1. PAINPOINT DRIVEN OPENING

Managing a highvolume limestone operation requires consistent yield and predictable costs. Yet, plant managers and engineering contractors face persistent challenges that directly impact profitability. Are you contending with excessive fines generation in your final product, reducing the percentage of highvalue sized material? Are crusher and screen wear rates causing unplanned downtime and consuming your maintenance budget? Is dust suppression failing to meet increasingly stringent environmental and workplace health standards, risking compliance violations? Furthermore, are energy costs per ton processed eroding your margin targets? These operational inefficiencies translate into quantifiable losses: every percentage point of yield loss, every hour of unscheduled downtime, and every premature wear part replacement directly affects your bottom line. The central question is: how can you achieve precise size reduction while controlling the total cost of ownership and maintaining full regulatory compliance?

2. PRODUCT OVERVIEW

The solution is a RoHS Compliant Limestone Processing Plant engineered for modern mining and aggregate production. This integrated system is designed for primary and secondary crushing, screening, and material handling of limestone deposits. The operational workflow is optimized for efficiency: (1) Primary jaw crushing reduces quarried rock to a manageable size; (2) Secondary cone or impact crushing further refines the material; (3) Multistage vibrating screens precisely separate product into specified grades; (4) Fines management systems capture and condition undersize material; (5) Conveyor networks transport sized product to stockpiles or loadout. This plant is specifically engineered for medium to hightonnage limestone operations producing aggregates, agricultural lime, or feed stock for cement plants. Its design is not suited for extremely abrasive igneous rock or for ultrafine grinding applications below 3mm without additional circuit components.

3. CORE FEATURES

RoHSCompliant Component Specification | Technical Basis: EU Directive 2011/65/EU restriction on hazardous substances | Operational Benefit: Eliminates risk of noncompliance for products shipped to regulated markets, ensures worker safety during maintenance | ROI Impact: Avoids costly export rejections, fines, and simplifies endoflife equipment recycling.

Advanced Chamber Geometry & CSS Automation | Technical Basis: Computermodeled crushing chambers paired with automated closedside setting adjustment | Operational Benefit: Maintains consistent product gradation with less operator intervention, adapts to feed variation | ROI Impact: Field data shows a 1218% improvement in yield of inspec product, reducing waste.

Integrated MultiPoint Dust Suppression | Technical Basis: Targeted fog cannons at transfer points with particlesizeaware water droplet calibration | Operational Benefit: Achieves >99% dust capture at source, maintaining visible emissions well below permit limits | ROI Impact: Reduces water usage by up to 40% versus flood systems and minimizes product moisture addition.

Wear Part Metallurgy & Design | Technical Basis: Ultrahighstrength steel alloys with ceramic composite liners in highabrasion zones | Operational Benefit: Extends service life of mantles, concaves, screen decks, and liner plates in abrasive limestone environments | ROI Impact: Industry testing demonstrates a 3050% increase in wear life, lowering costperton for consumables.

Variable Frequency Drive (VFD) Crusher Motors | Technical Basis: Direct drive crushers with VFD control instead of traditional hydraulic or belt drives | Operational Benefit: Allows soft starts reducing mechanical stress, enables power draw optimization based on feed hardness | ROI Impact: Documented 1525% reduction in energy consumption during crushing cycles.

Centralized PLC & Process Monitoring | Technical Basis: Plantwide automation with realtime data on throughput, power draw, and bearing temperatures | Operational Benefit: Provides operators with actionable insights to prevent bottlenecks and schedule predictive maintenance | ROI Impact: Minimizes unplanned stoppages; case studies indicate a 20% improvement in overall equipment effectiveness (OEE).

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Baseline | RoHS Compliant Limestone Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Product Yield (InSpec Material) | 8285% typical yield rate| 9092% consistent yield rate| +68% more saleable product |
| Wear Part Cost per Ton Processed| $0.85 $1.10 / ton| $0.55 $0.70 / ton| ~30% reduction in consumable cost |
| Dust Emissions at Transfer Points| 1525 mg/m³ (requires frequent mitigation)| Consistently 75% reduction vs. standard |
| Specific Energy Consumption| 1.8 2.2 kWh / ton crushed| 1.5 1.7 kWh / ton crushed| ~20% improvement in energy efficiency |
| Mean Time Between Failure (MTBF)| ~450 hours for critical crusher components| >650 hours for critical crusher components| ~44% increase in operational reliability |

5. TECHNICAL SPECIFICATIONS

Design Capacity: Configurable from 300 to 1,200 tonnes per hour (TPH).
Primary Crusher: Jaw crusher options from 900mm x 600mm to 1400mm x 1100mm feed opening.
Secondary Crusher: Hydraulic cone crushers with capacities matched to primary output.
Screening System: Multideck vibrating screens (triple or quadruple deck), sizes from 2m x 6m to 3m x 9m.
Power Requirements: Total installed plant power ranges from 500 kW to 2 MW depending on configuration; supplied for 400V/50Hz or customized voltages/frequencies.
Material Specifications: All electrical components, wiring harnesses, lubricants, and painted surfaces comply with RoHS Directive limits for lead, mercury, cadmium, hexavalent chromium PBBs & PBDEs (where technically feasible).
Key Physical Dimensions: Modular design; primary crusher module approx. L12m x W5m x H6m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust protection rating of IP65 on electrical panels.

6. APPLICATION SCENARIOS

[Aggregate Producer – Southeast Asia]

Challenge: A large aggregate supplier faced export contract rejections due to trace heavy metals found in finished limestone aggregates bound for the European market.
Solution: Implementation of a complete RoHS Compliant Limestone Processing Plant replaced the existing circuit.
Results: The producer achieved full compliance documentation enabling continued EU exports within one quarter postinstallation while simultaneously increasing plant throughput by an average of TPH due to improved reliability.

[Cement Plant Feedstock Operation – North America]

Challenge: Uncontrolled dust emissions triggered regulatory notices at the quarry site adjacent to residential areas.
Solution: Retrofitting an existing circuit with the integrated multipoint dust suppression system as part of a broader upgrade package.
Results: Visible dust plumes were eliminated; continuous monitoring data showed emissions reduced by over . This allowed the operation to secure a renewed operating permit without production capacity restrictions.

[Agricultural Lime Manufacturer – Europe]

Challenge: High energy costs and excessive fines generation were making their finegrind product line unprofitable.
Solution: Installation of a secondary cone crusher featuring VFD drives and advanced chamber geometry specifically tuned for their deposit's characteristics.
Results: The operation reduced its specific energy consumption by , increased its target fraction yield by , allowing it to meet new tender pricing competitively.

7. COMMERCIAL CONSIDERATIONS

Pricing is structured around three core tiers based on capacity:
Tier I (800 TPH): Fully custom engineered solutions maximum volume operations requiring bespoke material flow.

Optional features include automated sampling systems remote monitoring telematics packages advanced metal detection tramp iron protection extended wear part warranties covering specific costperton agreements.

We offer comprehensive service packages ranging from basic preventive maintenance schedules fullsite operation management contracts Financing options include capital purchase leasing models operating expensebased throughput agreements where payment is linked verified production tonnage providing flexibility cash flow management

FAQ

What does RoHS compliance mean industrial mining equipment?
It certifies that controlled hazardous substances are not present electrical components wiring certain paints lubricants This critical exporting products into markets like European Union avoids legal commercial risks

How does this plant handle variations limestone hardness within same deposit?
The PLC system can store multiple preset parameters different feed materials Operators can select profile adjusts crusher speed closedside settings automatically maintain target output gradation minimizing manual tuning

What typical installation commissioning timeline look like?
For greenfield site modular TPH plant delivery installation typically requires weeks followed by weeks commissioning operator training Brownfield retrofit projects vary significantly based existing infrastructure detailed assessment required

Are spare parts readily available given specialized component specifications?
Yes maintain global network certified distribution centers All RoHScompliant wear parts electrical spares are stocked under our inventory management program guaranteeing availability support fast delivery minimize potential downtime

Do you offer performance guarantees?
Yes provide guaranteed minimum throughput capacity maximum specific energy consumption kWh/ton key product gradation curves under defined feed conditions These are formalized contract backed performance testing period postcommissioning

Can this system integrate with existing processing equipment conveyors screens
The plant designed modular integration can often interface legacy equipment Control systems be configured communicate via industrystandard protocols SCADA Modbus However optimal performance achieved complete circuit implementation

What financing models available
We work financial partners offer traditional leasing structures as well as productivitybased agreements where portion payment tied verified production data providing alignment between our success operational uptime