JXSC has successfully delivered a 100TPH stone crushing plant in Trinidad. We designed the processing plant flowchart and plant layout drawing in accordance with the river stone project conditions in 2023. We provided a complete set of crushing machines and all accessories and shipped all machines to the destination port in Trinidad. The plant was installed in 2024.
EPCS
Engineering, Procurement & Construction Services
Case Study: Rock Stone Crushing Plant Project
Project Overview
Minerals
River Rock Stone
Capacity
100 TPH
Feed Size
≤ 500 mm
Location
Trinidad
Year
2023
Project Process
Solutions & Process
We have successfully designed, manufactured, and delivered a complete 100TPH stone crushing solution to a quarry operator in Trinidad, specialized for processing hard rocks including river stone, granite, basalt, andesite, and gold-bearing quartz.
Raw Stone Conditions & Plant Specifications
| Parameter | Specification |
|---|---|
| Processing Capacity | 100 TPH |
| Max. Feeding Size | ≤500 mm |
| Material Hardness | 5-7 Mohs (granite/river stone) |
| Target Product Sizes | 0-25 mm |
| Special Features | Iron protection system, multi-layer screening |
Process Flowchart
Process Design Solution
The 100TPH crushing plant operates through a precision-engineered, four-stage closed-circuit system. Raw material is first fed via dump trucks into the grizzly feeder, where 100mm screen bars perform initial classification—bypassing sub-100mm stones while directing oversize material to the jaw crusher for primary reduction. The jaw-crushed output (80- 150 mm) is then conveyed to the cone crusher for secondary grinding, where adjustable settings transform the material into uniformly shaped aggregates.
Material exiting the cone crusher undergoes intelligent screening via the two-deck vibrating screen. The upper layer protects the system by filtering oversized particles (>30 mm) that automatically recycle to the cone crusher for reprocessing, while the lower deck precisely grades final products (adjustable from 25-30 mm). This closed-circuit design ensures 100% material utilization with minimal waste, and the entire system can be fine-tuned by simply replacing screen meshes or adjusting crusher discharge settings—allowing the same plant to produce everything from construction sand to road base aggregates without mechanical modifications.
Core Equipment Selection
- Primary Crushing: PE-600×900 Jaw Crusher (Feed opening: 600×900mm, Max input: 500 mm, 50- 160 TPH capacity)
- Secondary Crushing: DN1200 Symons Cone Crusher (Closed-side setting: 13- 38 mm adjustable, 72-270TPH capacity)
- Pre-screening: DN3890 Vibrating Grizzly Feeder (100mm grizzly bars for pre-classification, 15kW motor)
- Final Screening: 2YK1860 Vibrating Screen (2-layer screen mesh, 30kW power, 80-200TPH capacity)
Integrated Material Handling
- 4 Units Belt Conveyors (B650/B800 widths)
- Centralized electric control panel
- Suspended magnetic separator (1200GS intensity)
Technical Advantages & Performance Metrics
1. High-Efficiency Pre-Screening
- 100mm grizzly bars reduce jaw crusher load by 15-20%
- Extended crusher liner lifespan (+30% vs direct feeding)
2. Two-Stage Crushing Optimization
- Jaw crusher produces 80- 150 mm primary crushed stone
- Cone crusher achieves 95% <40 mm final product
3. Intelligent Recycle System
- Upper screen mesh (40mm) protects lower mesh (20mm)
- Closed-circuit design ensures 100% material utilization
4. Iron Protection Guarantee
- Magnetic separator prevents 98% tramp metal damage
- Reduced unplanned downtime (+3000h/year operational time)
Customer Questions & Our Answers
Q1. What’s the purpose of the 100mm grizzly bars on the vibrating feeder?
A: The 100mm spacing achieves pre-classification by:
- Allowing sub-100mm material to bypass primary crushing
- Reducing jaw crusher workload by 15-20%
- Preventing crusher cavity overload that causes premature wear
Q2. Why install an iron remover before the cone crusher?
A: This critical safeguard:
- Intercepts tramp metal with 98% efficiency (1200GS magnetic field)
- Prevents costly cone mantle damage ($8,000+ per incident)
- Eliminates 90% of unplanned downtime from metal jams
Q3. Two-layer screen despite single product requirement – why?
A: Dual-layer screening delivers:
- Upper deck (30mm): Shields lower deck from impact (+300% mesh lifespan)
- Lower deck (25mm): Maintains precise sizing during throughput fluctuations
Bonus: Allows future multi-grade production without modification
Q4. Jaw crusher as primary – what operational advantages?
- Megabyte Crushing: Handles 500mm boulders that choke other crushers
- Brute Strength: 250MPa compression capability for hardest granites
- Economic Wear: $0.12/ton liner cost vs $0.35/ton for alternatives
- Reliability: <3% downtime in 10,000 operating hours
Q5. Cone crusher for secondary stage – the engineering logic?
A: This configuration achieves:
- Shape Control: 85% cubical particles vs 60% from impact crushers
- Throughput Stability: Maintains 100TPH even when feed hardness varies
- Precision Sizing: Adjustable CSS (13- 38 mm) for exact product specs
- Wear Optimization: Inter-particle crushing reduces liner wear by 40%
Pro Tip: Our DN1200 cone crusher includes hydraulic clearing – no manual digging during blockages.
Equipment In This Project
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We are a leading provider of innovative and efficient mining equipment and solutions. With years of experience in the industry, we specialize in designing and manufacturing high-quality machines tailored for various mineral processing needs, including gold, diamond, copper, tin, manganese, chrome, titanium, and other ore separations. Our commitment to technology and customer satisfaction drives us to deliver customized solutions that enhance productivity and ensure environmentally sustainable practices. Explore our extensive portfolio of successful case studies and discover how JXSC can transform your mining operations, helping you maximize your profitability while minimizing your ecological footprint. Choose Us—where technology meets efficiency in the world of mining!
