An 80-100 ton per hour stone crushing plant is a facility capable of processing 80 to 100 tons of natural stones (limestone, granite, basalt, gravel, etc.) per hour. These plants are designed for the production of aggregates (crushed stone, gravel, sand) used in the construction sector. They are commonly used in medium-scale projects and can be set up as both stationary and mobile plants.

How Does it Work?

  1. Feeding Unit:

    • Natural stones or large rock pieces are loaded into the feeding hopper.

    • Material from the feeding hopper is transferred to the crusher using a vibrating feeder or scraper to ensure a smooth flow.

  2. Crushing Process:

    • Primary Crusher: Material is first sent to the primary crusher (usually a jaw crusher or impact crusher). At this stage, large stones are broken into smaller pieces (approximately 100-150 mm).

    • Secondary Crusher: Material from the primary crusher is sent to the secondary crusher (cone crusher or impact crusher). Here, the material is reduced to smaller sizes (25-60 mm).

    • Tertiary Crusher (Optional): If fine material production is required, a tertiary crusher is used. At this stage, the material is crushed to a range of 5-25 mm.

  3. Screening Process:

    • Crushed material is passed through vibrating screens to separate it into different sizes.

    • Screens classify the material into desired sizes (e.g., 0-5 mm, 5-12 mm, 12-25 mm).

    • Material that does not meet the desired size is sent back for further crushing.

  4. Storage and Shipment:

    • Sized material is stored in stockpiles.

    • Material is shipped to construction sites or sales points using conveyor belts or trucks.

Working Principle:

  • Crushers: Break stones into smaller pieces. Primary, secondary, and tertiary crushers are used.

  • Screening Machines: Separate materials by size. Vibrating screens are the most commonly used equipment.

  • Conveyor Belts: Transport materials within the plant.

  • Control Systems: Ensure automatic operation and increase efficiency.

Advantages:

  • High efficiency and low operating costs.

  • Flexibility to produce aggregates of different sizes.

  • Mobile plants can be easily set up in different locations.