1. What is a stone crusher plant

A Stone Crusher Plant is one-stop crushing installation, typical materials like limestone, granite, river gravel, basalt, etc., the plant produces different sizes of gravels and sand which can be used for constructions.

The plant may be either fixed or mobile. A stone crusher plant has different stations, primary, secondary, tertiary, etc., where different crushing, selection and transport cycles are done in order to obtain different stone sizes, for fixed plant different stages combines together to form a complete stone crushing plant.

2. Stone crusher plant process

Feeding equipment: like vibration feeder or plate type feeder: These machines feed the jaw crusher or impact crusher with the rocks and stones to be crushed.

Crushing equipment: These are the machines where the rocks and stones are crushed. There are different types of crushers for different types of rocks and stones and different sizes of the input and output material. Each plant would incorporate one or several crushing machines depending on the required final material, gravels or sand or both. Generally jaw crushers and Gyratory crushers are used for primary crushing, while impact crusher, Symons cone crusher, hammer crusher are used for secondary crushing and tertiary crushing.

Vibrating Screen: These machines are used to separate the different sizes of the material obtained by the crushers.

Belt Conveyors: These elements are the belts used for transportation of the material from one machine to another during different phases of process.

Central electric control system: Control and monitor the operation of the entire system.

3. Types of stone crusher plants

The crushing part is the core system of the whole stone crusher plant, and the stone crushers, as the key equipment of the crushing part, plays an extremely important role in the product quality and stable operation of the whole production line. The current sand and gravel production line often adopts the method of graded production and the combination of multiple crushers to achieve the best results. The capacity of production, financial situation, maintenance and repair, product performance and proportion are the main factors.

1. Single-stage hammer crusher

It is good for soft and medium hardness of stones. The advantages of this system are simple process, easy operation and management. It needs small land area, low investment and low energy consumption per unit product. The disadvantages are that the product variety ratio is not easy to adjust, the applicability to the ore is narrow; the product particle shape is not as good as from an impact crusher, the amount of fine powder is large, while the consumption of wear parts is high and hammers need to changed frequently.

2. Jaw Crusher & Impact Crusher

The advantages of this system are more options of capacities, it has a wide range of application and can put into large scale production; easy to adjust the product particle variety ratio, good cubic product shape, less powder; good adaptability to materials with medium abrasion too. The disadvantages are low adaptability to high abrasion materials, higher wear parts consumption than cone crusher, and higher energy consumption per unit product.

3. Jaw Crusher & Cone Crusher

The advantages of this system are easy adjustment of product variety ratio; suitable for high abrasion materials; good product particle shape, small amount of fine powder, coarse size aggregates rate is high; low energy consumption per unit product; low consumption of wear parts. The disadvantage is that when the system capacity is large, three crushing stages or multiple crushers are required, which will lead to a complex process and high project investment in advance.

4. Jaw Crusher, Impact Crusher & VSI sand making machine

This system is based on the jaw crusher and impact crusher system, adds a vertical shaft crusher to form a three-stage crushing plant. The role of the vertical shaft crusher is to shape the aggregates, which will get better cubic products. In addition to the advantages of the jaw crusher and impact crusher system, this combination is capable of producing aggregates of different qualities. At the same time, it produces sand as well. The disadvantage is that it increases the crushing equipment, the initial investment increases and the total investment is high.

5. Jaw Crusher, Cone Crusher & Cone Crusher

This system is based on the jaw crusher and cone crusher system, adds a cone crusher to form a three-stage crushing. In addition to the advantages of the jaw crusher and cone crusher system, this combination also has the feature of large production capacity, which is suitable for larger scale production lines. The disadvantage is that it increases the crushing equipment, the initial investment increases and the total investment is high.

In the stone crusher plant, the crushing system is in a key position. The same crusher has different capacities when crushing different materials under the same conditions, and different crushers have different capacities when crushing the same material under the same conditions. The physical characteristics of the material, product quality requirements and production capacity need to be taken into consideration when choose the type & combination form of different stone crushers.

Impact crusher or Cone crusher? How to choose?

6. Technical and economical index

NO.Way of combinationCrushing stageRock hardness(MPa)Energy consumption per unit of productParticle size varietyPowder contentPre-investmentMaintenance cost
1Singe stage heavy hammer crushing systemSinge stage<100LowMonotonousA lotLowHigh
2Jaw crusher and impact crusherTwo stages<150Relatively highVarious SomeRelatively highRelatively high
3Jaw crusher and cone crusherTwo stages250-320LowVarious A fewRelatively highLow
4Jaw crusher, impact crusher and VSIThree stages<150Relatively highVarious A fewHighReltively high
5Jaw crusher, cone crusher and cone crusherThree stages250-320LowVarious FewHighLow

4. Stone crusher plant investment and cost

1. Jaw crusher & impact crusher in a stone crusher plant

Key equipment list20TPH40TPH80TPH120TPH200TPH300TPH
Vibrating feederGZD2500x750GZD3000x800ZSW3800x960ZSW3800x960ZSW4900x1100ZSW4900x1300
Primary crusherPE250x400PE400x600PE500X750PE600X900PE750X1060PE1000X1200
Impact crusherPF0807PF1007PF1210PF1214PF1214x2PF1315x2
Vibrating screen2YK12243YK12363YK15484YK18602YK1860
3YK1548
2YK2160
3YK1860
Belt conveyorsB500B500B650, B500B800, B500B1000, B800, B650, B500B1200, B800, B650
Total power approximately80 KW140 KW220KW300KW580KW800KW
Recommend max feed size210mm350mm425mm480mm630mm850mm
Area needed for the plant30x50m40x70m50x80m50x100m80x150m100x200m
Note: The above form and data are for reference only. Process capacity, total power, investment cost, land area are approximate data, they are related to different types of rocks, different requirements of the discharge size, labor cost, currency exchange, etc. Sand making machine and sand washer shall be added if need to produce more sand than gravels. Contact us to customize the stone crusher plant for you.

2. Jaw crusher & cone crusher in a stone crusher plant

Key equipment list20TPH40TPH80TPH120TPH200TPH300TPH
Vibrating feederGZD2500x750GZD3000x800ZSW3800x960ZSW3800x960ZSW4900x1100ZSW4900x1300
Primary crusherPE250x400PE400x600PE500X750PE600X900PE750X1060PE1000X1200
Symons cone crusher2 ft2 ft3 ft4.25 ft4.25 ft x 24.25 ft x 2
Vibrating screen2YK12243YK12363YK15484YK18602YK1860
3YK1548
2YK2160
3YK1860
Belt conveyorsB500B500B650, B500B800, B500B1000, B800, B650, B500B1200, B800, B650
Total power approximately70 KW120 KW200KW360KW600KW800KW
Recommend max feed size210mm350mm425mm480mm630mm850mm
Area needed for the plant30x50m40x70m50x80m50x100m80x150m100x200m
Note: The above form and data are for reference only. Process capacity, total power, investment cost, land area are approximate data, they are related to different types of rocks, different requirements of the discharge size, labor cost, currency exchange, etc. Sand making machine and sand washer shall be added if need to produce more sand than gravels. Contact us to customize the stone crusher plant for you.

5. Typical process diagram for reference

6. Stone crusher plant from client’s feedback

Stone crusher plant details, from A to Z

Stone crusher plant design, things to consider

Stone crusher plant investment, things you need to know

How to start a stone crusher plant

50 tph stone crusher plant