PE600×900 Jaw + PF1214 Impact — Closed-Circuit Crushing & Screening Plant
Process flow diagram · primary crushing → secondary / fine crushing → closed-circuit classification
Stationary Limestone Crushing Production Line (100 tph) Process Flow Diagram
| No. | Equipment | Model | Role in the circuit | Flow |
|---|---|---|---|---|
| A-1 | Grizzly vibrating feeder | ZSW380×96 | Pre-screens the run-of-mine feed, discharges the undersize and feeds the primary crusher at a controlled rate. | B-1 / B-2 |
| A-2 | Jaw crusher | PE600×900 | Primary crushing — reduces the oversize feed to a size the impact crusher can accept. | B-1 → B-3 |
| A-3 | Impact crusher | PF1214 | Secondary / fine crushing — also re-crushes the screen oversize returned in the closed circuit. | B-3 → B-4, B-5 |
| A-4 | Three-deck circular vibrating screen | 3YK1860 | Closed-circuit classification — splits the crushed material into three graded products and returns the oversize. | B-4 → B-5…B-8 |
Limestone is a classic example of a moderately soft material with low abrasiveness. A stationary limestone crushing line with an hourly output of 100 tons does not require a three-stage crushing process; a two-stage crushing and one-stage screening setup—comprising a ZSW380×96 grizzly feeder, a PE600×900 jaw crusher (primary crushing), a PF1214 impact crusher (secondary/fine crushing), and a 3YK1860 three-deck circular vibrating screen (closed-circuit classification)—is sufficient to achieve stable production targets.
I. Equipment Selection for Stationary Limestone Crushing Lines: Consider Abrasiveness First, Then Particle Shape
The primary criterion for selecting limestone crushing equipment is abrasiveness: the material typically has a compressive strength of 80–150 MPa and low free SiO₂ content.
Coarse, medium, and fine crushed limestone products
II. Determining the Model for a Limestone Crushing Line with a 100 t/h Capacity: Four Calculations
The model is derived from the following four calculations; this is how the PE600×900 + PF1214 configuration was selected.
primary crusher jaw crusher - pe600x900 jaw crusher
① Primary Crushing: Jaw crusher feed opening width ≥ maximum raw ore lump size &pide; 0.85. For raw ore ≤400 mm, select the PE600×900 (feed opening 600×900 mm, max. feed ≤500 mm, discharge opening 65–160 mm, rated capacity 48–180 t/h, 55–75 kW); with a discharge setting of 100–120 mm, the hourly capacity is approximately 110–140 t/h, allowing for a 20%–30% margin.
Second crushing - PF1214 Impact Crusher
② Secondary Crushing: Impact crusher rated capacity ≥ target capacity × 1.3. Closed-circuit material recirculation increases the secondary stage load by an additional 20%–35%; 100 × 1.3 = 130 t/h, which falls within the range of the PF1214 (feed opening 400×1430 mm, max. feed ≤350 mm, 100–180 t/h, 132 kW); the PF1210 (70–120 t/h) is considered only if the feed rate is stable.
③ Screening: Screen surface sizing is based on "throughput + recirculating load" rather than just the finished product output. The 3YK1860 (1800×6000 mm, triple-deck, 22–30 kW) has a rated capacity of 60–350 t/h, providing ample margin. ④ Electrical and Conveying: B800 conveyors handle the main material flow, while B650 conveyors handle finished products and recirculating material; motors for the stationary limestone crushing line are customized according to local standards (380/400/440V, 50/60Hz).
| Process | Equipment | Model | Key Parameters (Limestone Calibration) | Power |
|---|---|---|---|---|
| Feeding | Grizzly Vibrating Feeder | ZSW380×96 | Trough: 3800×960mm; Max. feed size: ≤500mm; 100–160 t/h | 11 kW |
| Primary Crushing | Jaw Crusher | PE600×900 | Feed opening: 600×900mm; Discharge opening: 65–160mm; 48–180 t/h | 55–75 kW |
| Secondary/Fine Crushing | Impact Crusher | PF1214 | Feed opening: 400×1430mm; Max. feed size: ≤350mm; 100–180 t/h | 132 kW |
| Screening | 3-Deck Circular Vibrating Screen | 3YK1860 | Screen surface: 1800×6000mm; Equipped with 5/10/20/31.5mm mesh | 22–30 kW |
| Conveying | Belt Conveyor | B800 / B650 | Main flow: B800; Finished product & return material: B650 | — |
| Environmental Protection | Pulse Bag Dust Collector | DMC Series | Spec selected based on number of dust emission points | — |
Total installed power for main equipment is approx. 230 kW; calculated at 100 t/h, specific energy consumption is approx. 1.2–1.8 kWh/t (including conveying).
III. Advantages of Stationary Crushing Production Lines and Three Points to Confirm in Advance
Advantages of stationary crushing production lines:
① Lowest investment per ton of capacity—Stationary limestone crushing lines lack chassis and travel mechanisms, resulting in significantly lower equipment costs compared to mobile stations of equal capacity;
② Low operating cost per ton—Material transfer via belt conveyors; no reliance on wheel loaders for intermediate transport;
③ Stable capacity and gradation—Rigid foundation and uniform feeding; controllable ratio of closed-circuit material return;
④ Easy maintenance and expansion—Ample space for servicing; sand-making stages, dust collection systems, and centralized control can be added later.
Key Considerations:
1. Do not sign contracts based solely on nominal capacity: Rated values are based on medium-hardness limestone; actual output fluctuates depending on raw material gradation, moisture content, and target product gradation. Contracts should specify both metrics, with acceptance testing anchored to the measured continuous hourly output.
2. Pre-process high clay and moisture content: High moisture causes screen clogging and material buildup in impact crushers; address this using a ZSW vibrating grizzly feeder with a bypass and anti-clogging screens. Add a sand-washing stage only if there are strict requirements for clay content in the finished product.
3. Site preparation, foundations, and environmental compliance drive the project schedule: Civil works, enclosure construction, and environmental inspections determine the final commissioning date; these should be advanced in parallel with equipment tendering.
Stationary Limestone Crushing Production Line (100 tph)
IV. FAQ (5 items)
Q1: How many crushers are needed for a stationary limestone crushing line with an hourly output of 100 tons?
A1: Two stages are sufficient. Use a jaw crusher for primary crushing and an impact crusher for secondary/tertiary crushing, paired with a three-deck circular vibrating screen for closed-circuit classification. Add a third stage for sand making only if the proportion of 0–5mm fine aggregate needs to exceed 40%.
Q2: Why is an impact crusher recommended for limestone instead of a cone crusher or hammer crusher?
A2: Limestone has a low abrasiveness index, making blow bar wear in impact crushers manageable. They produce a high percentage of cubical particles with low flake/elongation ratios and require the lowest initial investment. Cone crushers are better suited for highly abrasive materials like granite; hammer crushers offer single-stage shaping but result in excessive fines and frequent hammer replacements, leading to higher long-term costs per ton.
Q3: How do I distinguish between nominal capacity and actual operational capacity (100 tph)?
A3: Equipment specifications list nominal capacity, rated based on medium-hardness limestone. Actual output is influenced by raw material gradation, moisture content, and the desired product mix; acceptance testing should be based on measured continuous hourly output rather than the nameplate figure.
Q4: How should the configuration be adjusted for high clay content in raw materials or operations during the rainy season?
A4: At the feed end, use a ZSW grizzly feeder to bypass fines and soil into a separate stockpile, preventing material clogging in the secondary crushing stage; replace standard screen decks with anti-clogging polyurethane screens. If there are strict requirements regarding the silt/clay content of the final product, install a wheel-bucket sand washer and a fine sand recovery unit downstream of the product discharge conveyor, with overflow water settled and recycled.
Q5: For a 100-ton-per-hour capacity, should I choose a stationary or a mobile plant?
A5: Choose a stationary plant if the quarry site is fixed, the operational lifespan is long, and minimizing the cost per ton is the priority. Choose a mobile plant if quarry sites are dispersed, project timelines are tight, and frequent relocation is required. A stationary limestone crushing line offers lower operating costs per ton but requires land, concrete foundations, civil engineering work, and environmental compliance approvals, resulting in a longer lead time compared to a mobile plant.
Baichy Heavy Industry
Baichy Heavy Industry is a high-tech mining equipment company integrating R&D, manufacturing, sales, and after-sales service. Focusing on crushing, grinding, and mineral processing equipment, we provide professional solutions to our customers. We are ISO9001:2015 、certified, and our products include mobile crushing palnts, crawler crushing plant, construction waste crushing plants, jaw crushers, sand making machines, cone crushers, fine crushers, grinding mills, ball mills, etc., all with reliable performance to meet diverse project needs.
Baichy Heavy Industry – Your Trusted Partner
To ensure optimal performance of your equipment, Baichy Heavy Industry offers:
- Professional on-site installation guidance
- Comprehensive operator training
- 24/7 technical support & maintenance services
Our complete after-sales service system guarantees long-term, stable operation of your machinery with minimal downtime.
Protect Your Rights – Only Use Official Channels
To avoid scams and ensure authentic support, contact us exclusively through:
• Official Website: www.baichychina.com
• WhatsApp: +8615093222637
• Email: [email protected]
Your satisfaction is our priority – expect prompt, professional service every time.
(Note: Beware of unauthorized third parties claiming to represent Baichy. Always verify through official contacts.)
