Components Of A 400 Ton Per Hour Rock Crushing Plant

The Anatomy of a 400 Ton Per Hour Rock Crushing Plant: Core Components & Flow

Achieving a consistent output of 400 tons per hour (tph) in rock crushing requires a carefully engineered plant with robust, correctly sized components working in harmony. This scale is common for large quarry operations, major construction projects, or significant aggregate production facilities. Understanding the essential elements of such a plant is crucial for efficient operation and investment planning.

The Core Process Flow:

A typical 400 tph hard rock crushing plant employs a multi-stage process to efficiently reduce large raw feed into precisely sized aggregate products:

1. Primary Crushing: Large dump trucks deliver blasted rock (often up to 750mm – 1000mm in size) into the primary crusher.
2. Secondary Crushing: The primary crushed material is conveyed to the secondary crusher(s) for further size reduction.
3. Tertiary Crushing (Optional but Common): For producing finer, more cubical products like concrete sand or specific chip sizes, tertiary crushing may be employed.
4. Screening: Material from each crushing stage is screened using vibrating screens to separate it into desired product sizes (e.g., Rip Rap, Base Course, Chips, Sand). Oversized material is recirculated back to the appropriate crusher (closed-circuit operation).
5. Stockpiling: Sized products are conveyed to designated stockpiles for storage and loading.

Essential Components for a 400 TPH Plant:

1. Primary Crusher:
Type: Typically a large Jaw Crusher or robust Gyratory Crusher.
Function: Handles the largest feed size (often >700mm) and performs the initial coarse reduction.
Specs for 400 TPH: Requires a jaw crusher with an inlet opening around 1200mm x 900mm (48″x36″) or larger, or a gyratory crusher with comparable capacity and feed size acceptance. High throughput and ruggedness are paramount.

2. Secondary Crusher(s):
Type: Commonly one or more Cone Crushers. High-performance horizontal shaft impactors (HSI) can also be used depending on rock type and desired product shape.
Function: Further reduces the primary crushed material to an intermediate size suitable for final screening or tertiary crushing.
Specs