1. PAINPOINT DRIVEN OPENING

Are you managing a highvolume aggregate operation and facing persistent bottlenecks that erode profitability? For plant managers and engineering contractors, a 250300tph stone crushing plant is a critical production 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 & Product Quality: Fluctuations in final product gradation lead to rejected loads, contract penalties, and wasted raw material.
High Operational Costs: Spiking energy consumption from inefficient processes and excessive wear part replacement cycles directly cut into margins.
Scalability Limitations: Inflexible plant design struggles to adapt to changing feed material or market demand for different aggregate specifications.

Is your current setup delivering the reliable, costperton output required for competitive bidding and sustained project profitability? The specification of your 250300tph crushing plant is the decisive factor.

2. PRODUCT OVERVIEW

This product specification details a stationary 250300 tonperhour (tph) hard rock crushing and screening plant. Designed for highvolume aggregate production, this turnkey solution processes quarried limestone, granite, basalt, and similar abrasives to produce precisely graded aggregates for construction, road base, and concrete applications.

Operational Workflow:
1. Primary Reduction: Dumpfed material is crushed by a robust primary jaw crusher to a manageable size.
2. Intermediate Screening & Crushing: A conveyor transfers material to a vibrating screen. Oversize is routed to a secondary cone crusher for further reduction.
3. Final Sizing & Stockpiling: Correctly sized product from the screen is conveyed to designated stockpiles. Remaining material is sent to a tertiary cone crusher for final shaping before returning to the screen, creating a closedcircuit system for precise control.

Application Scope: Ideal for largescale quarry operations, major infrastructure projects requiring onsite aggregate production, and dedicated aggregate suppliers serving regional markets.
Limitations: This plant configuration is designed for stationary installation. Feed material hardness must be within the specified compressive strength limits of the crusher liners. Optimal operation requires consistent feed size distribution as per design parameters.

3. CORE FEATURES

HeavyDuty Primary Jaw Crusher | Technical Basis: Optimized kinematics & highstrength steel castings | Operational Benefit: Sustained high reduction ratios on toughest feed with minimal risk of fatigue failure | ROI Impact: Extended service life reduces capital replacement cycles; higher uptime protects revenue flow.

ClosedCircuit Secondary/Tertiary Crushing | Technical Basis: Return conveyor system recirculating oversize material | Operational Benefit: Allows precise control over final product cubicity and gradation without overcrushing | ROI Impact: Maximizes saleable product yield (reducing waste) and ensures premium product specs command better pricing.

HighCapacity Inclined Screens | Technical Basis: Multideck vibratory screening with adjustable throw | Operational Benefit: Efficient separation of multiple product fractions simultaneously under high load | ROI Impact: Directly increases plant throughput capacity and ensures product specification compliance.

Centralized PLC Control System | Technical Basis: Programmable Logic Controller with humanmachine interface (HMI) | Operational Benefit: Enables singleoperator monitoring of entire plant flow, motor loads, and fault diagnostics | ROI Impact: Lowers labor costs and enables rapid response to anomalies, preventing minor issues from escalating into major downtime.

Integrated Dust Suppression System | Technical Basis: Strategically placed spray nozzles at transfer points | Operational Benefit: Significantly reduces airborne particulate matter during operation | ROI Impact: Ensures compliance with environmental regulations, avoids fines, and improves site working conditions.

Modular Walkways & Access Platforms | Technical Basis: ANSI/OSHA compliant design with nonslip surfaces | Operational Benefit: Provides safe, easy access for routine maintenance inspections and wear part changes | ROI Impact: Reduces service time by up to 30%, enhancing maintenance efficiency and improving worker safety record.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | This 250300tph Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime)| 8588% (planned & unplanned downtime) |> 92% Availability Target| +5% to +8% More Production Time |
| Energy Efficiency| Fixed speed drives; basic motor selection| PLCcontrolled VFDs on conveyors & fans| Field data shows 1218% lower kWh/ton |
| Wear Part Consumption| Manganese steel standard liners| Interchangeable alloy liners with optimized profiles| Up to 25% longer life in abrasive granite/basalt |
| Product Yield (Spec Material)| Highly variable; often 92% inspec aggregate| +7% More Saleable Product Per Ton Processed |
| Reconfiguration Time| Major layout changes require weeks|< 5 days for primary circuit rerouting due to modular piping/wiring|75% Time Savings for Plant Adaptation |

5. TECHNICAL SPECIFICATIONS

Designed Capacity Range: 250 300 metric tons per hour (tph), based on standard limestone (bulk density ~1.6 t/m³).
Primary Crusher: Jaw Crusher Model Equivalent – Feed Opening ≥ 1200mm x 800mm; Power Rating ~160200 kW.
Secondary/Tertiary Crushers: Hydraulic Cone Crushers – Each rated ~250 kW; equipped with automatic setting regulation.
Screening Unit: Tripledeck inclined vibrating screen – Total screening area ≥ 20m²; Drive power ~22 kW.
Power Requirements: Total installed plant power approximately 800 950 kW. Recommended incoming supply: 1000 kVA.
Key Material Specifications: Main frame construction S355JR structural steel; Conveyor belt rating – Minimum EP630/4; Wear liners – Highchrome iron or equivalent alloy.
Approximate Footprint (L x W): Varies by layout but typically within 80m Length x 35m Width for full circuit including stockpile conveyors.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with appropriate lubrication specs. Dust emission control meets <10 mg/Nm³ at point of generation with suppression system active.

6. APPLICATION SCENARIOS

LargeScale Granite Quarry Expansion

Challenge: A regional quarry needed to increase output from 200tph to over 280tph of road base and concrete stone but was constrained by an aging singleline plant with poor product shape.
Solution: Implementation of this complete twostage cone crusherbased crushing plant in closed circuit configuration alongside existing infrastructure.
Results: Plant achieved sustained output of 290tph. Improved cubicity increased the market value of their products by approximately $1/ton while reducing crusher liner wear costs by an estimated $0.15/ton processed.

Major Highway Construction Project

Challenge: A contractor faced high logistics costs importing aggregates for a remote highway project bid required strict gradation control on six different aggregate products simultaneously.
Solution Deployment of this modular crushing plant configured with multiple final screening lines directly at the project site’s rock source.
Results Onsite production eliminated over $450k in transport costs over the project’s lifespan The closedcircuit design allowed operators to consistently meet all six gradation bands reducing material rejection to near zero

Commercial Aggregate Producer

Challenge An established producer operating multiple older plants experienced unpredictable maintenance events causing missed shipments
Solution Replacement of their most problematic line with this new standardized crushing unit featuring centralized PLC monitoring
Results Unplanned downtime events decreased by over % within the first year The PLC system provided clear data enabling predictive maintenance scheduling on conveyors

Commercial Considerations

Pricing tiers are structured around core configuration choices:

Tier Configuration Key Components Estimated Price Range
Tier Standard Duty Primary Jaw Secondary Cone Basic Screens PLC Control Mid Investment Range
Tier Heavy Duty Grizzly Feeder Primary Jaw Secondary Tertiary Cones High Capacity Screens Advanced PLC Dust Suppression Higher Investment Range

Optional Features Premium wear liner alloys extended conveyor warranties automated greasing systems advanced dust collection baghouses remote monitoring telemetry packages

Service Packages Annual inspection plans comprehensive parts agreements including wear parts emergency breakdown support field technician training programs

Financing Options Available equipment leasing structures through partners project financing solutions operating lease agreements tailored support available

FAQ

What if my feed rock is harder than typical granite This crushing plant can be specified with extra heavy duty crushers bearings structural reinforcements Consult engineering data sheets specifying maximum compressive strength MPa ratings

How quickly can operational personnel learn this new system Field experience indicates that operators familiar with basic crushing principles become proficient within one week due largely due intuitive HMI interface Structured training accelerates this process further

What are typical installation lead times From order placement following civil works completion major component assembly electrical commissioning typically requires weeks depending site readiness specific configuration chosen Detailed project schedule provided upon specification finalization

Are spare parts readily available Critical wearing spare parts jaw plates cone mantles screen meshes are standardized held regional distribution centers ensuring availability within hours days not weeks This minimizes potential downtime events significantly

Can this capacity be upgraded later beyond tph The foundational chassis conveyors primary structure are engineered headroom capacity exceeding tph Upgrading secondary tertiary crushers increasing screen area motor power can lift capacity toward tph range future investment protects initial capital outlay