This practical, technical guide explains an 80–120 tonnes-per-hour crusher solution for mid-size construction. It covers principles, key specs, verified operating data, two real projects, installation and upkeep guidance, plus clear selection advice to help engineers and managers decide with confidence.
An 80–120 TPH crusher line, here, means a stationary or mobile aggregate system that reliably delivers eighty to one-hundred and twenty tonnes per hour. It typically functions as a secondary plus tertiary stage, or as a compact primary-to-finish train for road and concrete work. Moreover, it fits mid-size sites that need steady daily output, yet limited footprint. ,
Crushing uses compression and shear to reduce rock size. A typical flow uses; a feeder, primary jaw breaker, a secondary cone (or impact) breaker, and screens. Feed passes the primary, then the secondary cavity reduces to spec by closed-side setting (CSS). The CSS, stroke and eccentric speed set the reduction ratio, and thus determine product curve and capacity. Metso design principles and industry practice stress correct feed distribution, and staged reduction to reduce recirculating load.
Understanding parameters prevents overspec and underperformance. Below are essentials, with typical ranges for 80–120 TPH lines.
• Throughput (capacity): 80–120 t/h, depends on material hardness, moisture and feed sizing. • Feed size: primary feed commonly 300–500 mm for compact plants; secondary feed 50–150 mm. • Product size: end gradients usually 0–5mm, 5–10mm, 10–20mm for aggregates. • Reduction ratio: primary ~6–10, secondary ~2–4. • CSS / OSS: closed-side setting normally 6–35 mm on secondary cones depending on cavity. • Speed & throw: higher eccentric speed raises capacity but increases wear. • Motor power: matched to capacity and rock type; typical cone drives for 80–120 t/h run between 75–220 kW.
For example; an optimized cone cavity with CSS 22–30 mm frequently yields 80–110 t/h in hard stone.
Below table shows verified ranges used in practice.
| Parameter | Range | Unit |
|---|---|---|
| Capacity | 80–120 | t/h |
| Max feed | 300–500 | mm |
| Product sizes | 0–5, 5–10, 10–20 | mm |
| CSS (secondary) | 6–35 | mm |
| Motor power (typ) | 75–220 | kW |
| Energy (typ) | 2–4 | kWh/t |
Drive selection must match torque, speed and duty cycle. Use V-belt or direct coupling depending on site. Generally, match motor rating to worst-case burden, then derate for site altitude and temperature. Fast eccentric speed raises throughput, however, it increases wear and power draw; therefore balance speed and throw. Studies show cone plants often consume 2–4 kWh per tonne; optimizing speed and feed curve can save ~15–20% energy.
Field metrics must guide selection. Typical real-world figures from validated plants are: availability 88–95%, downtime 200–400 hours/year depending on maintenance practice; average energy 2.0–4.0 kWh/t; mean time between wear replacement 2,000–6,000 operating hours (wear dependent). Track these three metrics: energy per tonne, downtime %, and wear part consumption. These numbers align with plant reports and published energy studies.
Case 1 — Coastal granite; 100–120 TPH, Tanzania: The plant processed granite (max feed 500 mm). Scheme: PE600×900 jaw primary, secondary cone, screens; final splits 0–5, 5–10,10–20 mm. The design concentrated on choke feeding the cone and robust fines handling; result: steady 100–120 t/h, stable gradation, low recirculation. Operators reported easy set changes and reliable daily output.
Case 2 — Regional portable granite line; 80–100 TPH: A modular portable train combined C6X jaw, HST single-cylinder cone, feeder and screens. It served concrete and rural road projects. The owner praised rapid installation, consistent production and straightforward maintenance. Production data reported matched design estimates within ±7% during first year.
Follow this decision tree. 1) Define required daily tonnage and product spec. 2) Analyze feed: max size, hardness (Mohs), moisture. 3) Choose primary: jaw for large feed >300 mm, gyratory for very high capacity. 4) Choose secondary: cone for cubical aggregates and tight gradation; impact where softer or for shaping. 5) Size motor to worst case. 6) Design screening and recirculation to minimize fines and avoid choke or dilute feeding. Finally, validate energy and maintenance budgets. Use short trials when possible.
Install on stable foundation. Then, align drives and set protective guards. Commission with stepwise loading: first run empty, then light feed, and finally design feed. Train operators on CSS adjustments and tramp relief procedures. Moreover, set lubrication schedules before full load; failing to do so often causes premature failures.
Routine checks: lubrication, liner thickness, drive belts and hydraulic systems. Replace liners at recommended wear limits; monitor power draw for spikes that indicate choking or bearing issues. Expected maintenance cycle: daily visual checks; weekly lubrication; monthly detailed inspection; major servicing at 2,000–6,000 hours depending on use. Common faults are liner wear, unbalanced feed and hydraulic leaks. Proper spare parts planning cuts downtime significantly.
Estimate capital vs operating tradeoffs. Higher-efficiency drives cost more up front, yet lower kWh/t reduces operating cost. Additionally, better screening lowers recirculation, thus reduces wear and saves fuel. Use site-specific kWh price and projected annual throughput to compute simple payback. Do not oversize; overspec adds cost without proportional benefit.
Answer: Control feed size and distribution; maintain correct CSS; size the feeder and hopper to avoid plugging. Also, keep a conservative stroke and speed setting during early commissioning, then tune. Use regular screen maintenance to prevent blinding. These steps stabilize throughput quickly.
Answer: Plan for about 2–4 kWh per tonne for cone-based secondary crushing under normal conditions. However, track initial kWh/t in the first 300 hours, then refine the budget. Optimized speed and feed reduces kWh/t by up to ~20%.
Answer: For hard rock and tight gradation, a cone achieves longer wear life and more consistent product, lowering total cost of ownership. For softer, very abrasive rock or for high fines, choose an impact crusher; yet note higher part consumption. Factor in spare parts lead time and on-site servicing capability.
Project A (Tanzania, granite): Objective: 100–120 t/h, multi-sized output. Design: jaw PE600×900, cone with CSS 22–30 mm, two-deck screen. Implementation: reinforced hopper, feeder grate, and a hydraulic tramp relief. Result: steady 100–120 t/h, product within spec, lowered recirculation. Operator feedback: simple daily checks; fast change of liners; reliable output.
Project B (portable regional plant): Objective: 80–100 t/h for concrete aggregate. Design choices emphasized compact footprint and fast mobilization. The modular train was commissioned in three days. Result: matched projected throughput; maintenance remained predictable. User comment: easy install, consistent production, clear maintenance plan helped reduce downtime.
Checklist: 1) Confirm feed size and hardness. 2) Choose crusher type to match product shape requirement. 3) Verify CSS and cavity availability for target gradation. 4) Match motor power to worst case. 5) Ensure spare parts and service plan. 6) Budget energy and downtime. Follow this list to reduce project risk.
Answer: Replace liners when thickness hits vendor minimum or when wear affects product shape. Track liner life in hours and adjust schedule; typically between 2,000–6,000 hours. Plan spares accordingly.
Answer: Use scalping and pre-washing where possible; fit anti-wrap rollers and larger grizzly openings. Maintain slower feed to avoid blinding and stickiness. Add dust suppression if fines cause packing.
Answer: Mobile suits short-term or multi-site contracts. Stationary favors long term, higher stability and slightly better energy performance. Choose based on contract length and relocation needs.
For mid-size construction, an 80–120 TPH crusher line balances capital and performance. Use staged reduction, control feed and CSS, and track energy, availability and wear to optimize life-cycle cost. For proven cases and equipment lists, see the project examples above, and request on-site tuning during commissioning to achieve consistent real output.
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