1. PAINPOINT DRIVEN OPENING

Are you managing a highvolume aggregate operation and facing persistent bottlenecks that cap your profitability? For plant managers and engineering contractors, a 250300tph stone crushing plant is a critical asset, yet its performance directly dictates your bottom line. Common challenges include:
Unscheduled Downtime: Frequent mechanical failures in crushers or screens halt your entire line, costing thousands per hour in lost production and idle labor.
Inconsistent Output & Gradation: Fluctuations in final product size reduce the percentage of highvalue spec material, leading to recrushing and lost revenue.
High Operational Costs: Spiking energy consumption from inefficient crushing chambers and excessive wear part replacement cycles erode profit margins.
Scalability Limitations: Inflexible plant layouts cannot easily adapt to changing feed material or market demand for different aggregate products.

Is your current setup delivering the reliable, costperton efficiency required in today's competitive market? The solution lies in a purposeengineered 250300tph stone crushing plant designed from the ground up for industrialscale durability and operational control.

2. PRODUCT OVERVIEW

This 250300tph stationary stone crushing plant is a complete, hardrock processing system engineered for continuous, highvolume production of aggregates for construction, road base, and railway ballast. It is configured for primary, secondary, and tertiary crushing stages to produce precisely graded final products.

Operational Workflow:
1. Primary Reduction: Large quarryrun rock (≤750mm) is fed into a robust primary jaw crusher for initial size reduction.
2. Secondary Crushing & Screening: The output is conveyed to a secondary cone crusher. Material is then screened; oversized material is recirculated back to the secondary crusher (closedcircuit).
3. Tertiary Shaping/Final Screening: Depending on configuration, a tertiary impact crusher or fine cone crusher further shapes the aggregate. Final screening decks separate the output into multiple specified product sizes (e.g., 05mm, 510mm, 1020mm).

Application Scope & Limitations:
Scope: Ideal for granite, basalt, limestone, and other medium to highabrasiveness rocks. Suited for largescale quarry operations, major infrastructure projects requiring onsite aggregate production, and dedicated commercial aggregate suppliers.
Limitations: Not designed for very soft, clayheavy materials without significant preprocessing. Requires stable foundation and substantial electrical supply. Feed size must be controlled per design parameters.

3. CORE FEATURES

Intelligent Crushing Chamber Design | Technical Basis: Computeraided kinematics & dynamics simulation | Operational Benefit: Optimized nip angle and stroke produce firstpass cubical product with fewer fines | ROI Impact: Reduces recirculating load by up to 15%, increasing net throughput and wear part life.

Centralized PLC Automation System | Technical Basis: Programmable Logic Controller with humanmachine interface (HMI) | Operational Benefit: Enables singlepoint start/stop sequencing, realtime monitoring of amp draw and pressure, and remote alarm diagnostics | ROI Impact: Minimizes personnel requirements for operation; prevents catastrophic damage through automated shutdowns on faults.

HeavyDuty Vibrating Screen with Deck Interchangeability | Technical Basis: HighG force linear motion drive with boltedin deck systems | Operational Benefit: High screening efficiency even with damp material; rapid panel changeover for different product specs | ROI Impact: Maximizes saleable product yield; reduces screen media downtime by approximately 30%.

Modular Conveyor System with Impact Zones | Technical Basis: Reinforced idlers at loading points; abrasionresistant belt compounds | Operational Benefit: Handles peak loads without spillage; dramatically reduces belt wear at transfer points | ROI Impact: Lowers conveyor maintenance costs and extends belt replacement cycles by an average of 40%.

Integrated Dust Suppression & Containment | Technical Basis: Nozzle spray system at key transfer points coupled with fabric filter baghouses | Operational Benefit: Maintains regulatory compliance for particulate emissions; improves site visibility and operator health | ROI Impact: Avoids regulatory fines and potential work stoppages; reduces cleanup costs.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Typical Plant) | Our 250300tph Stone Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Overall Availability (Scheduled Runtime) | 9092% | 95%+ | +3 to +5 percentage points |
| Energy Consumption per Ton Processed| Varies widely by rock type| Optimized circuit design reduces kWh/ton by documented average of 8%| Up to 8% |
| Wear Part Life (Manganese in Cone Crusher) Based on abrasive granite| ~40,000 tons| Up to 55,000 tons through improved metallurgy & chamber design| +37% |
| Product Shape (Cubicity Index) Secondary Stage Output| ~70% cubical content| Consistently achieves ≥85% cubical content| +21% |

5. TECHNICAL SPECIFICATIONS

Designed Throughput Capacity: 250 300 metric tons per hour (tph), depending on feed material hardness (<180 MPa compressive strength recommended).
Primary Crusher: Jaw Crusher Model JCE1303 / Feed Opening: 1300x300mm / Max Feed Size: ≤750mm / Power Rating: 160200 kW.
Secondary Crusher: SingleCylinder/Hydraulic Cone Crusher / Chamber Option Variants / Power Rating: 220315 kW.
Tertiary Crusher (Optional): MultiCylinder Cone Crusher or Vertical Shaft Impact (VSI) Crusher / Power Rating: 185250 kW.
Vibrating Screens: Tripledeck horizontal screen / Total Screening Area: ≥18 sqm / Drive Power: 30 kW.
Electrical Requirements: Total Installed Power ≈800 1000 kVA / Primary Voltage Supply Required at Site.
Key Material Specifications: Primary frame construction using S355JR structural steel; Highwear components manufactured from Mn18Cr2 or equivalent alloy steel; Conveyor belts rated for minimum PIW=1000.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with appropriate lubrication systems.

6. APPLICATION SCENARIOS

Highway Construction Project in Mountainous Region

Challenge A major contractor needed consistent Class A basalt aggregate for a remote highway project but faced logistical costs from distant quarries exceeding budget.
Solution A modulardesigned version of this stone crushing plant was established onsite near the rock source within the project rightofway.
Results The project became selfsufficient in aggregate supply within six weeks of equipment arrival. Production averaged 280tph of spec material over the project lifecycle reducing imported aggregate costs by an estimated $1.8M USD.

Commercial Granite Quarry Expansion

Challenge An existing quarry operation sought to expand its market reach but was limited by an aging plant producing inconsistent gradations at only ~220tph with high downtime.
Solution This complete turnkey stone crushing plant replaced the old circuit alongside an upgraded electrical system.
Results Within one month of commissioning consistent output reached sustained levels of over tph Plant availability increased from % to % allowing fulfillment of two new longterm supply contracts

Limestone Processing Facility Upgrade

Challenge A cement plant's adjacent aggregate division had excessive fines generation (>25%) in its final product mix reducing profitability
Solution The tertiary stage was configured with a specialized fine cone crusher chamber profile paired with precise screen deck configurations
Results Fines generation was reduced to below % while maintaining tph throughput increasing the yield of premiumgrade concrete sand by approximately tpd

COMMERCIAL CONSIDERATIONS

Our industrial stone crushing plants are offered under clear commercial frameworks:

Pricing Tiers:
Tier I Base Plant Configuration Includes primary secondary screening core conveyors dust suppression central control panel Starting range $850 $ million USD FOB
Tier II Enhanced Configuration Adds tertiary shaping stage automated grease systems additional product stockpile conveyors Starting range $ million USD FOB
Tier III Turnkey Project Includes civil works foundation design erection commissioning supervision training Priced upon project quotation

Optional Features:
Onboard power generation package advanced particle shape analysis system remote telematics monitoring extended wear part packages

Service Packages:
Standard Warranty months on machinery hours whichever comes first
Platinum Support Package Extended warranty annual planned maintenance inspections priority parts dispatch guaranteed response time

Financing Options:
We work with international export credit agencies and equipment financing partners to offer leaseto own capital loan or other structured finance solutions tailored to your cash flow requirements

FAQ

Q What if my feed rock hardness exceeds your recommended specification?
A For extremely hard abrasive materials we can specify alternative chamber designs higher grade metallurgy throughout the flow line We will adjust motor power ratings accordingly during engineering review

Q How does this plant manage variations in feed size from the quarry face?
A The primary jaw crushers large feed opening combined with its deep symmetrical chamber effectively handles normal variation For extreme oversize we recommend pairing our solution with a hydraulic hammer breaker at the grizzly feeder stage

Q What are typical installation lead times?
A From order confirmation delivery of major components typically requires months depending on configuration complexity Full installation commissioning requires an additional weeks subject to site readiness civil works completion

Q Can this system be integrated into my existing partial processing line?
A Yes Our engineering team can conduct a site audit We often supply key components like new secondary tertiary stations as retrofit upgrades into existing circuits ensuring proper interface design

Q What operator training is provided?
A We provide comprehensive classroom mechanical electrical operational training plus minimum one week of onsite hands over training during commissioning Documentation includes detailed operation maintenance manuals parts catalogs schematic diagrams