A compact, robust 200 TPH basalt crushing plant designed for road base. This article explains how the plant works. It lists key specs. It shows performance metrics, real project cases, and selection guidance. The tone is practical, and, technical. Readers will gain clear, usable answers.
The 200 TPH basalt crushing plant is a fixed aggregate system. It is sized to deliver two hundred tonnes per hour, under steady feed. The plant was designed for highway subbase and asphalt base production. The material is hard basalt, with Mohs hardness about 6-7, and high abrasiveness. Typical feed size is 0-300 mm. Operating climate in the Tanzania includes tropical humidity, high rain days, and occasional coastal salinity. Equipment list commonly includes: vibrating feeder, primary jaw crusher, secondary cone crusher, vibrating screens, conveyors, dust suppression, control cabin, and electrical panels. The plant layout aims for 120–200 m2 footprint.
The workflow is simple. First, the feeder meters blasted basalt into the jaw crusher. Next, primary reduction lowers size to the cone crusher feed range. Then, the cone crusher shapes the rock to graded sizes. Finally, screens separate fractions and conveyors stockpile the products. The key control is CSS/OSS (closed/open side setting) on the cone. CSS controls final product size, while OSS controls feed acceptance. Rotor speed, eccentric throw, and chamber type shape the crushing action. Power is supplied by an AC motor, sized to match the crusher torque curve. The system uses PLC control for start-stop and interlocks.
Design capacity: 200 tph. Feed size: 0–300 mm. Output gradation: 0–5 mm, 5–10 mm, 10–20 mm, 20–40 mm. Crushers: jaw as primary; short-head or medium cone as secondary. Typical cone CSS: 6–30 mm. Crushing ratio: jaw 6–8:1; cone 8–15:1. Cone speed: 400–650 rpm depending on model and chamber. Motor power match: jaw 55–132 kW; cone 110–250 kW. Drive type: direct coupling or V-belt, with gearbox for cone eccentricity. Electrical supply: 380–415 V, 50 Hz; or 440 V, 60 Hz for local grids. These values align with industry practice, and, with field tuning, deliver stable throughput.
Operational metrics recorded in field tests show typical indicators. Average energy use: 25–45 kWh per tonne of finished graded aggregate, depending on feed hardness and recirculation rate. Average downtime: 2–5% per month for planned maintenance. Mean time between failures for key rotating parts: 3,000–6,000 hours. Maintenance cycle for jaw liners: 1,200–2,000 hours. For cone mantles and concaves: 1,500–3,000 hours. These ranges are conservative. They help planners size spare parts and predict OEE. In practice, actual energy and wear track feed gradation, moisture, and operator settings.
When selecting a plant, compare crushing chamber types. Standard chamber suits secondary coarse crushing. Short-head chamber yields finer products. For road base, select a chamber that produces required interlock and fines. Choose motor power with 15–20% margin to handle peak loads. Prefer hydraulic CSS adjustment where uptime matters. Include a modular screen layout for split sizes. Add dust control to comply with local regs. Finally, size conveyors to avoid bottlenecks, and include surge bins to smooth feed.
The following list reflects a field-validated configuration. It supports continuous 8–10 hour shifts, with normal recirculation.
| Item | Model/Type | Spec |
|---|---|---|
| Vibrating feeder | GZD | 1.2×4.5m, 30–80 tph |
| Jaw crusher | C6X/SBM | Feed 0–300 mm, 110 kW |
| Cone crusher | HPC/SBM | 200 tph, 160 kW, CSS 6–30 mm |
| Vibrating screen | 3-deck | 2.4×7.3 m, 200 tph |
| Conveyors | 4 units | 400–800 mm belts |
Energy is predictable if the feed is consistent. For dense basalt, expect higher power draw. Control recirculating load to cut energy. Wear depends on abrasiveness and fines. Use manganese liners and chromium alloys in high-wear zones. Schedule lubrication every 250 hours for bearings. Implement belt inspections weekly. Plan shutdown for liner replacement every 1,000–2,000 hours. Keep a spare parts kit on site for key items. This lowers mean downtime, and improves throughput consistency.
Use PLC with interlocks for feed block, belt misalignment, and high temperature. Fit emergency stops at key access points. Maintain fall protection on screen decks. Train operators for liner changes and unblocking procedures. Document lockout-tagout. Monitor performance metrics weekly. Adjust CSS based on particle size analytics. These steps reduce incidents, and stabilize product gradation.
Basalt offers high strength and good angularity. It compacts well. It resists polishing under traffic. In tropical climates, basalt resists weathering. For subbase and base layers, basalt produces durable layers with high CBR. Contractors prefer angular, interlocking aggregates. Thus, this plant matches road building needs.
Project: Provincial highway upgrade in Luzon. Challenge: supply 200 tph of crushed aggregate near the job. Solution: a 200 TPH plant with jaw + cone circuit, mobile chassis, dust wetting, and large surge bin. Design note: feed was blasted basalt, 0–500 mm. We reduced feed to 0–300 mm at primary, then to 10–40 mm graded. Result: stable output, 95% availability, and reduced haul distance. Client feedback: fast installation, easy commissioning, and lower diesel use; maintenance intervals matched forecast. The client praised SBM-supplied wear parts technical support; they noted quick liner change and clear manuals.
Project: island bridge approach. Challenge: coastal salt, high humidity, and dust. Solution: stainless treated control panels, sealed bearings, and an enclosed conveyor transfer. Design aimed for 0–5 mm fines for asphalt emulsion base. Outcome: product met gradation specs for two months, then liners required scheduled change. The operator highlighted easy access for maintenance, and low fault frequency. The plant delivered consistent particle shape. Client comment: “installation fast, service reliable, and output matched plan”.
A: Expect 5–15% throughput drop in heavy rain. Wet material sticks and raises recirculation. Reduce feed rate, and add pre-screening. Use water sprays and anti-clogging liners. These actions restore stable output quickly.
A: Adjust cone chamber type and CSS. Use closed-circuit with return screens. Tune feed gradation and rotor speed. Install tertiary crushing if you need cubical shape. Monitor samples hourly, and adjust accordingly.
A: Jaw and cone liners, manganese wedges, wear plates, belts, and bearing kits. Also keep spare hydraulic hoses and PLC modules. Inventory reduces downtime and saves cost over time.
Step 1: Confirm feed size and hardness. Step 2: Choose jaw size to accept maximum feed. Step 3: Select cone chamber to hit gradation. Step 4: Size screen decks for target fractions. Step 5: Add dust control and scaling features. If feed is very coarse, prefer two-stage reduction. If fines are critical, add tertiary shaping. This process reduces rework.
Install on compacted pad with drainage. Anchor main frames. Connect utilities and test motor rotation. Commission with empty run then light feed. Train two operators for 3 days. Maintenance plan: weekly belt checks, monthly liner inspection, quarterly gearbox oil change, annual major overhaul. Provide clear checklists. This reduces surprises, and extends component life.
CapEx depends on customization and local supply. Operating cost drivers: fuel/electricity, wear parts, labor, and fines handling. Payback often falls within 1–3 years for continuous road projects. Optimize by reducing recirculation, by predictive maintenance, and by local spare sourcing.
For road-building with basalt, a 200 TPH plant is an efficient choice. Choose chamber, motor, and screen carefully. Plan spares and a maintenance routine. Test feed and tune CSS on site. Work with suppliers who offer spare parts and commissioning. XinHai and SBM components integrate well. This yields reliable output, predictable costs, and satisfied contractors.
1) “How fast can you commission a 200 TPH plant?” Answer: typically 7–21 days depending on site work. 2) “Can the plant run on limited grid power?” Answer: yes, with phased motors and soft starters; add diesel gen-set as backup. 3) “What warranty and support are provided?” Answer: standard OEM warranty, plus spare-kits and remote support options.
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