1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks? For plant managers and engineering contractors, a 250300tph crushing circuit is critical infrastructure, yet its performance gaps directly impact your bottom line. Common challenges include:
Unscheduled Downtime: Component failures in key crushers or screens halt your entire line, costing thousands per hour in lost production and idle labor.
Inconsistent Throughput: Fluctuations in feed material hardness or size lead to chokefeeding or cavitation, preventing you from reliably hitting your 300tonperhour target and fulfilling contracts.
High Operational Costs: Excessive wear part consumption, coupled with high energy consumption from inefficient crushing chambers and conveyors, erodes profit margins.
Product Quality Variance: Inadequate screening or improper crusher settings result in offspec product, leading to material reprocessing or customer rejections.

The central question is: how do you achieve a steady 250300tph output with predictable operating costs and maximum plant availability? The answer lies not just in individual machines, but in a fully integrated and optimized ODM 250300tph Stone Crushing Plant Assembly Plant.

2. PRODUCT OVERVIEW

The ODM 250300tph Stone Crushing Plant is a preengineered, stationary crushing and screening solution designed for highvolume production of aggregates for construction, road base, and railway ballast. It represents a complete processing system assembled from coordinated modules.

Operational Workflow:
1. Primary Reduction: Large feed material (up to 750mm) is consistently fed via a vibrating grizzly feeder to a primary jaw crusher for initial size reduction.
2. Secondary & Tertiary Crushing: The crushed material is conveyed to a secondary cone crusher for further reduction. A tertiary cone crusher or impact crusher module can be integrated for precise shaping and final size control.
3. Material Screening & Classification: Multiple decks of highefficiency vibrating screens separate the crushed stone into specified size fractions (e.g., 05mm, 510mm, 1020mm).
4. Stockpiling & Conveyance: Onspec product is transferred via radial stackers or fixed conveyors to designated stockpiles. Oversize material is recirculated back to the appropriate crusher.

Application Scope & Limitations:
Scope: Ideal for granite, basalt, limestone, and other mediumtohigh abrasiveness materials. Suited for greenfield quarry sites or major plant upgrades requiring reliable, highcapacity output.
Limitations: Not designed for portable applications. Feed material with very high clay or moisture content exceeding design parameters may require preprocessing scrubbing modules.

3. CORE FEATURES

Modular PreAssembly | Technical Basis: Unitized skid/baseframe construction | Operational Benefit: Reduces onsite installation time by up to 40%, minimizing weather delays and expediting commissioning | ROI Impact: Faster timetorevenue; lower labor costs for installation

Intelligent Feed Control System | Technical Basis: Variable Frequency Drive (VFD) on feeders paired with crusher amp monitoring | Operational Benefit: Automatically regulates feed rate to prevent crusher overload (choking) or underutilization (cavitation) | ROI Impact: Protects crushers from damage; optimizes power draw; ensures consistent throughput close to rated capacity

HeavyDuty Circuit Design | Technical Basis: Oversized conveyor belts, impact beds, and screen duty motors | Operational Benefit: Handles peak loads and surge conditions without transfer point spillage or premature component failure | ROI Impact: Reduces cleanup labor and unplanned stoppages; extends mechanical component life

Centralized Greasing & Dust Suppression | Technical Basis: Automated lubrication points on all major bearings and integrated spray bars at transfer points | Operational Benefit: Ensures critical components are lubricated on schedule; suppresses airborne particulate at source | ROI Impact: Extends bearing service life by up to 30%; improves compliance with environmental health standards

PLCBased Control & Monitoring | Technical Basis: Industrial programmable logic controller with humanmachine interface (HMI) in control cabin | Operational Benefit: Allows operators to start/stop sequence, monitor motor loads, belt alignment statuses, and bin levels from a single location | ROI Impact: Enables operation with fewer personnel; provides diagnostic data for predictive maintenance planning

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | ODM Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Plant Availability | ~8588% (planned & unplanned downtime) | Target >92% availability | +47% improvement |
| Energy Efficiency| Fixed speed motors across conveyors & feeders| VFDs on feeders & select conveyors optimize power use| Up to 15% reduction in specific energy per ton |
| Wear Part Cost/Ton| Highly variable based on manual feed control| Optimized crushing chamber flow & automated feed reduces metalonmetal wear| Field data shows 1020% lower cost per ton |
| Installation Timeline| 812 weeks for field assembly & alignment| Major modules preassembled & aligned; timeline reduced| ~40% faster commissioning |

5. TECHNICAL SPECIFICATIONS

Designed Capacity: 250 300 metric tons per hour (varies based on material density & hardness).
Primary Crusher: Jaw Crusher Model PEV900x1200 or equivalent. Feed opening up to 900mm x 1200mm.
Secondary Crusher: MultiCylinder Hydraulic Cone Crusher (e.g., HPT300). Tertiary module available as option.
Screening Module: Tripledeck horizontal vibrating screen(s), total screening area ≥18m².
Power Requirement: Total installed power approximately 550 650 kW. Main voltage supply: AC380V/50Hz/3Ph (or as specified).
Key Material Specifications: Main frame fabricated from Q345B steel; Highwear liners use Mn18Cr2 or equivalent alloy; Conveyor belting minimum EP400/3.
Physical Dimensions (Modular): Primary module approx. L15m x W5m x H6m. Overall layout customizable per site plan.
Environmental Operating Range: Designed for ambient temperatures 20°C to +45°C. Dust emission control meets standard regulatory limits.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: A quarry operator needed to increase output from 180tph to a consistent 280tph to fulfill a new highway contract but had limited space for plant expansion and needed minimal disruption during commissioning.
Solution: Implementation of an ODMdesigned modular crushing plant where the secondary/tertiary crushing module and screening tower were preassembled offsite.
Results: The modular approach cut field connection time by six weeks. The plant achieved rated throughput of 285tph within one week of commissioning, meeting the project's aggregate delivery schedule.

Limestone Processing for Cement Plant Feed

Challenge: A cement producer's existing crushing circuit suffered from frequent plugging at the secondary crusher due to sticky clay content in the limestone seam, causing unpredictable downtime averaging 15 hours per week.
Solution: An ODM plant featuring an enhanced feed control system with cavitylevel sensors was installed alongside a heavierduty screen deck configuration prior to secondary crushing.
Results:The intelligent feed system adjusted rates during highclay conditions.The revised screening removed more fines prior to the cone crusher.Downtime related to plugging was reduced by over80%.

7.COMMERCIAL CONSIDERATIONS

Pricing tiers are structured around core configuration:
• Base Configuration Tier:Covers primary jaw crusher,vibrating feeder,single cone crusher,screening module,and basic conveyors.Suitable for less abrasive materials like limestone.Pricing typically quoted FOB factory port after final specification review
• Enhanced Configuration Tier Includes tertiary crushing stage,taller multistage screening towers,and full PLC automation with remote monitoring capabilities.Recommended for abrasive materials(granite,basalt)
• Optional Features Mobile truck loading stations,dust encapsulation covers,wash plants addon modules,and advanced rockbreaker systems at primary hopper
• Service Packages Available options include annual scheduled maintenance plans,wear part supply agreements,and priority technical support packages which can help stabilize longterm operating costs
• Financing Options Flexible commercial terms can be discussed including leasing structures equipment financing through partners that allow capital preservation

FAQ

Q1:What level of foundation work is required prior this plant’s installation?
A1:The modular skids require substantial concrete foundations designed according provided load drawings We supply complete foundation layout engineering drawings as part of technical documentation package Site civil works remain responsibility buyer

Q2 Can this plant configuration process recycled concrete aggregate(RCA)?
A2 Yes but must specified during design phase For processing RCA we recommend incorporating additional magnetic separatorfor rebar removaland potentially an impactcrusherrather than conefor tertiary stage due higher presenceof impurities Final product quality will depend input RCA feedstock cleanliness

Q3 How many operators are typically required run this tphplant?
A3 With centralized PLC control system one operatorin control cabin can manage entirecrushingscreening flow Typically two personnelare deployedfor ground patrol visual inspectionand routine manual tasks

Q4 Whatis typical lead timefrom order placementto shipment?
A4 Leadtime variesbasedon final specifications complexity Currentproduction leadtimesrange betweenweeksfor standardconfigurations Customizedmodulesmay extendthis period Detailed scheduleprovided upon project initiation

Q5 Are spare parts interchangeablewith otherbrandcrushers screens?
A5 Critical wear partslike jaw plates concavemantlesare machinedto original equipment specificationsand are notdirectly interchangeablewith other brands without modification We maintain comprehensiveinventoryof genuine spareparts ensureoptimal performanceand warranty compliance