What Is The Best Equipment Configuration For A 200tph Mobile Granite Crushing Production Line For Highway Base Stone?

Configuration Scheme for a 200tph Mobile Granite Crushing Production Line

I. Project Overview

Granite, as a high-quality building stone, is the preferred material for highway foundation stones due to its high hardness (compressive strength ≥120MPa), high compressive strength, and excellent wear resistance. The configuration of a 200-ton-per-hour mobile granite crushing production line requires comprehensive consideration of multiple factors, including material characteristics, capacity requirements, finished product specifications, and investment budget. A scientifically sound process flow must be adopted to ensure efficient and stable operation of the production line, producing high-quality aggregates that meet highway construction standards.

Mobile crushing plants, with their advantages of flexible relocation, rapid deployment, and no need for civil engineering foundations, are particularly suitable for mobile operation scenarios such as highway construction, mining, and construction waste treatment. The integrated unit design combines feeding, crushing, screening, and conveying, allowing for rapid production deployment and significantly reducing overall investment costs.

II. Core Equipment Configuration Scheme

2.1 Coarse Crushing Stage: Mobile Jaw Crusher

Recommended Model: YDPZ106-1142 Mobile Jaw Crusher

• Feed Size: ≤750mm

• Discharge Size: ≤150mm

• Power: 110kW

• Processing Capacity: 200-300t/h

The mobile jaw crusher features a deep cavity design, resulting in a large crushing ratio, suitable for high-hardness granite. It is equipped with a ZSW420×110 vibrating feeder to ensure uniform feeding. The hydraulically adjustable discharge port can quickly accommodate different particle size requirements. The moving/fixed jaw liners are made of high-manganese steel (Mn13+) with a heat treatment process, achieving a hardness ≥55HRC and extending service life by 20% compared to ordinary liners.

2.2 Medium and Fine Crushing Stage: Mobile Cone Crusher

Recommended Model: YDPZ300-2460 Mobile Cone Crusher

• Feed Size: ≤150mm

• Discharge Size: ≤30mm (Adjustable)

• Power: 250kW

• Processing Capacity: 270-535t/h

The cone crusher adopts the principle of layered crushing, producing uniform finished particles with a needle-like and flaky content ≤15%. Equipped with automatic iron overload protection and a hydraulic clearing system, it prevents damage to core components from hard objects, shortening maintenance time. Wear-resistant parts use high-chromium alloy milling chambers with a service life of 1500-2000 hours.

2.3 Screening System Configuration

Recommended Model: 4YK2160 Mobile Vibrating Screen

• Screening Specifications: 0-5mm, 5-10mm, 10-20mm, 20-30mm

• Power: 22kW

• Screening Efficiency: ≥90%

The screening equipment uses a heavy-duty circular vibrating screen. The screen material is polyurethane-edged manganese steel screen, which is wear-resistant and anti-clogging, with a lifespan twice that of ordinary steel screens. It is equipped with a belt conveyor system to achieve closed-loop production.

Configuration Scheme for a 200tph Mobile Granite Crushing Production Line

III. Process Flow Design

3.1 Three-Stage Crushing Process

The granite mobile crushing production line adopts a two-stage crushing process of "jaw crusher + cone crusher". The specific process is as follows:

1. Coarse Crushing: Large granite raw materials (≤750mm) are evenly fed into the mobile jaw crusher by a vibrating feeder for primary crushing. The output particle size is controlled below 150mm.

2. Medium and Fine Crushing: The coarsely crushed material is conveyed by a belt conveyor to a mobile cone crusher for secondary crushing, with the output particle size controlled within 30mm.

3. Screening and Grading: The crushed material is screened by a 4YK2160 vibrating screen into four sizes: 0-5mm, 5-10mm, 10-20mm, and 20-30mm.

4. Return Material Circulation: Material larger than 30mm is returned to the cone crusher via a return conveyor belt for secondary crushing, forming a closed-loop circulation system to ensure maximum raw material utilization.

3.2 Technological Advantages

• High Crushing Efficiency: Utilizing the principle of layered crushing, the content of needle-like and flaky particles is ≤15%, resulting in uniform particle shape.

• Low Energy Consumption: The two-stage crushing process saves 20-30% more energy than traditional processes.

• Low Wear Part Wear: Employing highly wear-resistant materials reduces wear part consumption by 60-70%.

• High Automation: Equipped with a PLC control system for remote monitoring and operation.

• Flexible Relocation: Tracked vehicle allows for flexible movement within ordinary roads and work areas, facilitating easy relocation.

IV. Highway Foundation Stone Quality Standards

4.1 Aggregate Technical Indicators

Highway construction imposes strict quality requirements on sand and gravel aggregates. The main technical indicators are as follows:

4.2 Grading Requirements

The crushed stone used for highway base courses should be processed using impact crushing technology, and the gradation must meet the following requirements:

• Coarse aggregate specifications: Use single-size aggregate with a nominal maximum particle size of 31.5mm

• Continuous gradation: The proportion of 5-10mm, 10-20mm, and 20-31.5mm particles must meet the design mix ratio

• Content of particles smaller than 0.075mm: ≤5%-7% (water-stabilized base course mixture)

V. Core Advantages of Mobile Crushing Plants

5.1 Flexibility and Mobility

Mobile crushing plants utilize tracked or wheeled chassis, allowing for flexible movement on ordinary roads and within work areas, facilitating convenient and efficient relocation. The integrated unit design eliminates the need for complex infrastructure and factory buildings, enabling rapid production upon arrival at the site, significantly reducing initial civil engineering costs and time. Its mobility further allows the equipment to "follow the material source," completely eliminating the cost of long-distance material transportation.

5.2 Low Overall Investment Cost

Compared to fixed production lines, mobile crushing plants eliminate the need for factory buildings and civil engineering foundations, saving approximately 1.5-3 million RMB in infrastructure costs. For example, a 200-ton-per-hour granite production line requires approximately 1.7 million RMB for a fixed line, while a mobile line requires approximately 1.87 million RMB. Although the equipment purchase cost is slightly higher, the overall investment cost (including infrastructure) is lower.

5.3 High Production Efficiency

Integrating feeding, crushing, screening, and conveying into a compact closed-loop production system, the operation process is smooth and efficient. The produced aggregate has uniform particle size and good shape, requiring no secondary processing and fully meeting the standards for high-grade construction sand and gravel, directly improving project profitability. The annual operating rate can reach 91.5%, far exceeding the 68-75% of fixed production lines.

5.4 Environmental Protection and Energy Saving

Equipped with a pulse dust collector (99.9% dust removal efficiency) and a negative pressure conveying system, dust emissions can be controlled below 10mg/m³. Utilizing a hydraulic drive and intelligent control system, energy consumption is reduced by 25%, with an energy cost of approximately 2.8 yuan/ton, a 22-33% reduction compared to traditional equipment.

VI. Investment Cost Analysis

6.1 Equipment Investment Budget

The investment budget for a 200-ton-per-hour mobile granite crushing production line varies depending on the equipment brand, quality, and configuration, with market prices ranging from 1.8 million to 2.2 million yuan.

Investment Breakdown:

• Main Equipment (Mobile Jaw Crusher, Mobile Cone Crusher): Approximately 1.2-1.5 million RMB

• Auxiliary Equipment (Vibrating Screen, Conveying System): Approximately 300,000-500,000 RMB

• Environmental Protection Equipment (Dust Collector): Approximately 100,000-200,000 RMB

• Installation and Commissioning Costs: Approximately 200,000-300,000 RMB

Choosing well-known, high-quality brand equipment with complete configurations may result in a higher investment; choosing cost-effective, ordinary brand equipment will require a relatively lower investment.

6.2 Operating Cost Analysis

Compared to stationary production lines, mobile crushing plants can reduce production costs per ton by approximately 20-30%, reduce main equipment investment by 15.4%, and eliminate the need for 3 conveyor belts and 5 main equipment units, including 1 cone crusher, 3 sand making machines, and 1 vibrating screen.

6.3 Investment Recovery Period

The investment recovery period for a 200-ton-per-hour mobile granite crushing production line is typically 1-2 years. Based on a finished sand and gravel aggregate market price of 80-120 RMB/ton, the annual output value can reach 4-6 million RMB. After deducting operating costs such as electricity, labor, and spare parts (approximately RMB 4.44/ton), the annual profit can reach RMB 2-3 million. If a short-process sand production combination is adopted, the investment payback period can be shortened to less than one year.

VII. Successful Case Sharing

7.1 Sichuan Xichang Hefeng Mining Granite Crushing Project

Project Overview:

• Project Address: Xichang, Sichuan

• Owner: Hefeng Mining

• Designed Output: 200 tons per hour

• Crushed Material: Granite

• Equipment Configuration: ZGC1250 feeder, KPC1313 hard rock crusher, 3YKQ2470 vibrating screen, etc.

• Commissioning Time: June 2016

Project Advantages:

• The hard rock crusher rotor can rotate in both directions, eliminating the need for manual hammer rotation.

• Hydraulic cylinders control the adjustment of the gap between the hammer and the main liner plate, eliminating the need for machine downtime.

• Low production line failure rate; intelligent control system ensures safety and efficiency.

• Reasonable equipment layout facilitates inspection and maintenance.

7.2 Malaysia 250 Tons per Hour Mobile Sand and Gravel Production Line

Project Overview:

• Project Address: Sabah, Malaysia

• Designed Output: 250 tons per hour

• Crushed Material: Granite

• Equipment Configuration: NK Mobile Crushing Station

• Commissioning Time: 2024

Project Achievements:

• Stable aggregate output of 250 tons/hour during the rainy season

• Actual dust emission measured at only 9.8 mg/m³, lower than the environmental standard of 10 mg/m³

• Cumulative supply of 500,000 cubic meters of green recycled aggregate, replacing 120,000 tons of mined stone

• Modular design saved 1.2 million RMB in infrastructure construction costs

7.3 Mexico Iron Ore Mobile Crushing Project

Project Overview:

• Project Location: Mexico

• Design Output: 200 tons/hour

• Crushed Material: Iron Ore

• Equipment Configuration: 16 mobile crushing stations

• Commissioning Time: 2025

Project Features:

• Covers 8 mining areas, with a dispersed layout and large span

• Mobile crushing stations flexibly move between mining areas, completing ore crushing directly on-site

• Daily operating time reaches 18 hours, continuously processing magnetite raw materials

• The final output is finished ore with a size of 0-10mm, fully meeting the requirements of subsequent production and processing.

VIII. Equipment Selection Recommendations

8.1 Key Points for Core Equipment Selection

Mobile Jaw Crusher:

• Heavy-duty jaw crushers (such as PEW series, CJ series) are preferred.

• The moving/fixed jaw liners are made of high-manganese steel Mn13+ heat-treated, with a hardness ≥55HRC.

• The bearing housing adopts an integral cast steel structure, with 30% higher impact resistance than welded parts.

Mobile Cone Crusher:

• Fully hydraulic cone crushers (HPT series) are recommended for hard rock crushing.

• Crushing force can reach 2500-4000kN, specifically for hard rock.

• Equipped with high-chromium alloy mantle walls, with a service life of 1500-2000 hours.

• Supports remote adjustment of the discharge opening, with a high degree of automation.

8.2 Auxiliary Equipment Configuration

• Feeding System: Heavy-duty plate feeder for raw material feeding, impact resistant, suitable for materials with a block size ≥500mm, equipped with a magnetic separator to remove metal impurities.

• Screening Equipment: Heavy-duty circular vibrating screen (e.g., 3YK2460 model) is selected, with polyurethane-edged manganese steel screen mesh, wear-resistant and anti-clogging.

• Conveying Equipment: Conveyor belt is selected with cut-resistant steel wire rope core (thickness ≥16mm), inclination angle ≤16°, and buffer idlers are installed at transfer points.

IX. Frequently Asked Questions (FAQ)

Q1: How much space is needed for a 200-ton-per-hour mobile granite crushing production line?

A: A 200-ton-per-hour mobile granite crushing production line requires approximately 2000-3000 square meters of land, depending on the equipment layout. A stepped layout is recommended, utilizing the height difference to reduce the use of elevators, which can reduce power consumption by 10-15%. The distance between mobile crushing stations should be ≥8 meters to facilitate forklift replacement of liners; a 2-meter clearance should be reserved under the screening machine for easy cleaning of screen debris.

Q2: What is the payback period for a mobile granite crushing production line?

A: The payback period for a 200-ton-per-hour mobile granite crushing production line is typically 1-2 years. Based on a market price of 80-120 yuan/ton for finished sand and gravel aggregate, the annual output value can reach 4-6 million yuan. After deducting operating costs such as electricity, labor, and spare parts (approximately 4.44 yuan/ton), the annual profit can reach 2-3 million yuan. If a short-process sand making combination is adopted, the payback period can be shortened to less than 1 year.

Q3: How to control dust pollution in a mobile granite crushing production line?

A: The following measures should be taken to control dust pollution:

1. Equipment Sealing: Crusheres, screening machines, and other equipment should be fully sealed and equipped with pulse jet bag filters (handling air volume of 12000 m³/h).

2. Spray Dust Suppression: Spray devices should be installed in crushing, screening, and conveying processes.

3. Washing Process: A wheel-type sand washer should be installed to effectively remove mud and stone powder, controlling the mud content to ≤3%.

4. Site Hardening: The production site should be hardened and equipped with water trucks for regular dust suppression.

5. Enclosed Plant: It is recommended to construct an enclosed plant, placing the main equipment indoors for production.

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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