Mobile Combined Crushing Station (200–250 tph)
The standard solution for a 200–250 tph mobile modular crushing station is a tandem setup comprising a mobile jaw crusher station and a mobile impact crusher station. The primary crushing unit features a PE750×1060 jaw crusher, while the secondary unit integrates a PF1315 impact crusher with a 4YK2160 four-deck circular vibrating screen; material flows in a closed loop within the station, eliminating the need for ground stockpiling or intermediate handling. It requires no concrete foundation and can be operational within 24 hours of arrival. Rated at 200–250 t/h for limestone applications, the comprehensive cost is approximately ¥3.1 per ton. Whether this combination achieves full capacity depends on three factors: keeping the feed size within the 630mm limit, sizing the secondary stage based on throughput rather than just final product output, and ensuring adequate power supply for the entire line.
I. Mobile Jaw Crusher + Mobile Impact Crusher
1. The jaw crusher handles the initial intake, while the impact crusher ensures high-quality output. The jaw crusher relies primarily on compression; with a 750×1060mm feed opening and a maximum allowable feed size of 630mm, it reduces blasted run-of-mine ore to 80–140mm in a single pass, serving as the bottleneck of the entire line. The impact crusher utilizes impact-based crushing and offers a high reduction ratio, producing graded aggregates in a single pass; the product is cubic in shape, with the content of needle-like or flaky particles kept below 10%.
2. Material characteristics dictate the choice for the secondary stage. Limestone, dolomite, bluestone, and construction waste are classified as medium-soft materials with a Mohs hardness of 3–4 and low abrasiveness; here, blow bars can last over 180 hours, making the impact crusher the economical choice. Conversely, for high-silica, highly abrasive materials like granite, basalt, or river pebbles, blow bar lifespan drops to around 70 hours, necessitating a switch to a cone crusher for the secondary stage. Using the same mobile chassis, simply swapping the main crusher creates a completely different process route—this is the true meaning of "modular combination."
3. It is a three-unit system, not merely two standalone machines. The difference between an integrated modular system and simply "purchasing several mobile units and connecting them on-site" lies in the design: the mobile jaw crushing unit comes with a built-in ZSW490×110 grizzly feeder, while the mobile impact crushing unit has the main screening machine mounted on the same chassis. The manufacturer completes the final assembly and integrated commissioning of the three units, leaving only "connecting power, test running, and feeding material" for the on-site team. Material flow remains in a closed loop within the station; there are no transfer conveyors or intermediate stockpiles, thereby eliminating the production capacity losses typically caused by secondary material handling.
Mobile combined crushing station
| Equipment Unit | Main Machine Model | Quantity | Power (kW) | Feed Size (mm) | Output Size (mm) | Single-Unit Capacity (t/h) |
|---|---|---|---|---|---|---|
| Mobile Jaw Crushing Unit (Primary) | YDPZ-1060J / PE750×1060 | 1 | 110 + 15 | ≤630 | 80-140 | 110-320 |
| Mobile Impact Crushing Unit (Secondary) | PF1315 | 1 | 220 | ≤350 | 5-40 (Adjustable) | 130-250 |
| Mobile Screening Unit | YDPZ-2160S / 4YK2160 (4-Deck) | 1 | 37 | ≤200 | 0-5 / 5-20 / 20-40 / 40-80 | 80-320 |
| Total Line | — | 3 | Approx. 382 | ≤630 | 4 Finished Product Grades | 200-250 |
Motors for the entire line are customized for 380/400/440V and 50/60Hz; transport dimensions for each unit are kept within 13.5m × 3.0m × 4.2m, making them compatible with 40HQ flat-rack containers or Ro-Ro (Roll-on/Roll-off) shipping.
II. Application Scenarios for Mobile Stations
The value of a mobile modular crushing station lies not merely in the *ability* to move, but in the economic value generated by the *act* of moving itself. The following six scenarios represent situations where mobile stations offer a clear return on investment compared to fixed production lines.
| Scenario | Typical Requirements | Matching Points for the Two-Unit Combination |
|---|---|---|
| Aggregate lines for cement plants / commercial concrete stations | 0–31.5mm continuous gradation; short supply radius | Impact crusher for secondary shaping (flakiness/elongation <10%); four-deck screen produces four fractions in one pass |
| Limestone for steel plant / power plant desulfurization | 40–80mm lump flux; concentrated particle size distribution | Customizable screen aperture combinations; controllable finished product size |
| Highway / railway linear projects | Material sourcing along the route; relocation following project sections | Three units feature wheeled chassis; entire plant can relocate and resume production within one day |
| Temporary quarries / riverbed material extraction | Short operational windows; rapid site clearance required | Foundation-free; leaves no trace upon removal; mobilization occurs only after approvals are secured |
| On-site construction waste recycling | Limited space; dispersed work sites | Compact two-unit footprint; allows for on-site crushing/backfilling or off-site transport |
| Overseas projects / areas with limited power supply | No stable grid; rapid commissioning required | Supports dual diesel-electric power; options for 380/400/440V and 50/60Hz |
Quick Assessment: If the project cycle is under 3 years, involves multiple work sites, or lacks a stable grid and concrete foundation capabilities, the TCO (Total Cost of Ownership) of a mobile station is superior to a fixed line. Conversely, for a single quarry site with a cycle exceeding 5 years, a fixed line can reduce the cost per ton by an additional 10–15%.
III. Three Critical Figures to Verify
① Feed lump size ≤630mm. While the PE750×1060 crusher has a feed opening of 750×1060mm, the maximum permissible feed edge length is only 630mm. On-site control of lump size via blasting gradation or grizzly screens is mandatory—a single jam causes 30–60 minutes of downtime, which is costlier than any spare part wear.
② Size the secondary stage based on throughput, not finished product output. In a closed-circuit setup with material recirculation, the secondary crusher and screen must handle the combined volume of the finished product and the recirculated material. Based on an oversize rate of 15% (material retained on the screen), a finished product output of 250 t/h implies a secondary stage throughput of approximately 294 t/h (250 &pide; 0.85), which pushes the PF1315 impact crusher to its upper operational limit. This figure must be verified against the actual gradation of the raw ore: if the gradation is favorable and the oversize rate can be kept below 10%, a single PF1315 unit suffices; if the gradation is poor, provision should be made for a potential upgrade in the secondary stage.
③ Power supply: A 500 kVA transformer is required. The total installed power for the line is approximately 382 kW; however, on temporary job sites, insufficient generator capacity often forces reduced-speed operation, effectively cutting actual output by 30%. A diesel generator set of at least 450 kW is recommended, with a provision for switching to mains power.
IV. FAQ
Q1: What are the primary models for a 200–250 t/h mobile crushing plant combining a mobile jaw crusher and a mobile impact crusher?
A1: Primary crushing unit: PE750×1060 jaw crusher (YDPZ-1060J, 110 kW, feed size ≤630 mm); secondary crushing unit: PF1315 impact crusher (220 kW, feed size ≤350 mm); screening unit: 4YK2160 four-deck circular vibrating screen (37 kW). The system comprises three units with a total installed power of approximately 382 kW, rated for an output of 200–250 t/h when processing limestone.
Q2: Can the capacity of a mobile plant really match that of a stationary line?
A2: Yes. The main crushers used in mobile plants are the same models as those in stationary lines (PE750×1060, PF1315) and feature identical crushing chamber designs; the only difference in capacity stems from feeding continuity. When equipped with a standard grizzly feeder and hopper, the feed rate matches that of a stationary line, keeping the output variance within 5%. It is the chassis that is mobile, not the main crusher itself.
Q3: Should an impact crusher or a cone crusher be used for the secondary stage?
A3: It depends on the abrasiveness of the material. For limestone, dolomite, bluestone, and construction waste, an impact crusher is used; it yields well-shaped, rounded aggregate and offers a blow bar lifespan exceeding 180 hours. For granite, basalt, and river pebbles, a cone crusher is used; its liner lifespan is 3–4 times that of blow bars, resulting in a lower Total Cost of Ownership (TCO) over five years when processing hard rock.
Q4: Can it process materials containing moisture or clay?
A4: Direct processing is possible if the moisture content is below 5%. For 5%–8% moisture, we recommend adding a spray system to the screening unit and including a discharge outlet for clayey fines. In cases of high clay content, a grizzly screen and a dedicated fines conveyor should be installed at the feeding stage to separate soil before primary crushing; this protects the blow bars and ensures the final product meets clay content standards.
Q5: How long does it take from order placement to commissioning? Is export available?
A5: The delivery lead time for a standard three-unit configuration is 25–35 days, with production commencing within 24 hours of arrival on-site. Inpidual units fit within dimensions of 13.5m × 3.0m × 4.2m, making them compatible with 40HQ flat-rack containers or Ro-Ro (Roll-on/Roll-off) shipping; the equipment supports 380/400/440V and 50/60Hz power standards. For export projects, we provide multilingual operation manuals and remote commissioning guidance at the destination port.
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.
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