100–130 TPH Crushing and Screening Plant
A 100–130 TPH crushing and screening plant sits between the commonly used 80–120 TPH and 120–150 TPH capacity ranges. This means the equipment should not be selected by production capacity alone. The final configuration also depends on the material hardness, maximum feed size, moisture and clay content, required product sizes, circulating load, and expected operating hours.
For many medium-hard and hard-rock applications, a typical process is:
Vibrating Feeder → PE600×900 Jaw Crusher → CS110 or CS160 Cone Crusher → Circular Vibrating Screen → Finished Aggregate and Return Material
Schematic diagram of a spring cone crusher production line process
The PE600×900 jaw crusher can be considered for primary crushing when the largest feed lump is no more than 500 mm and the actual operating conditions fall within its rated range. A CS110 cone crusher is suitable for many 100–120 TPH applications, while a CS160 may be preferred when the plant must maintain approximately 130 TPH, handle a higher circulating load, or operate with additional capacity margin. The final selection should be confirmed after reviewing the complete process and material data.
Important: All equipment capacities shown below are reference values from product specifications. Actual output depends on material properties, feed gradation, crusher settings, screen efficiency, circulating load, and plant layout.
Recommended Configuration at a Glance
| Process stage | Typical equipment | Selection guidance |
|---|---|---|
| Feeding | ZSW960×3800 vibrating feeder or equivalent | Select according to the raw-material feed size, hopper arrangement, and required steady feed rate. |
| Primary crushing | PE600×900 jaw crusher | Suitable for many applications when the maximum feed size is within 500 mm and the required primary feed rate is within its operating range. |
| Secondary crushing, Option A | CS110 medium chamber | A practical option for many 100–120 TPH applications under suitable feed conditions. |
| Secondary crushing, Option B | CS160 medium chamber | Consider for a sustained output close to 130 TPH, higher circulating load, or additional secondary-crushing capacity margin. |
| Screning | 4YK2160 or another YK-series screen | Select the number of decks and screen area according to the number of product fractions, feed gradation, moisture, and required screening efficiency. |
| Main conveying | B800 or an equivalent belt conveyor | A B800 is generally more suitable than a B650 for the main line when the target output approaches 130 TPH. Confirm the belt capacity against the actual material load. |
| Return and branch conveying | B650, B500, or other suitable belts | Select according to the quantity and path of finished products and circulating material, not simply the final product output. |
1. How Should the 100–130 TPH Capacity Range Be Understood?
The 100–130 TPH range crosses the boundary between two common equipment tiers. A 100 TPH target and a sustained 130 TPH target do not necessarily require the same secondary crusher, screen arrangement, or conveyor capacity.
For preliminary equipment selection, a design margin may be considered above the required finished-product output. For example, a 130 TPH target could lead to a preliminary crushing-circuit design range of approximately 143–163 TPH when a 10–25% margin is used. This is only an initial engineering assumption. It is not a guaranteed production figure and should not replace a complete circulating-load calculation or a material test.
The final design point should be based on:
• Required finished-product output
• Maximum feed size and feed-size distribution
• Material hardness and abrasiveness
• Moisture and clay content
• Required product fractions and specifications
• Open-circuit or closed-circuit operation
• Expected circulating load
• Daily operating hours and required availability
2. Primary Crushing: When Is the PE600×900 Suitable?
The PE600×900 jaw crusher is a commonly used primary crusher for medium-sized aggregate and mining applications. Its published reference parameters include:
Primary crushing - pe jaw crusher
• Maximum feed size: 500 mm
• Discharge opening adjustment range: 60–125 mm
• Rated motor power: 55 kW
• Reference capacity: 90–180 TPH
The PE600×900 can be considered when the raw material is compatible with these parameters and the plant does not require a higher primary-crushing capacity or a larger feed opening.
However, the model should not be selected by feed opening alone. The final decision also depends on the required reduction ratio, material hardness, feed gradation, crusher setting, and the stability of the upstream feeding system.
A larger jaw crusher, such as the PE750×1060, may be considered when:
• The largest feed lumps exceed 500 mm;
• The required primary feed rate is beyond the practical operating range of the PE600×900;
• The raw material is particularly hard or abrasive;
• The plant requires a larger capacity margin for long-term continuous operation.
Therefore, a PE750×1060 is not automatically required for every 100–130 TPH plant. It should be selected only when the feed size, capacity, or operating conditions justify the upgrade.
3. Secondary Crushing: CS110 or CS160?
The secondary crusher is selected according to more than the final product output. In a closed-circuit plant, the cone crusher may process both the discharge from the jaw crusher and the oversize material returned from the screen. The actual secondary-crushing load can therefore be higher than the finished-product output.
symons cone crusher
CS110 Medium Chamber
The CS110 medium chamber has the following published reference parameters:
• Maximum feed size: 130 mm
• Discharge opening adjustment range: 13–38 mm
• Motor power: 110 kW
• Reference capacity: 80–180 TPH
The CS110 is a practical option for many 100–120 TPH crushing lines when the feed is well controlled, the circulating load is reasonable, and the required product gradation is compatible with the selected chamber and discharge setting.
CS160 Medium Chamber
The CS160 medium chamber has the following published reference parameters:
• Maximum feed size: 178 mm
• Discharge opening adjustment range: 16–38 mm
• Motor power: 160 kW
• Reference capacity: 132–253 TPH
The CS160 may be preferred when the plant is expected to maintain approximately 130 TPH for extended periods, when the circulating load is high, or when additional secondary-crushing capacity is required. Its nominal lower capacity for the medium chamber is close to the 130 TPH target, so the final selection still needs to be checked against material characteristics, feed distribution, chamber selection, and operating conditions.
Practical Selection Guide
| Target and operating condition | Initial option to evaluate |
|---|---|
| Approximately 100 TPH, moderate circulating load, suitable feed | PE600×900 + CS110 medium chamber |
| Approximately 100–120 TPH, stable feed and conventional product requirements | PE600×900 + CS110 medium chamber |
| Sustained output close to 130 TPH | PE600×900 + CS160 medium chamber, subject to full process verification |
| High circulating load or demanding hard-rock application | Evaluate CS160 or an alternative process configuration with the engineering team |
| Feed larger than the selected cone chamber allows | Add suitable primary-stage reduction or select a larger secondary-crushing model |
This table is for preliminary selection only. It should not be interpreted as a production guarantee.
4. Screening Configuration and Product Sizes
The screening system determines how the crushed material is separated into finished products. The number of screen decks should be selected according to the required number of product fractions, while screen area and feed conditions affect screening capacity and efficiency.
YK series vibrating screen
A 4YK2160 circular vibrating screen may be considered when the project requires several aggregate fractions from one screening stage. Its published reference parameters include:
• Screen surface: 6000 × 2100 mm
• Number of decks: 4
• Screen aperture range: 3–100 mm
• Reference capacity: 81–720 TPH
• Motor power: 37 kW
• Maximum feed size: 400 mm
A four-deck screen can be configured for multiple product fractions, but the final product sizes depend on the selected screen apertures, feed gradation, moisture, material shape, and required screening efficiency. A four-deck screen should not be presented as an automatic guarantee of four qualified products.
For projects requiring fewer fractions, a two- or three-deck YK screen may be more economical.
The final model should be selected after confirming:
• Number of required product fractions
• Screen aperture sizes
• Percentage of each feed-size fraction
• Material moisture and clay content
• Required separation efficiency
• Quantity of oversize material returned to the crusher
5. Conveyor Selection: Avoiding a Hidden Bottleneck
The main conveyor should be sized according to the material it actually carries, including any return material or combined streams. Selecting a belt only according to the final saleable output can create a capacity bottleneck.
Belt conveyor
As a preliminary reference:
• B500: approximately 40–100 TPH
• B650: approximately 80–120 TPH
• B800: approximately 120–200 TPH
• B1000: approximately 200–320 TPH
A B650 may be suitable for a branch line or a lower-load return stream, but it may not be appropriate as the main conveyor for a line designed around a 130 TPH target. A B800 is generally a more suitable starting point for the main line in this capacity range. The final belt width and motor power must still be checked against belt length, inclination, material density, loading method, and actual conveying rate.
6. Reference Equipment Data
| Process | Model | Qty. | Reference motor power | Reference capacity or key parameter |
|---|---|---|---|---|
| Feeding | ZSW960×3800 or equivalent | 1 | Subject to final selection | Confirm according to feed size, hopper layout, and required feed rate. |
| Primary crushing | PE600×900 | 1 | 55 kW | 90–180 TPH; maximum feed size 500 mm. |
| Secondary crushing, Option A | CS110 medium chamber | 1 | 110 kW | 80–180 TPH; maximum feed size 130 mm. |
| Secondary crushing, Option B | CS160 medium chamber | 1 | 160 kW | 132–253 TPH; maximum feed size 178 mm. |
| Screening | 4YK2160 | 1 | 37 kW | 81–720 TPH reference capacity; four decks; 3–100 mm aperture range. |
| Main conveying | B800 or equivalent | As required | Subject to layout | Select according to actual conveying load and distance. |
| Branch and return conveying | B650/B500 or equivalent | As required | Subject to layout | Confirm according to branch-flow and circulating-load calculations. |
Installed Power Note
Using the main equipment listed above, the approximate installed power of the two secondary-crusher options can be summarized as follows, excluding conveyors, dust-collection systems, electrical controls, and auxiliary equipment:
• PE600×900 + CS110 + 4YK2160: 55 + 110 + 37 = 202 kW, excluding the feeder and auxiliary equipment.
• PE600×900 + CS160 + 4YK2160: 55 + 160 + 37 = 252 kW, excluding the feeder and auxiliary equipment.
If a 11 kW feeder is included, the corresponding subtotal becomes approximately 213 kW for the CS110 option and 263 kW for the CS160 option.
These figures represent rated installed power, not actual electricity consumption per ton. Actual specific energy consumption depends on the load factor, material hardness, feed size, circulating load, operating time, and equipment settings. Any energy-saving percentage should be treated as a manufacturer claim under specified conditions rather than a universal performance guarantee.
FAQ
1. Is the PE750×1060 jaw crusher mandatory for a 100–130 TPH plant?
No. A PE600×900 may be suitable when the maximum feed size is no more than 500 mm and the primary-crushing duty remains within its practical operating range. A PE750×1060 should be considered when the feed lumps are larger, the required primary feed rate is higher, or the material and operating conditions require additional capacity margin.
2. Should I choose CS110 or CS160 for a 130 TPH target?
For a sustained output close to 130 TPH, CS160 is an option worth evaluating because it provides a larger secondary-crushing capacity range. CS110 may still be suitable for lower output or favorable operating conditions. The final choice depends on the circulating load, material hardness, feed size, product gradation, and selected chamber.
3. Can a 4YK2160 produce four aggregate sizes in one pass?
A 4YK2160 can be configured for multiple product fractions because it has four decks. However, the actual number and quality of the finished products depend on the screen apertures, feed gradation, moisture, material shape, and required screening efficiency. The configuration should be confirmed through process calculations or testing.
4. Can a B650 belt conveyor be used as the main conveyor?
A B650 may be suitable for a lower-load branch or return line, but it may be undersized for the main line when the target approaches 130 TPH. A B800 is a more appropriate preliminary option for the main conveyor in this capacity range. The final selection must consider the actual material load, belt length, inclination, and conveying route.
5. What is the exact electricity consumption per ton?
It cannot be determined from the rated motor power alone. Actual electricity consumption depends on the material, feed size, crusher settings, circulating load, operating hours, and load factor. A project-specific estimate or field measurement is required for a reliable kWh/t value.
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