500t/h Stationary Crushing Plant Selection Guide

Site layout of 500tph fixed crushing station.jpg

In large-scale mining and aggregate production lines, 500t/h stationary crushing plantsare core equipment for handling high production demands. Choosing the right model directly impacts production efficiency, operating costs, and return on investment. This article systematically analyzes the key factors in selecting a 500t/h stationary crushing plant to help you make an informed decision.

1. Accurate Production Capacity Calculation

1.1 Verification of Theoretical Output

• Require suppliers to provide actual production data under similar material conditions

• Consider the impact of material hardness (Praeters hardness coefficient), moisture content, and mud content on production capacity

• It is recommended to reserve 10-15% of production capacity to cope with peak demand

1.2 Crushing Ratio Calculation

• Primary crushing (jaw crusher) recommended crushing ratio of 4-6

• Secondary crushing (cone crusher/impact crusher) crushing ratio of 3-5

• The overall crushing ratio must meet the requirements for feed size (e.g., 800mm) to finished product size (e.g., 0-31.5mm)

2. Equipment Configuration Selection

Comparison of Typical Configuration Options

Configuration Options	Applicable Materials	Energy Consumption (kWh/t)	Finished Product Shape	Maintenance Cost
Jaw Crusher + Cone Crusher	High Hardness Rock	1.8-2.2	Cubic	Medium
Jaw Crusher + Impact Crusher	Medium-Low Hardness	1.5-1.8	Multi-Angular	Gyratory Crusher + Cone Crusher
Gyratory Crusher + Cone Crusher	Extra-Large Mine	1.6-2.0	excellent	High

Key Equipment Selection Recommendations

• Primary crushing: Select a C-series jaw crusher (feed opening ≥ 800 x 1000mm)

• Secondary crushing: HP multi-cylinder hydraulic cone crusher (for highly abrasive materials) or CI-series impact crusher

• Screening Equipment: 3-4 decks of heavy-duty vibrating screens (screening efficiency ≥ 90%) are recommended.

3. Site Planning and Infrastructure Requirements

3.1 Key Site Layout

• Equipment Spacing: A 15-20 meter buffer zone is recommended between the jaw crusher and cone crusher.

• Stockpile Height: Buffer pile capacity before primary crushing ≥ 2 hours' output (approximately 1,000 tons).

• Conveyor Angle: Conveyor inclination ≤ 18° (≤ 15° for high-water content materials).

3.2 Infrastructure Standards

• Concrete Foundation Thickness: ≥ 2.5 meters for main equipment.

• Spring shock absorbers are required for vibrating equipment.

• Maintain a safe distance of at least 10 meters between the electrical room and the crushing area.

4. Energy Consumption and Operating Cost Analysis

4.1 Recommended Power Supply Configuration

• Total Installed Power: Approximately 800-1000 kW (including auxiliary equipment).

• Power Factor Compensation (cosφ ≥ 0.92) is recommended.

• Power consumption per ton of aggregate is controlled at 1.6-2.0 kWh.

4.2 Estimated Wear Parts Consumption

• Jaw plate life: Approximately 60,000-80,000 tons/set under granite conditions

• Cone crusher liner: 30,000-50,000 tons/set

Welding repair technology is recommended to extend service life by 30%

5. Intelligent and Environmentally Friendly Configurations

5.1 Intelligent Control System

• Required Functions: Automatic load adjustment, blockage warning, remote monitoring

• Recommended Configuration: Online particle size analyzer (can reduce over-crushing by 15%)

5.2 Environmental Compliance Plan

• Spray system: Water consumption 0.05-0.1 m³/ton of material

• Dust removal efficiency: ≥99% (pulse bag filter)

• Noise control: Overall ≤75 dB (using a soundproof enclosure + muffler)

6. Return on Investment Calculation

Economic Evaluation Parameters

• Equipment Investment: Approximately 8-12 million RMB (including auxiliary equipment)

Payback period: Approximately 2-3 years based on current aggregate prices.

• An LCC (Life Cycle Cost Analysis) analysis is recommended.

Selecting a 500-ton fixed crushing plant requires comprehensive consideration of multiple factors, including material characteristics, site conditions, investment budget, and environmental requirements.

For a customized selection plan or to schedule a site visit, please contact our technical team. We will provide a complete solution, including equipment configuration drawings, basic construction drawings, and an investment budget.