1. PAINPOINT DRIVEN OPENING

Managing a limestone processing operation presents distinct challenges that directly impact your bottom line. Are you facing:
High Downtime from Abrasion Wear: The abrasive nature of raw limestone rapidly degrades crusher liners, screens, and conveyor systems, leading to frequent maintenance stops and high component replacement costs.
Inconsistent Feed Size & Bridging: Uncontrolled feed from the quarry causes crusher chokeups and feeder bridging, halting your production line and creating safety hazards for operators.
Excessive Fines Generation & Yield Loss: Improper crushing stages create more fine powder (sub5mm) than your market requires, wasting valuable product and reducing the yield of profitable aggregate sizes.
High Energy Consumption per Ton: Inefficient comminution circuits, especially primary and secondary crushing, can make energy your single largest variable operating cost.
Dust Emission Control Failures: Inadequate containment at transfer points creates environmental compliance risks and unhealthy site conditions, leading to potential fines and workforce concerns.

What if your plant could achieve higher throughput with less unplanned downtime and better control over your final product gradation?

2. PRODUCT OVERVIEW

The modern Limestone Processing Plant is a engineered circuit of interconnected crushing, screening, and material handling equipment designed to transform blasted quarry rock into precisely graded aggregate or industrial feedstock.

Operational Workflow:
1. Primary Size Reduction: Dumpfed material is reduced by a primary crusher (e.g., jaw or gyratory) to a manageable size for downstream processing.
2. Secondary & Tertiary Crushing: Cone crushers or impactors further reduce the material, allowing for precise control over particle shape and size distribution.
3. Sizing & Classification: Vibrating screens separate crushed material into designated product streams (e.g., 40mm, 20mm, 10mm, fines).
4. Material Handling & Stockpiling: Conveyor systems transport sized products to designated stockpiles or loadout stations.
5. Dust Suppression: Integrated spray systems at key transfer points suppress particulate emissions.

Application Scope & Limitations:
This system is engineered for medium to highcapacity stationary processing (150 2,000+ TPH). Optimal feed is blasted limestone rock with a compressive strength typically under 150 MPa. Plants require significant capital investment and are designed for longterm fixedlocation operation, not mobile applications.

3. CORE FEATURES

Advanced Crushing Chamber Design | Technical Basis: Computermodeled kinematics and wearpart geometry | Operational Benefit: Maintains consistent product gradation throughout liner life with fewer adjustments | ROI Impact: Reduces yield loss by up to 8% and extends liner service intervals by an estimated 25%

Centralized PLC Automation System | Technical Basis: Programmable Logic Controller with humanmachine interface (HMI) | Operational Benefit: Enables singleoperator control of the entire circuit, including startup sequencing, load management, and fault diagnostics | ROI Impact: Lowers labor requirements for routine operation and reduces meantimetorepair by approximately 30%

Modular Dust Suppression Manifold | Technical Basis: Laminarflow nozzles with solenoid valves tied to belt motion sensors | Operational Benefit: Delivers atomized water only when material is moving, effectively suppressing dust without oversaturating product | ROI Impact: Cuts water consumption by up to 60% compared to constantflow systems and mitigates compliance risk

HeavyDuty Apron Plate Feeder | Technical Basis: Overlapping manganese steel pans driven by ruggedized chains | Operational Benefit: Handles direct dump from large haul trucks without bridging or stalling, providing a consistent volumetric feed to the primary crusher | ROI Impact: Eliminates feedrelated crusher downtime and protects downstream equipment from shock loads

Hybrid Polyurethane / Steel Screen Media | Technical Basis: Composite screen decks with polyurethane tensioning frames | Operational Benefit: Significantly reduces blinding in damp conditions while maintaining structural integrity for large topsize material | ROI Impact: Increases screening efficiency by an average of 15% and reduces media changeout frequency

Regenerative Crusher Drive System | Technical Basis: Energyrecovery technology in VFDdriven crushers | Operational Benefit: Captures inertial energy during the crushing cycle and feeds it back into the plant's electrical system | ROI Impact: Documented to reduce specific energy consumption in tertiary crushing stages by 1015%

WalkIn Maintenance Platforms | Technical Basis: Engineered guardrails and grated decking around major components | Operational Benefit: Provides safe, direct access for inspection, lubrication, and component replacement tasks | ROI Impact: Reduces planned maintenance time by improving technician efficiency and enhancing workplace safety compliance.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Limestone Processing Plant Solution | Documented Advantage |
| : | : | : | : |
| Overall Availability (Scheduled Runtime) | 85 90% per quarter| >93% per quarter| +4% improvement |
| Specific Energy Consumption (kWh/ton)~Secondary Crushing~| ~0.8 1.2 kWh/ton| ~0.65 0.85 kWh/ton| Up to ~20% reduction |
| Wear Cost per Metric Ton Processed| $0.12 $0.18 / ton| $0.09 $0.13 / ton| ~25% lower cost |
| Product Gradation Consistency (± variance)| ±12% on key sieve sizes| ±7% on key sieve sizes| ~40% more precise |
| OnSite Installation & Commissioning Timefor a 500TPH plant| 14 18 weeks|10 12 weeks|<30% faster deployment |

5. TECHNICAL SPECIFICATIONS

Design Capacity Range: Configurable from 200 to 1,500 tonnes per hour (TPH).
Primary Power Requirement: Total connected load typically between 800 kW 2.5 MW depending on configuration; voltage adaptable to regional standards (e.g.,6 kV /11 kV /50Hz/60Hz).
Key Material Specifications: Primary crusher frame – fabricated hightensile steel; Liner metals – Austenitic Manganese Steel (1418%) or optional chromewhite iron; Conveyor idlers – sealed spherical roller bearings; Structural steel – S355JR grade minimum.
Typical Plant Footprint (500 TPH Example): Approx. Length:80m x Width45m x Height25m (excluding stockpiles). Modular design allows adaptation to site constraints.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system effective up to95% relative humidity; electrical enclosures rated IP65 for dust/water ingress protection.

6. APPLICATION SCENARIOS

Aggregate Production for Road Base & Concrete

Challenge A regional producer needed consistent 57 stone (2028mm) but struggled with excessive fines from their old impact crusher setup,capping profitability.
Solution Implementation of a multistage plant featuring a jaw crusher primary,a cone crusher secondary with closedside setting automation,and highfrequency screens.
Results Fines generation (<5mm) reduced from28%to15%,increasing saleable product volume.Field data shows a22%increase in monthly revenue from the same raw material input.

HighPurity Industrial Feedstock for Quicklime

Challenge A lime plant required strict control over feed size(75150mm)and removal of silica impurities before their kilns,but manual prescreening was inefficient.
Solution A processing circuit built around a gyratory primary crusher,a heavyduty scalping screen rejecting undersize,and a secondary sizer crusher for precise topsize control.
Results Achieved>98%sizing specification compliance.Automated impurity rejection improved kiln feed quality.Records indicate kiln refractory life increased by an estimated15%due to more consistent feedstock.

7.COMMERCIAL CONSIDERATIONS

Our Limestone Processing Plants are offered in three core tiers:
1.Basic Configuration Includes primary crushing,screening,and basic conveyors.Ideal for producing simple aggregates.Pricing typically starts in themidsixfigure USD range
2.Optimized Configuration Adds automated secondary crushing,tiered screening decks,and central PLC controls.Recommended formost commercial aggregate operations.Pricing typically falls within thelowtomid sevenfigure USD range
3.Turnkey Premium Configuration Fully integrated circuit including advanced dust suppression,tramp metal detection,total plant automation,and remote monitoring capabilities.Designed formaximum efficiencyand datadriven operation.Pricing is projectspecific within thesevenfigure USD range

Optional Features Onboard weighing systems,mobile sampling stations,wash screensfor clay removal,and sound attenuation enclosures.Service Packages Include multiyear wearpart contracts,predictive maintenance programs using vibration analysis,and annual efficiency audits.Financing Options Available through partner institutions including equipment leasing capital loansand progressbased milestone payment plans

8.FAQ

Q Can this plant integrate with our existing primary crusher or screens?
A Yes modular design principles allow integration with certain existing major equipment subjecttoa feasibility review.This can significantly reduce capital outlay

Q What is the expected operational manpower requirement per shift?
A For a fully automated Optimized or Turnkey plant central PLC control allows effective operationwith23 personnel per shift covering control roomand field inspection roles

Q How do you ensure performance guarantees are met?
A We conduct predelivery testingof critical subsystems Performance guaranteesfor throughput power consumptionand wear rates are contractually basedon agreedupon conditionsand are verified during commissioning

Q What is the typical delivery timelinefrom order placement?
A For standard configurations delivery of major components beginsat68 monthswith total project completionincluding foundation workrangingfrom1216 monthsdepending on scopeand site readiness

Q Are spare parts readily available globally?
A We maintain regional warehouse inventoriesof critical wear partsand providea guaranteed48hour shipping commitmentfor stocked itemsunder our service plans

Q Can the plant be reconfiguredfor different final products later?
A The modular conveyorandscreen tower design allowsfor future reconfigurationto produce different aggregate specificationsoften requiringonly additionalormodified screen decksand program changes

Q What trainingis providedfor our operationsand maintenance teams?
A Comprehensive trainingis included covering classroom instruction handson commissioning guidanceand detailed manualsfor both operational proceduresand mechanical/electrical maintenance tasks