1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks? The challenges of a 250300tph stone crushing plant are significant: inconsistent feed material degrading final product spec, unplanned downtime from component failure costing thousands per hour, and energy consumption eroding profit margins. Your plant’s output directly dictates project timelines and commercial viability.

Are you experiencing:
Throughput falling below 300tph due to inefficient crushing chamber design or improper screening, leaving revenue on the table?
Frequent maintenance stops for liner changes or bearing issues, creating unpredictable operational schedules?
High operational costs from excessive power draw and rapid wear part consumption?
Difficulty meeting stringent aggregate gradation requirements for asphalt or concrete mixes, leading to product rejection?

The central question is: how can you achieve reliable, costperton production within the 250300tph range while maintaining product quality and controlling operational expenses?

2. PRODUCT OVERVIEW

This product description details a complete, stationary 250300tph Stone Crushing Plant designed for highvolume aggregate production in quarrying, mining, and large infrastructure projects. It is engineered as a turnkey solution for contractors and mining companies requiring consistent output of highspecification aggregates.

Operational Workflow:
1. Primary Crushing: Large feed material (up to 750mm) is reduced by a robust primary jaw crusher.
2. Intermediate Screening & Crushing: Prescreened material is routed to a secondary cone crusher for further reduction, while oversize is recirculated.
3. Tertiary/Fine Crushing: For cubical product requirements, a tertiary cone crusher or impact crusher processes material.
4. Final Screening & Sorting: Multipledeck vibrating screens precisely separate output into finished product sizes (e.g., 05mm, 510mm, 1020mm).
5. Material Handling: A network of conveyors with centralized PLC control ensures efficient material transfer between stages.

Application Scope: Ideal for producing aggregates for road base, concrete, asphalt, and railway ballast. Suitable for hard rock (granite, basalt) and mediumhard rock (limestone).
Limitations: Not designed for very soft, cohesive materials without significant configuration changes. Requires stable foundation and substantial electrical supply.

3. CORE FEATURES

HighCapacity Primary Jaw Crusher | Technical Basis: Optimized nip angle and deeper crushing chamber | Operational Benefit: Handles larger feed size with fewer blockages, increasing effective feeding time | ROI Impact: Reduces idle time by up to 15%, directly protecting throughput targets.

Hydraulic Adjustment & Clearing Systems | Technical Basis: Integrated hydraulic cylinders for CSS adjustment and tramp iron release | Operational Benefit: Enables quick setting changes for product gradation and protects crusher from uncrushables in minutes | ROI Impact: Minimizes risk of major mechanical damage; downtime for adjustments cut by over 70%.

MultiStage Precision Screening | Technical Basis: Highfrequency vibrating screens with tensioned wire mesh or polyurethane panels | Operational Benefit: Delivers precise product separation with minimal blinding or carryover | ROI Impact: Improves product yield within spec by an average of 812%, reducing waste.

Centralized PLC Automation System | Technical Basis: Programmable Logic Controller with touchscreen HMI monitoring motor loads, bin levels, and conveyor sequencing | Operational Benefit: Allows singleoperator oversight of entire plant flow; enables smooth startup/shutdown sequences | ROI Impact: Lowers labor costs and prevents costly cascading equipment failures.

HeavyDuty Conveyor System | Technical Basis: Channel frame design with impact idlers at loading points and dustsealed bearings | Operational Benefit: Provides reliable material transfer with reduced spillage and belt wear | ROI Impact: Extends belt service life by approximately 30%, lowering maintenance part costs.

Dust Suppression & Reduction Package | Technical Basis: Strategically placed spray nozzles at transfer points coupled with encapsulation | Operational Benefit: Actively controls airborne particulate matter | ROI Impact: Ensures compliance with environmental regulations, avoiding potential fines and work stoppages.

Modular Structural Steel Framework | Technical Basis: Prefabricated, bolted support structures for major components | Operational Benefit: Simplifies site installation and future relocation if necessary | ROI Impact Reduces civil works cost and installation time by an estimated 25%.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Range) | This 250300tph Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime)| ~85% 88% due to mechanical delays| >92% via robust components & hydraulic protection| +5% to +8% |
| Power Consumption per Ton| Varies widely; often less optimized circuits| Lower specific draw via efficient drive systems & chamber design| Up to 10% reduction |
| Wear Part Life (Primary)| Dependent on abrasiveness; standard manganese liners| Optimized alloy liners & cavity design extend service intervals| 1525% longer life |
| Product Shape Consistency| Often requires tertiary stage for high cubicity| Achieves superior shape in secondary stage via advanced cone crusher kinematics| Reduces need for additional crushing in many applications |
| Installation & Commissioning Time| Can exceed 46 weeks for full system integration| Streamlined modular design reduces onsite assembly work by approximately ~25% |

5. TECHNICAL SPECIFICATIONS

Designed Throughput Capacity: 250 300 metric tons per hour (varies based on feed material hardness and size distribution).
Primary Crusher: Jaw Crusher Model [e.g., JC150], Feed Opening ≥750mm x ≤500mm.
Secondary Crusher: SingleCylinder or MultiCylinder Hydraulic Cone Crusher.
Tertiary Crusher (Optional): Fine Cone Crusher or Vertical Shaft Impact Crusher.
Screens: Two (2) or Three (3) units of HeavyDuty Vibrating Screens (Size: e.g., 2400mm x 6000mm), tripledeck configuration.
Power Requirement: Total installed power approximately 450 550 kW. Requires stable industrial power supply (400V/50Hz or as specified).
Key Material Specifications: Main frame construction from S355JR structural steel; Wear parts in high manganese steel or proprietary alloys.
Overall Plant Footprint (L x W): Approximately ~80m x ~45m (layout dependent).
Environmental Operating Range: Designed for 20°C to +45°C ambient temperature; dust suppression system rated for local environmental standards.

6. APPLICATION SCENARIOS

Large Infrastructure Contractor – Highway Project

Challenge: Required consistent supply of over 280tph of certified aggregates for road base and asphalt layers. Previous mobile fleet struggled with consistent gradation and high fuel/maintenance costs.
Solution: Installation of a stationary 250300tph stone crushing plant with tertiary shaping stage near the project site.
Results: Achieved steady output of 295tph meeting all gradation specs. Reduced cost per ton by 22% through lower fuel consumption (stationary vs mobile)and reduced wear part turnover. Plant availability recorded at 94% over the 18month project duration.

Established Granite Quarry Operator

Challenge: Existing aging plant produced only 230tph at peak,causing backlog,and suffered from weekly unplanned downtime. Product yield in the premium 1020mm category was low (~25%).
Solution: Commissioning of a new 250300tph stone crushing plant featuring advanced secondary/tertiary crushing circuitsand precision screening decks.
Results: Throughput stabilized at 310tph. Yield in the premium 1020mm category increased to 35%, significantly boosting revenue.Availability improved to 93%,with maintenance scheduled predictably.

7. COMMERCIAL CONSIDERATIONS

Our trading company provides comprehensive solutions tailored to project scope:

Equipment Pricing Tiers:
Base Configuration (~250tph): Includes primary jaw crusher secondary cone crushers basic screeningand conveyors
Enhanced Configuration (~2801tphto max capacity) Adds tertiary crusheradvanced automationdust control systemand reinforced structures
Full Turnkey Solution Includes civil works designfoundationsinstallation supervisionand commissioning

Optional Features:
Automated wear part monitoring systems
Advanced noise encapsulation packages
Onsite generator packagesfor areaswith unreliable grid power

Service Packages:
Annual Preventive Maintenance Contracts including inspectionand parts discounting
Remote Monitoring & Diagnostics Service
Ondemand technical supportand operator training programs

Financing Options:
We work with international export credit agenciesand financial institutions to offer flexible purchaseor leaseto own structures typically ranging fromto year terms subjectto credit approval

FAQ

Q1 What is the lead time from order placementto deliveryfora standardplant configuration?
A1 Fora standard configuredplant lead timeis typically monthsfrom confirmed order Exworks This includes manufacturing testingand preparationfor shipment Sitespecific customizationsmay extend this timeline

Q2 How does thisplant handle variationsin feed rock hardnessor size?
A2 The core crushersare equippedwith hydraulic adjustmentand clearing systems allowing operators to quickly adaptthe closedside setting(CSS)to accommodatechanges Field data showschangesto CSScan be madein under minutes minimizing throughput loss The PLC systemcan also regulate feeder speedbasedon motor load tomaintain optimal performance

Q3 What arethe ongoing spare part requirementsand arethey readily available?
A3 Critical wear parts(jaw plates mantleconcaves screen meshes)are standardizeditems We maintainan inventoryof critical sparesandsupplya recommendedinitial spare part kitwith eachplant Delivery schedulesfor subsequent ordersare managedto ensure minimal operational disruption

Q4 Can thisplant be relocatedafter initial installation?
A4 Yes The modular structural designallowsfor disassembly relocationandrecommissioning While not as mobileas a tracked plant relocationis feasiblefor longterm projectsin new locations A relocation service packageis availablewhich includes engineering supportfordismantlingandreassembly

Q5 What levelof technical trainingis providedfor our operational staff?
A5 Comprehensive trainingis includedas partof commissioning Our engineers provide both classroom instructionon plant theoryandsafetyand extensive handson trainingat the operating controls fora period typically coveringweeks We also provide full operationaland maintenance manuals

Q6 Areyour plants compliantwith international electricalandsafety standards(e g CE)?
A6 Our plantsare manufacturedto complywith core international machinery safety standards(ISO ) Electrical panelsandsystemsare builtto IEC standards Specific certificationmarks(like CE)can be providedas requiredfor the destination market which may affect lead timeand cost

Q7 Do you offerperformance guaranteeson throughputand final product gradation?
A7 Yes We provide contractual performance guaranteesbasedon agreed feed material specifications These guaranteescover minimum throughput capacitywithin the tphp rangeandaspecified final productgradation curve Testingis conductedduring commissioningwith client representativespresent