100 TPH stone crusher plant
A production capacity of 100 tons per hour represents a standard configuration for small-to-medium-scale stone production lines. Outlined below are two common configuration schemes, which can be selected based on the hardness of the raw materials, the desired finished product size, and the available budget.
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Scheme 1: Classic Two-Stage Crushing—Jaw Crusher + Impact Crusher/Cone Crusher (Most Widely Used)
This scheme offers high adaptability and produces finished products with excellent particle shape, making it the most mainstream choice in the market.
1. Primary Coarse Crushing – Jaw Crusher
◦ Recommended Model: PE-600×900
◦ Function: Performs the initial crushing of large excavated stones (up to 500mm in size), reducing them into smaller stones under 150mm. With its simple structure and reliable operation, the jaw crusher is the ideal equipment for coarse crushing.
2. Secondary Medium & Fine Crushing – Impact Crusher OR Cone Crusher
◦ Recommended Impact Crusher (Suitable for medium-to-low hardness stones, such as limestone and bluestone):
▪ Models: PF-1214 or PF-1315
▪ Advantages: Produces finished products with a cubic particle shape and high quality, making it ideal for the production of construction aggregates. Both equipment investment and operating costs are relatively low.
◦ Recommended Cone Crusher (Suitable for high-hardness, highly abrasive stones, such as granite and basalt):
▪ Models: Single-cylinder cone crusher (e.g., SC160S) or multi-cylinder cone crusher
▪ Advantages: Features a long service life for wear parts, stable operation, and high production efficiency. However, the content of needle-like and flaky particles in the finished product may be slightly higher than that produced by an impact crusher, and both investment and maintenance costs are higher.
3. Screening Equipment – Vibrating Screen
◦ Recommendation: A circular vibrating screen with 2–3 decks and a screening area of approximately 10–15 m² (e.g., Model 3YK1860).
◦ Function: Separates the crushed mixture into different specifications (e.g., 0–5mm, 5–10mm, 10–20mm, 20–31.5mm). Oversized particles that do not meet the specifications are returned to the crusher for further processing (forming a closed-circuit loop), thereby ensuring the required finished product size.
jaw and impact crusher setup for 100 TPH
Option 2: Mobile Crushing Station (The Flexible Choice)
If the raw material site is not fixed or requires frequent relocation, a mobile crushing station is the ideal choice.
• Configuration: Options include a combination of "Mobile Jaw Crusher + Mobile Impact/Cone Crusher + Mobile Screen," or a single multi-functional mobile unit that integrates feeding, crushing, and screening functions.
• Advantages: Highly flexible for site transfers; requires no permanent foundation; allows for rapid commissioning immediately upon arrival at the site; particularly suitable for processing demolition waste and short-term engineering projects.
• Note: The capital investment for a single mobile unit is higher than that of a fixed production line; however, it results in significant savings on installation and transportation costs.
Typical Production Process Flow
Raw Material Bin -> Vibrating Feeder (Uniform Feeding) -> Jaw Crusher (Primary Crushing) -> Belt Conveyor -> Impact/Cone Crusher (Secondary/Tertiary Crushing) -> Belt Conveyor -> Vibrating Screen (Screening) -> Finished Product Stockpile.
• Closed-Circuit Loop: Oversized particles retained on the vibrating screen are returned to the secondary crusher via a return conveyor belt for re-crushing, creating a closed loop that ensures all finished products meet the required specifications.
Key Application Scenarios
• Construction Aggregate Production: Supplying commercial concrete plants, asphalt mixing plants, and precast component factories with crushed stone and manufactured sand of various specifications.
• Highway and Railway Construction: Producing various grades of crushed stone required for roadbed base layers.
• Mining Operations: Serving as the primary crushing stage in mineral processing workflows.
• Urban Construction Waste Recycling: Crushing concrete, bricks, tiles, and similar materials for conversion into recycled construction materials.
Key Factors for Investment and Operation
1. Raw Material Characteristics: Hardness, abrasiveness, and moisture content are critical factors in determining whether to select an impact crusher or a cone crusher. The size of the raw material directly influences the selection of the primary (coarse) crusher.
2. Finished Product Requirements: The required specifications for the finished products (e.g., specific stone sizes? Is manufactured sand required?) and the desired particle shape determine the overall process flow and the type of secondary crushing equipment needed.
3. Power Supply: The total power demand for the entire production line typically ranges from 250 to 350 kW; therefore, ensuring access to a stable and reliable power supply is essential.
4. Site and Environmental Considerations: Sufficient site space must be allocated to accommodate the equipment layout, material stockpiles, and access routes. Dust (requiring the installation of pulse bag dust collectors) and noise control measures must be taken into account to ensure compliance with environmental regulations.
5. Investment Budget: For a stationary production line with a capacity of 100 tons per hour, the equipment investment (excluding civil works, installation, and auxiliary facilities) typically falls within the range of RMB 800,000 to RMB 1.5 million; the exact figure varies depending on the equipment brand, configuration, and level of automation. The price for a single mobile crushing station unit can range anywhere from several hundred thousand to over a million RMB.
Summary and Recommendations:
For a stone crushing plant with a capacity of 100 tons per hour, the stationary production line configuration consisting of a "PE600×900 Jaw Crusher + PF1214/PF1315 Impact Crusher (or an equivalent-class Cone Crusher) + 3YK1860 Vibrating Screen" represents a "golden combination" that has been extensively validated through practical application. Prior to procurement, it is imperative to provide material samples and specific requirements for the finished products to the equipment supplier; this allows for the conducting of crushing tests and the customization of a tailored solution—a step that is absolutely critical to the success of the project.
About of 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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