Step - by - Step Guide to Designing an Efficient 200tph Granite Crusher Plant

Designing a granite crusher plant with a capacity of 200 tons per hour (tph) demands meticulous planning, taking into account material characteristics, equipment performance, and process optimization. Here is a detailed, step - by - step approach to guarantee a high - efficiency operation.

1. Raw Material Analysis

Granite Properties: Granite is renowned for its high compressive strength, typically ranging from 100 to 200 MPa, and its abrasiveness. These properties have a direct impact on the selection of equipment and wear parts.

Moisture Content: A moisture level exceeding 5% can lead to issues such as material clogging. Therefore, pre - drying might be necessary in certain cases.

Feed Size: The maximum size of the incoming granite should be clearly defined. For instance, it could be in the range of 300 - 500 mm.

2. Select Equipment Configuration

2-1. Primary Crushing (Jaw Crusher)

Function: The jaw crusher is responsible for reducing large - sized granite boulders into smaller pieces, typically in the range of 50 - 100 mm.
Recommended Model: A heavy - duty jaw crusher with a capacity of 250 - 300 tph, such as the C6X series or PE750X1060, is a good choice.

2-2. Secondary Crushing (Cone Crusher)

Function: It further reduces the material to a size of 10 - 50 mm.
Recommended Model: A multi - cylinder hydraulic cone crusher, like the HPC series, which is designed for high - hardness materials.

2-3. Tertiary Crushing (Impact Crusher)

Function: This stage is for shaping the material into cubical particles, with a size of 5 - 20 mm.
Recommended Model: A CI5X impact crusher, which can enhance the quality of the finished product.

2-4. Screening Equipment

Function: It is used to classify the crushed material according to different sizes, such as 0 - 5mm, 5 - 10mm, 10 - 20mm, and 20 - 30mm.
Recommended Model: A 3 - or 4 - deck vibrating screen with a high screening efficiency.

2-5. Auxiliary Equipment

Vibrating Feeder: It ensures a continuous and uniform flow of material into the primary crusher.
Belt Conveyors: These should have a width of 650 - 800 mm and be capable of handling the required capacity.
Dust Collection System: It helps to comply with environmental regulations by controlling dust emissions.

3. Design the Granite Crushing Plant Process Flow

This is a Closed - Circuit Three - Stage Crushing Circuit Process Plant
3-1. Primary Crushing: The jaw crusher reduces the feed size from 500 mm to 100 mm.
3-2. Secondary Crushing: The cone crusher further reduces the size to 30 mm.
3-3. Tertiary Crushing: The impact crusher produces a final product with a size of 5 - 20 mm.
3-4. Incorporate a vibrating screen to return over - sized material to the cone crusher for re - processing. This helps to improve the overall efficiency of the crushing process.

4. Optimize Plant Layout

Layout Principles
4-1. Minimize Material Handling: Arrange the equipment in a linear or U - shaped configuration to reduce the distance that the material needs to travel.
4-2. Accessibility: Ensure that there is sufficient space around each piece of equipment for maintenance purposes.
4-3. Foundation Requirements: Heavy equipment such as the jaw and cone crushers need reinforced concrete foundations to ensure stability.

5. Ensure Power and Utility Provisions

5-1. Electric Power: A 200tph plant typically requires a total power supply of 400 - 600 kW.
5-2. Water Supply: Water is used for dust suppression and cooling. A supply of 10 - 15 m³/h is usually sufficient.
5-3. Air Compressor: It is needed for pneumatic controls and valve operations.

6. Implement Environmental Controls

Dust Control: Install dust collectors and misting systems at the transfer points and crusher inlets.
Noise Reduction: Use sound - proof enclosures around the crushers and screens.
Waste Management: Recycle water and reuse fines in the production process.

7. Commission and Test the Plant

Pre - operation Checks: Verify the alignment of the equipment, the lubrication levels, and the safety devices.
Load Testing: Gradually increase the feed rate to the design capacity of 200 tph.
Performance Monitoring: Keep track of the production metrics, such as the particle size distribution and the power consumption.

8. Develop a Maintenance Plan

Wear Parts Replacement: Schedule regular replacements for parts like jaw plates, cone liners, and impact hammers.
Preventive Maintenance: Inspect the bearings, belts, and hydraulic systems on a monthly basis.
Spare Parts Inventory: Maintain an inventory of critical components to minimize downtime.

Conclusion

Designing an efficient 200tph granite crusher plant involves a combination of proper equipment selection, optimized process design, and strict adherence to environmental standards. By following this step - by - step guide, operators can achieve high productivity, low operating costs, and long - term equipment reliability. Baichy Machinery has a history of more than 20 years. It not only produces a full set of crushing and sand making equipment, but also provides EPC project general contracting services, including plant site selection and construction, production line design and installation, and production and operation technical training. Welcome to consult online to get your exclusive stone crushing plant solution.