×900 jaw crusher (power 75kW) with a feed port size of 600×900mm, crushing construction waste ≤500mm to ≤150mm to meet the feeding requirements of medium crushing.
- Medium Crushing Link: PF1315 impact crusher (power 160kW) with a processing capacity of 100-180t/h. It uses the impact crushing principle to refine materials to ≤30mm, and at the same time shapes brick slag and concrete blocks to improve the finished product’s particle shape.
- Screening System: 3YK2160 vibrating screen (power 15kW). The three-layer screen mesh produces three specifications of finished products: 0-5mm, 5-10mm, and 10-20mm respectively. The screening efficiency is over 95%, and oversize materials are returned to the medium crusher for re-crushing through the return belt.
- Auxiliary System: Including pulse bag filter (air handling capacity 25000m³/h), PLC control system, and anti-clogging alarm device, which meets the dust emission limit (≤50mg/m³) of the Bangladesh Ministry of Environment.
Key Performance Parameters
- Designed production capacity: 120t/h (actual operation is stable at 110-130t/h, with a 10% fluctuation margin reserved)
- Qualified rate of finished products: ≥90% (0-20mm graded aggregate accounts for 85%)
- Total power of equipment: About 320kW (adapted to Bangladesh’s 380V/50Hz industrial power grid)
- Floor area: About 3000㎡ (adopting modular layout to shorten the installation period)
National Condition Adaptation Design: Coping with Special Working Conditions in Bangladesh
Adaptation to Raw Material Characteristics
Construction waste in Bangladesh is mainly composed of brick slag (60%) and concrete blocks (30%), mixed with impurities such as plastics and wood. The project achieves efficient treatment through three optimizations:
- The moving jaw of the jaw crusher is made of high-chromium cast iron, which improves wear resistance by 40% to cope with the wear caused by silicate components in brick slag;
- The impact crusher’s blow bars are made of bimetallic composite materials, with a service life extended to 800 hours (the average of similar equipment is 500 hours);
- A magnetic separation drum (magnetic field strength 12000Gs) is added to remove metal impurities such as steel bars to avoid equipment jamming.
Adaptation to Infrastructure
- Power Supply Guarantee: Equipped with a 350kVA diesel generator to cope with frequent power outages in the suburbs of Dhaka and ensure the continuous operation of the production line;
- Site Conditions: Adopting a semi-mobile steel structure foundation to adapt to the muddy ground in the rainy season in Bangladesh (bearing capacity requirement ≥150kPa);
- Transportation Adaptation: The outlet of the finished product warehouse is connected to a 1000mm wide belt conveyor, which directly connects to the commonly used 6-wheel dump trucks (load 15t) in the local area, reducing the transfer links.
Environmental Compliance
In response to the requirements for construction waste treatment in Bangladesh’s “Environmental Protection Act 2021”, the project has taken double measures:
- Closed design of the crushing workshop + fog cannon dust suppression, controlling the concentration of unorganized emission dust below 0.5mg/m³;
- Wastewater is recycled for equipment cooling after treatment in a sedimentation tank (three-stage sedimentation), achieving zero discharge.
Customer Application Scenarios and Feedback
Project Owner and Application Scenarios
The project is invested by the local Bangladeshi construction group, and the finished products are mainly used in two scenarios:
- Road Engineering: The mixture of 0-5mm fine materials and 5-10mm aggregates is used as the base filler for municipal roads in the new urban area of Dhaka (replacing traditional river sand, reducing costs by 30%);
- Recycled Brick Production: 10-20mm aggregates are supplied to surrounding brick factories for the production of environmental protection non-fired bricks, with an annual supply of 80,000 tons.
Operation Data and Customer Evaluation
- Commissioning Time: June 2025(installation period 45 days, 15 days shorter than the contract period)
- Operating Cost: The treatment cost per ton is about 120 Bangladeshi Taka (including labor, energy consumption, and maintenance), which is lower than the 180 Taka/ton of purchased natural aggregates;
- Customer Feedback:
- “The equipment’s handling capacity for wet materials (15% moisture content in the rainy season) exceeds expectations, and there is no clogging problem” — Md. Hasan, Production Director;
- “The remote diagnosis system provided by Chinese engineers is very practical. 80% of faults can be solved through video guidance, reducing downtime” — Rahman, Equipment Manager;
- “30% of the investment has been recovered in half a year, and it is expected to pay back in 2 years” — Iqbal, Project Investor.
Project Value and Promotion Significance
The successful operation of this 120t/h crushing line provides a replicable model for the resource utilization of construction waste in Bangladesh:
- Economic Value: It handles about 800,000 tons of construction waste annually and reduces the exploitation of natural sand and gravel by 600,000 cubic meters;
- Social Value: It creates 50 local jobs and reduces the land occupied by construction waste landfills by 12,000 square meters annually;
- Technology Export: It proves the adaptability of Chinese crushing equipment in tropical high-humidity environments, providing a reference for subsequent projects in other cities in Bangladesh (such as Chittagong and Khulna).
At present, the project party has signed a phase II expansion agreement with the Chinese mnufacturer, planning to increase the production capacity to 200t/h to further cover the aggregate demand in the surrounding areas.
