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 combination | Crushing stage | Rock hardness(MPa) | Energy consumption per unit of product | Particle size variety | Powder content | Pre-investment | Maintenance cost |
|---|---|---|---|---|---|---|---|---|
| 1 | Singe stage heavy hammer crushing system | Singe stage | ＜100 | Low | Monotonous | A lot | Low | High |
| 2 | Jaw crusher and impact crusher | Two stages | ＜150 | Relatively high | Various | Some | Relatively high | Relatively high |
| 3 | Jaw crusher and cone crusher | Two stages | 250-320 | Low | Various | A few | Relatively high | Low |
| 4 | Jaw crusher, impact crusher and VSI | Three stages | ＜150 | Relatively high | Various | A few | High | Reltively high |
| 5 | Jaw crusher, cone crusher and cone crusher | Three stages | 250-320 | Low | Various | Few | High | Low |
4. Stone crusher plant investment and cost
1. Jaw crusher & impact crusher in a stone crusher plant
| Key equipment list | 20TPH | 40TPH | 80TPH | 120TPH | 200TPH | 300TPH |
|---|---|---|---|---|---|---|
| Vibrating feeder | GZD2500x750 | GZD3000x800 | ZSW3800x960 | ZSW3800x960 | ZSW4900x1100 | ZSW4900x1300 |
| Primary crusher | PE250x400 | PE400x600 | PE500X750 | PE600X900 | PE750X1060 | PE1000X1200 |
| Impact crusher | PF0807 | PF1007 | PF1210 | PF1214 | PF1214x2 | PF1315x2 |
| Vibrating screen | 2YK1224 | 3YK1236 | 3YK1548 | 4YK1860 | 2YK1860 3YK1548 | 2YK2160 3YK1860 |
| Belt conveyors | B500 | B500 | B650, B500 | B800, B500 | B1000, B800, B650, B500 | B1200, B800, B650 |
| Total power approximately | 80 KW | 140 KW | 220KW | 300KW | 580KW | 800KW |
| Recommend max feed size | 210mm | 350mm | 425mm | 480mm | 630mm | 850mm |
| Area needed for the plant | 30x50m | 40x70m | 50x80m | 50x100m | 80x150m | 100x200m |
2. Jaw crusher & cone crusher in a stone crusher plant
| Key equipment list | 20TPH | 40TPH | 80TPH | 120TPH | 200TPH | 300TPH |
|---|---|---|---|---|---|---|
| Vibrating feeder | GZD2500x750 | GZD3000x800 | ZSW3800x960 | ZSW3800x960 | ZSW4900x1100 | ZSW4900x1300 |
| Primary crusher | PE250x400 | PE400x600 | PE500X750 | PE600X900 | PE750X1060 | PE1000X1200 |
| Symons cone crusher | 2 ft | 2 ft | 3 ft | 4.25 ft | 4.25 ft x 2 | 4.25 ft x 2 |
| Vibrating screen | 2YK1224 | 3YK1236 | 3YK1548 | 4YK1860 | 2YK1860 3YK1548 | 2YK2160 3YK1860 |
| Belt conveyors | B500 | B500 | B650, B500 | B800, B500 | B1000, B800, B650, B500 | B1200, B800, B650 |
| Total power approximately | 70 KW | 120 KW | 200KW | 360KW | 600KW | 800KW |
| Recommend max feed size | 210mm | 350mm | 425mm | 480mm | 630mm | 850mm |
| Area needed for the plant | 30x50m | 40x70m | 50x80m | 50x100m | 80x150m | 100x200m |
5. Typical process diagram for reference
