1. PAINPOINT DRIVEN OPENING

Are you managing a commercial aggregate operation where consistent, highvolume output is critical to profitability? Your 250300 tph stone crushing plant faces significant operational pressures. Inconsistent feed material causes unexpected wear and crusher stalls, leading to costly, unplanned downtime. Energy consumption per ton remains stubbornly high, eroding margins. Meeting strict, dualgrade specifications for base and chip products often requires inefficient, multistage recrushing. Furthermore, the total cost of ownership—from liner replacements to conveyor maintenance—accumulates faster than projected.

How do you increase plant availability beyond 92%? Can you reduce your cost per ton while maintaining precise product shaping? Is your current setup flexible enough to handle varying rock hardness without sacrificing throughput? The solution requires a system engineered not just for capacity, but for predictable, efficient commercial production.

2. PRODUCT OVERVIEW

This 250300tph Turnkey Stone Crushing and Screening Plant is a stationary, hardrock processing solution designed for highvolume production of aggregates (05mm, 510mm, 1020mm, 2031.5mm) and other specification materials. It integrates primary crushing, secondary/tertiary crushing, screening, and material handling into a coordinated system.

Operational Workflow:
1. Primary Reduction: Dump trucks feed <750mm rock into a vibrating grizzly feeder which bypasses sub100mm fines and directs oversize to a robust primary jaw crusher.
2. Secondary & Tertiary Crushing: Primary crushed material is conveyed to a cone crusher for intermediate reduction. A second cone crusher or impact crusher in closed circuit performs final shaping and size refinement.
3. Sizing & Classification: Material is routed to a multideck vibrating screen where it is precisely separated into finished product stockpiles.
4. Recirculation: Oversize from the screens is automatically returned via closedcircuit conveyors to the appropriate crusher for further processing.
5. Dust Suppression: Integrated spray systems at transfer points control particulate emissions.

Application Scope: Ideal for granite, basalt, river pebble, limestone, and other abrasive materials with compressive strength up to 350 MPa. Suitable for large quarry operations, major infrastructure project support (highways, railways), and dedicated commercial aggregate supply yards.

Limitations: Not designed for mobile or semimobile applications requiring frequent relocation. Site requires stable foundation preparation and adequate space for plant layout and stockpiling.

3. CORE FEATURES

Intelligent Feed Control System | Technical Basis: Variable Frequency Drive (VFD) on feeder & level sensors | Operational Benefit: Maintains optimal chokefeed condition for cone crushers automatically | ROI Impact: Increases throughput by 812% and reduces liner wear by up to 15%
HeavyDuty Crusher Configuration | Technical Basis: Hydraulic adjustment & clearing on all crushers | Operational Benefit: Enables rapid CSS changes for product sizing and safe clearing of tramp metal/stalling | ROI Impact: Reduces downtime for chamber clearing from hours to minutes
Centralized Process Control | Technical Basis: PLCbased automation with touchscreen HMI | Operational Benefit: Allows singleoperator monitoring of entire flow from a control room; logs production data | ROI Impact: Lowers labor costs and provides data for production optimization
Modular Electrical & Hydraulic Design | Technical Basis: Preassembled skids with quickdisconnect couplings | Operational Benefit: Simplifies installation, commissioning, and future maintenance access | ROI Impact: Reduces installation time by ~30% and lowers service costs
MultiStage Dust Suppression | Technical Basis: Pressurized spray nozzles at key transfer points with moisture sensors | Operational Benefit: Effectively controls dust without overwetting material | ROI Impact: Ensures environmental compliance and protects downstream equipment

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | This 250300tph Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Plant Availability | 88 91% | 92 95%| +4% (Reduced Downtime) |
| Power Consumption (kWh/ton)| 1.8 2.2 kWh/t | 1.65 1.85 kWh/t| Up to 12% (Energy Savings) |
| Crusher Liner Life (Abrasive Rock)| ~450 operating hours| 520+ operating hours| +15% (Reduced Wear Cost) |
| Product Shape Index (Flakiness)| >18% in chip products| <15% in chip products| Higher Product Value |
| Reconfiguration Time (CSS Change)| Manual shim adjustment (~4 hrs)| Hydraulic adjustment (~30 min)| 87% (Operational Flexibility) |

5.TECHNICAL SPECIFICATIONS

Designed Throughput Capacity: 250 300 metric tons per hour (based on material density of ~1.6 t/m³)
Primary Crusher: Jaw Crusher Model JC1303 / Feed Opening:1300x300mm / Max Feed Size: ≤750mm
Secondary/Tertiary Crushers: Two units of Cone Crushers Model CC300 / Each with hydraulic adjustment & clearing
Screening Unit: Tripledeck Vibrating Screen Model VS2460 / Screen Area: ~14 sqm
Power Requirement: Total installed power approximately 650 kW; Mains connection recommended at400V/50Hz or480V/60Hz.
Key Material Specifications: Main frame construction Q345B steel; Conveyor belts EP630/4; Crusher liners Mn18Cr2 high manganese steel.
Physical Dimensions (Approx.): Overall layout length ~85m; width ~25m; max height ~12m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust emission concentration at outlet ≤20mg/m³.

6\. APPLICATION SCENARIOS

Highway Base Course Production | Challenge:A national contractor required consistent,sustained production of Class A base course(031\.5mm)and chip sealing aggregates(510mm)from hard granite for a toll highway project.Plant stoppages directly threatened project timelines.| Solution:A turnkey250\300tph plant was installed featuring twostage cone crushing in closed circuit with precise screening.The automated control system allowed quick switching between product specifications.| Results:The plant achieved an average output of280tph over22months.Availability averaged94\.2%.The consistent cubical shape of the chip product reduced bitumen consumption by an estimated7%,noted by the paving contractor.

Commercial Quarry Expansion Challenge:A regional quarry operator needed to upgrade from150tph to meet new supply contracts but had limited space for expansion and needed to maintain production during phased commissioning.| Solution:The modular design of the250\300tph plant allowed it to be constructed parallel to the old line.Critical preassembled skids reduced onsite assembly time.The old line was decommissioned only after the new plant was fully operational.| Results:The expansion was completed with only48hours of total production stoppage.The new plant's energy efficiency reduced power costs by$0\.11per ton produced,increasing annual gross margin significantly.

Limestone Processing for Concrete Aggregates Challenge:A readymix concrete supplier's own aggregate plant struggled with excessive fines generation(<0\.075mm)and poor shape in the critical10\20mm fraction,increasing cement demand in their mixes.| Solution:The plant configuration prioritized lowwear,cubicalproduct crushing stages.An impact crusher was selected as the tertiary unit,and screen deck configurations were optimized to remove excess fines early.| Results:Fines generation was reduced by22%.The improved particle shape increased the workability of the concrete mix.Field data showed a potential3\5%reduction in cement usage while maintaining slump specifications.

COMMERCIAL CONSIDERATIONS

Pricing is structured around core configuration levels:

• Tier1(Base Configuration):Includes primary jaw crusher,single cone crusher,tripledeck screen,basic conveyors,and central control panel.Priced as acapital investmentfor standard materials like limestone.
• Tier2(Enhanced Configuration):Adds secondary cone crusherfor full closedcircuit operation,intelligent VFD feed control,and enhanced dust suppression.Recommendedfor abrasive materials(granite,basalt).
• Tier3(Custom Configuration):Incorporates specific options such as washing systemsfor manufactured sand,finer screening decksfor specialized products,and extended weather protection enclosures.

Optional features include remote monitoring telematics,mobile generator hookups,and automated lubrication systems.Service packages range from basic commissioningand operator trainingto comprehensive annual maintenance contracts with guaranteed parts availability.Financing options including equipment leasingand term loans are available through partnered financial institutions,making capital expenditure manageable against longterm supply contracts.

FAQ

Q:What if my feed material size or hardness varies frequently?
A:The hydraulic adjustment on the crushers allows operators to change the Closed Side Setting(CSS)in minutes via the control panel.This adapts the crushing chamberto different conditions without stopping production,a key featureof this commercial stone crushing plantsolution.

Q.How many operators are requiredto run this plant?
A.The centralized PLC automationis designedfor singlestation control.One trained operatorin the control room can manage the entirecrushingandscreening process.Routine ground inspectionsare still recommended,but direct machinelevel operationis not required.

Q.Can this system integratewith our existing primary feedingor downstream equipment?
A.YES.The design includes standardized feedand discharge heights.Conveyor lengthsand transfer pointscan be modifiedduring engineering.We will review your site layoutto ensure compatibilitywith your current stockpile feedersor existing tertiary processing lines.

Q.What isthe typical installationand commissioning timeline?
A.For aprepared foundation site,the modular skidded components allow erectionin approximately8\10weeks.Commissioningand performance testingtypically takes an additional1\2weeks.This timeframe assumes all civil worksare complete prior todelivery.

Q.Are spare parts readily available,and what arethe lead times?
A.We maintaina strategic inventoryof highwear parts(jaw plates,mantles,screen meshes).For standard wear parts,the commitmentis shipmentwithin72hours.For major components,a stocklistwith guaranteed lead timesis providedwith themaintenance contract.

Q.What kindof trainingis providedfor our maintenance team?
A.Comprehensive trainingincludes both classroom instructionon system principlesand handson field training.It covers daily checks,troubleshooting usingthe HMI diagnostics,routine maintenance procedures,and safe liner changeout protocols.Training documentationis supplied digitallyandin print