Designing a 300 TPH aggregate plant is a big task. It requires smart choices. We want high efficiency. We want low cost. This article explains the design. It is based on real experience. It helps you build a good plant. SBM helps you do this.
What is 300 TPH? It means 300 tons per hour. This is a medium scale. It is a golden capacity. Many investors like this size. Why? It balances cost and profit well.
The output is huge. In one day, it makes 3000 tons. This assumes 10 hours of work. It fits road building. It fits concrete making. But, you need good raw material. The stone must be enough.
We look at data. The International Journal of Mineral Processing has data. It says medium plants survive better. They are flexible. Big plants are hard to move. Small plants earn less. So, 300 TPH is safe.
The feed size matters. Usually, rocks are 600mm or 700mm. The machine must eat them. The final product varies. It can be 0-5mm sand. It can be 10-20mm gravel. We design for this.
You need strong machines. The heart is the crusher. We use a Jaw Crusher first. Then we use a Cone Crusher. This is a classic setup. It works for hard rocks.
The Primary Jaw Crusher
How does it work? It mimics a mouth. One jaw is fixed. The other moves. This is the swing jaw. It squeezes the rock. The rock breaks. Gravity pulls it down.
Technical point: The Toggle Plate. It acts as a fuse. If iron enters, it breaks. This protects the machine. Why? It saves the expensive motor. The reduction ratio is big. It is usually 4:1 to 6:1.
We check the OSS. This is Open Side Setting. It controls output size. For 300 TPH, use PE-900×1200 model. The motor power is 110kW. This is standard data. Don’t use small motors. They burn out.
The Secondary Cone Crusher
This is for fine crushing. It uses a mantle and concave. The rock falls between them. The mantle spins. It wobbles. This breaks the stone. It creates cubic shapes. Good shape is vital.
Key term: CSS. This is Closed Side Setting. It decides the final size. We set it to 22mm or similar. The speed is high. It is about 300-350 rpm. Why? High speed makes better sand.
SBM uses hydraulic types. They are smart. If rock gets stuck, it opens. The pressure releases. Then it resets. This reduces downtime. Old springs are slow. Hydraulics are fast.
This is a big pain point. Many clients ask this. Flaky stone is bad. Concrete does not like it. It makes weak roads. Buyers refuse it. Why does it happen?
Reason 1: The feed is too small. The crusher is not full. This is “choke feeding.” You must fill the chamber. Rock must crush rock. This is “lamination crushing.”
Reason 2: The reduction ratio is wrong. You crush too much at once. The rock splits badly. You need steps. Jaw does a little. Cone does a lot. Balance the load.
Solution: Keep the cone full. Use a surge bin. This is a buffer. It feeds the cone steadily. Also, check the liners. Worn liners make bad shapes. Change them on time.
Let’s look at the numbers. We need facts. A 300 TPH plant needs power. It needs space. Here is a typical list. It is for hard granite. Granite is tough. It wears metal fast.
The Feeder is first. It is a Vibrating Feeder. Model GZD-1300×4900. It handles heavy shocks. It removes dirt too. Why? Dirt clogs the crusher. Dirt lowers quality.
The Belt Conveyors are the veins. They move rock. We need width. Use B1000 belts. The speed is 1.6 m/s. Don’t go too fast. Rocks will fly off. Safety is key.
The Screen is the filter. It separates sizes. We use 3 decks. Model 3YZS-2160. It has big area. Efficiency must be 85%+. If not, good stone returns. This wastes energy.
| Equipment Name | Model | Power (kW) | Weight (t) | Function |
|---|---|---|---|---|
| Vibrating Feeder | GZD-1300×4900 | 22 | 6.5 | Feed & Scalp |
| Jaw Crusher | PE-900×1200 | 110 | 52 | Primary Crush |
| Cone Crusher | HST-250 | 250 | 18 | Secondary Crush |
| Vibrating Screen | 3YZS-2160 | 37 | 8 | Sizing |
| Control System | PLC Cabinet | – | – | Automation |
Energy is money. Mining uses lots of power. Clients worry about bills. A 300 TPH plant uses 400-500 kW. That is a lot. How to fix this?
First, match the motor. Don’t use a huge motor for small work. It wastes power. Use soft starters. They reduce spikes. Spikes hurt the grid. They cost extra fees.
Second, arrange the layout. Use gravity. Put the crusher high. Let rock fall to the next one. This shortens belts. Short belts use less power. It is simple physics.
Third, maintain the machine. A dull liner needs more force. A dry bearing creates heat. Heat is wasted energy. Grease it often. Keep it sharp. This saves 10-15%.
Let’s talk about a real job. SBM did this. The location was Sonora, Mexico. The client has a quarry. The stone is Basalt. Basalt is very hard. It is abrasive.
Project Background
The client wanted 300 TPH. The final size was 1/2 inch and 3/4 inch. The voltage was 440V. The altitude was 1200m. Air is thin there. Motors get hot easier.
The Solution Design
We chose the PE-900×1200 Jaw. For the second stage, we used HST-250 Cone. It is a single cylinder cone. It is strong. We added a VSI crusher too. Why? To shape the sand. The market pays more for good sand.
Operational Data
After 6 months, we checked. The output was 315 TPH. It beat the target. The power use was 1.4 kWh per ton. This is low. The liners lasted 4 months. Standard is 3 months. The client was happy.
Customer Feedback
“The SBM team was great,” said Mr. Carlos. “The installation took 20 days. Fast. The cone crusher is smart. It auto-adjusts. My workers find it easy. We save money on maintenance.” This proves our design works.
A good design needs good care. Installation is the base. The foundation must be flat. Concrete must cure. Wait 28 days. Do not rush. Vibration cracks green concrete.
Alignment is vital. The motor and pulley must line up. Use a laser tool. If not, belts break. Bearings fail. This causes stops. Stops cost thousands.
Create a logbook. Write down temperatures. Write down amps. If amps go up, something is wrong. Maybe a block. Maybe wear. Check it fast. Early fixes are cheap. Late fixes are dear.
Keep spares ready. Stock a toggle plate. Stock liners. Stock belts. Shipping takes time. You cannot wait. A day off is a day lost. Be prepared.
This is scary. The machine stops. The belt is full. What happened? This is a common panic. We must find the cause.
Cause 1: Iron entry. A digger tooth fell in. The detector missed it. The protection triggered. This is good. It saved the shaft.
Cause 2: Overload. You fed too much. The motor tripped. It is a thermal relay. It got too hot. Let it cool. Check the feed rate.
Cause 3: Power drop. The grid is weak. Voltage dropped. The motor lost torque. It stalled. You need a capacitor bank. It stabilizes voltage.
We don’t guess. We calculate. We use the Bond Work Index. It measures hardness. Granite is 16-18 kWh/t. Limestone is 10-12 kWh/t. We size motors based on this.
We check mass balance. Feed in = Product out. If Jaw outputs 350 TPH, Cone must take 350 TPH. If Cone only takes 200, you have a bottleneck. Rock piles up. This is bad design.
We use flowcharts. We draw the flow. We simulate it. SBM uses software. It predicts the load. It prevents errors. This is professional work. It builds trust.
1. Can I process river stone with this?
Yes, you can. River stone is hard. It is like granite. The Cone crusher is perfect. But, river stone is round. It slips. You might need a different jaw plate. Use a toothed plate. It grips better.
2. How much land do I need?
For 300 TPH, you need space. Roughly 100m x 50m. You need stock piles. Trucks need to turn. Don’t make it tight. Safety needs room. Leave space for future machines.
3. What is the ROI period?
It depends on the market. Usually, it is 6 to 10 months. Stone sells for $10-$20 per ton. Cost is $3-$5. The margin is good. If you run every day, money comes fast.
Designing a 300 TPH plant is science. It is also art. You balance power and cost. You balance wear and yield. The SBM solution is proven. It uses modern tech.
Do not buy cheap fakes. They break. They consume power. They have no support. Buy quality. Buy support. Look at the long term. A cheap machine costs more in the end.
Visit a working plant. See it run. Talk to the boss. Ask about SBM. They will tell the truth. We are confident. We build success. Start your mine right.
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