60-100 tph Stone Crushing Plant
A 60-100 tph stone crushing plant built on a ZSW850×3000 feeder, PE500×750 jaw crusher, PF1010 impact crusher and 3YK1548 screen is a two-stage circuit for medium-hard, low-abrasion stone — and its capacity band needs one honest reading before you buy. The feeder is rated 80-120 t/h and the jaw 40-130 t/h, both above the band; the PF1010 is rated 50-80 t/h. That is the binding number. Expect 60-80 tph of 0-5, 5-10 and 10-20 mm aggregate on limestone; for a contract that says 100 tph, the secondary moves up to PF1210.
Why jaw + impact is the right pairing — and where it stops
Impact crushing wins on limestone and dolomite because blow bars break rock along its natural fractures, not by squeezing it: the 10-20 mm fraction comes out cubical with low flakiness, which is what ready-mix and asphalt plants pay for, and two stages do the work of three. The same design turns against you on granite, basalt and quartz. Those rocks are abrasive, and abrasiveness, not compressive strength, is what consumes blow bars, so wear cost per ton climbs faster than throughput. On that feed, keep the PE500×750 jaw crusher and change the secondary to a CS75 cone — the configuration our hard stone 80-100 tph line uses.
60-100 tph stone crushing plant
The "under 425 mm" feed spec has two ceilings
The PE500×750 accepts a maximum feed of 425 mm; the ZSW850×3000 above it is rated for material up to 400 mm. The feeder is therefore the tighter limit, and the 400-425 mm band is where bridging and uneven feed begin. Fix it at the quarry face: tighten the blast pattern so the largest lump stays under 400 mm, or specify a grizzly section to drop soil and fines before the jaw.
Three decks, three products, one return belt
The 3YK1548 vibrating screen carries 4800×1500 mm of screening area on three decks, rated 30-275 t/h — three to four times this plant's output. That margin is deliberate. Screening is where under-sized circuits fail quietly: fines stay in the oversize return, lifting circulating load and power per ton. Set the decks to 5, 10 and 20 mm and you take off 0-5, 5-10 and 10-20 mm in one pass, with everything above 20 mm returning to the PF1010. To change products, re-mesh — not re-machine.
What the plant draws per ton of stone
Installed power on the four main machines is 122.5-142.5 kW — feeder 7.5, jaw 45, PF1010 55-75, screen 15 kW; belt conveyors and dust collection are additional. Against 60-80 tph that is a nominal 1.5-2.4 kWh/t for crushing and screening alone, a calculated ceiling rather than a metered figure: the closer the jaw runs to its 130 t/h limit, the lower the number falls.
Equipment configuration
| Equipment | Model | Key parameters | Qty | Power (kW) |
|---|---|---|---|---|
| Hopper | — | Buffer storage ahead of the feeder | 1 | — |
| Vibrating feeder | ZSW850×3000 | Trough 850×3000 mm; feed ≤400 mm; 80–120 t/h | 1 | 7.5 |
| Jaw crusher | PE500×750 | Feed opening 500×750 mm; max feed 425 mm; discharge 50–100 mm; 40–130 t/h | 1 | 45 |
| Impact crusher | PF1010 | Rotor Φ1000×1050 mm; feed opening 400×1080 mm; max feed edge ≤350 mm; 50–80 t/h | 1 | 55–75 |
| Vibrating screen | 3YK1548 | 4800×1500 mm; 3 decks; mesh 3–100 mm; feed ≤400 mm; 30–275 t/h | 1 | 15 |
| Belt conveyor | Matched to layout | Feed, discharge, screen return and product belts | Set | — |
Host-machine installed power: 122.5-142.5 kW (belt conveyors and dust collection excluded). Parameters are nominal ratings on limestone; hard or abrasive feed de-rates capacity and wear life.
limestone crushing plant
FAQ
Can a 60-100 tph limestone crushing plant with a PF1010 really reach 100 tph?
On limestone, assume 60-80 tph of finished 0-5, 5-10 and 10-20 mm. The ZSW850×3000 (80-120 t/h) and PE500×750 (40-130 t/h) have headroom, but the PF1010 secondary is rated 50-80 t/h and becomes the bottleneck. To hold 100 tph, upgrade the secondary to PF1210.
Will it crush granite, basalt, river stone and quartz?
Granite, basalt and quartz are abrasive, so PF1010 blow-bar consumption per ton rises sharply — for those feeds we switch the secondary to a CS75 cone. River stone is usually rounded, which helps throughput, but it is quartz-bearing and still abrasion-heavy over long runs: budget for shorter blow-bar cycles or plan the cone from the start.
The spec says feed size under 425 mm. Is that the whole limit?
No. The jaw accepts 425 mm, but the feeder is rated ≤400 mm, so 400 mm is the practical ceiling for steady feed. Keep the largest lump under 400 mm by blast design, or add a grizzly section to the feeder.
How do I produce 0-5, 5-10 and 10-20 mm at the same time — and can I change the fractions?
Yes. On this 60-100 tph stone crushing plant, the 3YK1548 vibrating screen's three decks are meshed at 5, 10 and 20 mm, giving three products in one pass; anything above 20 mm returns to the PF1010 on the closed circuit. Changing the product mix means re-meshing the decks, not replacing machines — 0-40 mm and other splits run on the same screen.
What does the circuit need besides the machines?
Power is built to your grid (380V/50Hz, 400V/50Hz or 440V/60Hz), plus belt conveyors, a control panel and dust collection at the impact crusher. Foundations follow our layout drawing, and the plant needs only a small crew for start/stop and routine maintenance.
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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