Stationary Crushing and Screening Line (Output: 100–150 T/H)
With the arrival of the Year of the Horse (Bingwu), the mining and infrastructure sectors are ushering in a new wave of development opportunities. Stable, efficient, and eco-friendly aggregate production has become the key to project success. For mining projects aiming for large-scale, continuous-flow production, a well-engineered, electrically powered stationary crushing and screening line represents the embodiment of core competitiveness. This article provides an in-depth analysis of a classic configuration with a nominal output of 100–150 tons per hour, offering an authoritative reference for your equipment selection and project planning.
Core Configuration Overview: A Classic Combination for Stable Output
The production line solution discussed here is designed to provide users with a stationary system characterized by high stability, ease of maintenance, and optimized power costs. Its core design philosophy employs the classic three-stage crushing process—featuring jaw crushing for primary reduction followed by cone crushing for secondary and tertiary reduction—to ensure superior product shape and adaptability to processing rocks of medium-to-high hardness.
PE Jaw Crusher
Symons Cone Crusher
The list of core equipment for this production line is as follows:
| Equipment Name | Model/Specification | Primary Function | System Accessories |
| Vibrating Feeder | Customized to match output | Uniform, continuous feeding; protects the jaw crusher | Heavy-duty grizzly bars; pre-screening capability |
| Jaw Crusher | 1100 x 750 | Primary coarse crushing; high impact resistance | Heavy-duty frame; large flywheel design |
| Cone Crusher | 4–5 ft Standard Symons Type | Secondary/tertiary crushing; produces superior product shape | Complete hydraulic and lubrication systems |
| Triple-Deck Vibrating Screen | 6.0m x 2.5m | Material classification; separates multiple finished products | Complete support structure, chutes, and chassis |
Solution Highlight: The entire production line is electrically driven. Compared to diesel-powered systems, it offers significant advantages in energy consumption costs, as well as lower noise levels and emissions, making it fully aligned with the growing trend toward Green Mining.
Analysis of Configuration Advantages
Why has this specific configuration become a popular choice in the 150-ton-per-hour market segment? Its advantages are manifested in the following aspects:
Exceptional Foundation of Reliability
• Both the jaw crusher and the Symons cone crusher are classic models that have been proven over decades of operation in mines worldwide. Featuring robust structures, mature designs, and low failure rates, they guarantee maximum uptime for the production line.
• Fixed installation ensures a more stable foundation, resulting in minimal equipment vibration and more uniform wear. Consequently, the service life of the equipment is significantly longer than that of mobile crushing units.
Outstanding Quality Control of Finished Products
• The Symons cone crusher is renowned for its principle of laminated crushing, which produces high-quality aggregates characterized by excellent particle shape and low content of needle-like and flaky particles. This makes it particularly suitable for applications—such as commercial concrete batching plants—where strict requirements regarding aggregate shape are in place.
• A 6x2.5-meter triple-deck vibrating screen provides ample screening area and high screening efficiency. It allows for the precise separation of finished products into various specifications—such as 0–5mm, 5–10mm, and 10–20mm (or 31.5mm)—thereby enhancing the added value of the final product.
Intelligence and Ease of Maintenance
• A comprehensive hydraulic system makes the adjustment of the cone crusher's discharge opening, tramp iron release, and chamber clearing operations both safe and convenient, significantly reducing maintenance risks and labor intensity.
• An independent, self-contained lubrication system ensures that critical components—such as bearings and gears—operate under optimal conditions, serving as a vital life support system for the equipment during prolonged periods of high-speed operation.
Virtual Case Study: A Granite Quarry Project
Project Background: A large-scale granite mine located in East China was previously utilizing an outdated production line characterized by low output, poor product quality, and high energy consumption. A technical upgrade and renovation project was undertaken at the end of 2025 (the Year of the Snake).
Implemented Solution: A configuration closely mirroring the standard setup described above was adopted; however, the cone crusher was upgraded to a multi-cylinder hydraulic cone crusher equipped with a more advanced control system to achieve a finer crushing effect.
Operational Results: Since commencing operations shortly after the Spring Festival in the Year of the Horse, the production line has maintained a stable hourly output of approximately 140 tons. The cubic content of the finished aggregates now exceeds 90%, electricity consumption costs have been reduced by approximately 18% compared to the old production line, and the overall equipment utilization rate has risen to 92%. The superior quality of the finished products produced by this system has secured it a significant price advantage in the building materials market since the beginning of the year.
Recommended Equipment Alternatives
Depending on the specific characteristics of your raw materials and your investment budget, you may also wish to consider the following alternative configurations:
1. High-Hardness Rock Solution: Replace the standard Symons cone crusher with a Short Head type to achieve a finer discharge size; this configuration is ideal for sand making or crushing ultra-hard rock materials.
2. High-Automation Solution: Integrate a centralized electrical control system, an online particle shape analyzer, and automatic adjustment modules into the entire production line to enable intelligent manufacturing and further reduce labor costs.
3. Compact Layout Solution: For clients with limited site space, a multi-tier platform layout can be designed to optimize the routing of chutes and conveyor belts, thereby minimizing the overall footprint of the facility.
Frequently Asked Questions (FAQ)
Q1: Does this electric-powered production line place high demands on the power grid? What is the approximate total power consumption?
A: The total installed power capacity for this specific configuration is estimated to be between 450 kW and 550 kW. We recommend installing a dedicated transformer and connecting to a stable high-voltage power grid. During startup, soft start or star-delta starting methods should be employed to minimize the impact on the power grid. The specific power supply solution must be professionally designed based on the actual grid conditions at your site.
Q2: Is the maintenance of the Symons cone crusher's hydraulic lubrication system complex?
A: Although this system represents the core technology of the machine, its maintenance is not complex. The key lies in consistency and regularity. Daily checks should be performed on oil levels, temperature, and pressure, while periodic laboratory analysis of the oil's cleanliness is also required. For the hydraulic system, the primary focus is on seal integrity; for the lubrication system, filter elements and lubricating oil must be replaced on schedule. The equipment manufacturer typically provides a detailed maintenance schedule and offers relevant training.
Q3: The current configuration features a three-deck vibrating screen. If I only require two specific finished product sizes, can I switch to a two-deck screen instead?
A: Absolutely. A 6x2.5-meter two-deck screen would be a more economical choice. However, retaining the three-deck screen offers greater production flexibility. For instance, you could utilize one of the decks for pre-screening—removing naturally occurring fines early in the process to reduce the load on the crusher—or reserve a specific product size slot to accommodate potential shifts in future market demand. Your final selection should be determined based on both your current and future product planning requirements.
