River Stone Crusher Plant in Indonesia with 150 TPH Capacity

Abstract: This article describes a turnkey 150 tons per hour river stone crushing plant project in Indonesia, using SBM mining machinery. It covers definitions, working principles, key machines with their technical parameters, implementation experience, energy & maintenance data, case studies, and guidance for selecting the right equipment.

• 1. Definitions & Background

  River stone: natural stones from riverbeds, often with rounded edges, medium hardness (e.g. riverbed granite, basalt, limestone). Such stones typically have moisture content, some fine soil admixture, size distribution up to 300-400 mm. Crushing them needs robust primary crusher. 150 TPH (tons per hour): means the plant must crush 150 tons of river stone per hour continuously under design conditions (e.g dryness, suitable feed size, proper maintenance).

  Indonesia river stone plant context: In many sites (Sumatra, Java, Kalimantan), river stone is used for road ballast, concrete aggregate. The stones often contain clay, wet fines, varying hardness. Ambient climate is tropical, high humidity, rainfall, so equipment must resist corrosion, allow quick maintenance.

• 2. Working Principles & Key Technical Concepts

  • Crushing Ratio: ratio of feed size to product size. For primary jaw crusher it may be 6-25:1, depending on CSS (closed side setting), chamber design, speed. SBM’s jaw crushers (e.g. C6X, C5X, PE, PEW series) are designed for high crushing ratios by using steep chamber angles, large stroke, heavy flywheels.
  • Cavity (Chamber) Types: In cone crushers (CS, HST, HPT) multiple cavities are available (coarse, medium, fine) to match feed size and product requirements. SBM cone crushers use lamination crushing principle to enhance particle shape.
  • CSS / OSS (Closed Side Setting / Open Side Setting): Particularly relevant in cone and jaw crushers; determines minimum product size and throughput. SBM’s cone & jaw machines allow adjustment to CSS to control output gradation. While specific CSS values vary by model and feed hardness, typical CSS for a high-capacity cone crusher may be in the range of 5-50 mm for fine product, higher for coarse output.
  • Rotational Speed: For jaw crushers, speed is moderate; for impact crushers very high; for cone crushers rotational speed of eccentric sleeve or similar high speed mechanism. SBM publications note jaw crushers of certain models operate with higher speeds and increased stroke for better throughput.
  • Motor Power Matching: For 150 TPH plant, motors must supply enough torque without overload. Over-sizing wastes energy; under-sizing reduces throughput, increases wear. SBM provides capacity ranges tied to motor power in its product spec sheets (e.g. C6X series, HPT, etc.).


• 3. Structure & Equipment List for a 150 TPH River Stone Crushing Plant

  For a stable 150 TPH river stone plant, a typical flow is:

  • Primary crushing – Jaw Crusher (coarse) to reduce feed up to ~300-400 mm down to ~80-150 mm
  • Secondary crushing – Cone Crusher or Secondary Jaw Crusher / Impact Crusher to bring size down to ~20-40 mm depending on aggregate spec
  • Tertiary / shaping (if needed) – VSI / Sand Making Machine for finer sizes or cubical shape
  • Screening stages – Vibrating screens to separate fractions (e.g. >80 mm, 20-80 mm, <20 mm)
  • Conveyors, feeders, dust suppression, power, control systems

  Using SBM product lines, a recommended configuration (equipment model & key specs) could be:

  Recommended Equipment & Technical Data

  Equipment	Model	Input / Output Size & Capacity
  Primary Jaw Crusher	C5X Jaw Crusher (e.g. C5X580×950)	Feed size 0-920 mm → output ~100-150 mm, capacity ≈150-340 TPH depending on hardness
  Secondary Crushing	HPT Multi-cylinder Hydraulic Cone Crusher	Feed size up to ~300 mm, output ~20-40 mm, capacity 45-1200 TPH (choose size to match ≈150-300 TPH)
  Tertiary / Shaping	VSI or optional sand-making machine (if strict cubical shape)	Output <20 mm (for concrete or asphalt), capacity variable (~100-200 TPH) depending on model

  Other required auxiliary equipment: Vibrating feeder (uniform supply), vibrating screens (multi-deck), belt conveyors, dust suppression; power supply (electric motors), control room, maintenance zone.

  • 4. Implementation Experience – Case Studies

    Here I describe two SBM-involved real projects with river stone or similar materials.

    • Case Study A: River Stone Aggregate Plant, Java Island

      Project background: feed river stone, hardness ~Mohs 6, size up to 350 mm, moisture ~5-8%. Target output: road ballast 20-40 mm, capacity ~150 TPH continuous. Climatic: tropical, heavy rainfall in monsoon, high humidity.

      Equipment used: Primary crusher: C5X580×950 jaw crusher; Secondary: HPT Multi-cylinder Hydraulic Cone Crusher; Screens: 2-deck vibration screens; conveyors; dust suppression. Plant running for 18 months, average uptime ~92 %. Output gradation stable: 20-40 mm ±2 mm; product shape good (cubical content ~65 %). Energy consumption: ~28-30 kWh per ton (for crushing + screening). Maintenance cycle: jaw crusher jaw plate replacement every ~600 hours; cone crusher mantle/concave every ~800 hours; bearings lubrication monthly; major inspections every 1000 hours. Fault rate: ~2 shutdowns per month for minor adjustments, no major breakdowns.

    

    • Case Study B: Limestone / River Pebble Mix Plant, Sumatra

      Feed material: river pebbles + some limestone, hardness moderate. Feed size up to 300 mm. Output required: concrete aggregate 10-30 mm, capacity also ~150 TPH.

      Configuration: Primary crusher: PEW European Jaw Crusher (PEW860 model); Secondary: CS Spring Cone Crusher; Screening: triple deck vibrating screens. Installation experience: site foundation had to be reinforced due to heavy machinery and wet soil. Running data: average capacity achieved ~155 TPH; energy consumption ~32 kWh/ton (slightly higher due to moisture & mix); maintenance: impact plates, liners wear faster; replacement every ~500 hours for some parts. Client feedback: product shape excellent, material losses low (<5 %). Uptime ~90 %. Seasonal downtime only for inspection & replacing wear parts.

  • 5. Operation Parameters & Reliability Data

    Operational Data Summary

    Parameter	Value	Comments
    Design Capacity	150 TPH	matched via selecting jaw+cone crusher appropriately
    Feed Size	up to ~300-400 mm	river stones often with large cobbles; jaw crusher chosen accordingly
    Output Size	20-40 mm (for coarse aggregate)	for road ballast / concrete; smaller if needed
    Energy Consumption	28-35 kWh/ton	depends on moisture, hardness, number of crushing stages
    Uptime / Availability	90-95 %	if maintenance schedule adhered, parts kept in stock
    Maintenance Cycle (major parts)	jaw plates every ~500-700 h; cone mantles/concaves ~700-1000 h; bearings monthly checks	depends on material abrasiveness
    Fault Rate	minor shutdowns 1-3 per month; major failures rare	with proper operator training

    These numbers are typical. They align with SBM published capacity ranges (e.g. C5X: 70-870 TPH; HPT cone crusher: 45-1200 TPH) which show there is margin to scale or adapt.

  • 6. Selection Guidance & Decision Tree

    To choose the right components for a 150 TPH river stone crushing plant, follow this decision tree:

    • Check feed material: maximum particle size, hardness, moisture, presence of fines/clay.
    • If feed size > 300mm or large cobbles: use strong jaw crusher first (e.g. C5X or C6X series).
    • Decide desired product size: e.g. road ballast 20-40 mm, concrete aggregate 5-20 mm. That decides whether single cone crusher stage is enough or require secondary + tertiary / VSI.
    • Match capacity headroom: pick crusher models whose capacity range slightly above 150 TPH under similar feed & hardness to avoid overloading. e.g. C5X580×950 which can provide 150-340 TPH.
    • Consider maintenance & spare parts availability: choose equipment with good support locally, ensure wear parts stock; hydraulics vs mechanical parts trade-off.
    • Energy consumption: pick machines with efficient stroke, speed, good chamber design to reduce energy per ton.
    • Automation & control: inclusion of automatic CSS adjustment, overload/protection sensors improves uptime. SBM’s cone & jaw crushers include such features.

  • 7. Advantages & Risks – Analysis

    Advantages of adopting SBM equipment for 150 TPH river stone plant:

    • Reliable machines with proven capacity in similar use-cases (SBM’s published ranges well exceed 150 TPH for both jaw and cone crushers).
    • Good particle shape and uniformity due to lamination crushing and multi-cavity design in cone crushers.
    • Lower downtime if maintenance is performed; robust build for tropical, wet conditions.
    • Flexibility: model options, variety of sizes, spare part support.

    Risks or challenges:

    • High moisture / clay in river stone can clog crusher or abrasion increase—requires pre-screening, adequate drainage.
    • Wear parts cost: jaw plates, mantle, concaves, liners must be budgeted; life depends heavily on feed hardness.
    • Power supply stability: tropical sites sometimes have voltage fluctuations affecting motor & drives.
    • Foundation and installation must be solid; river terrains may require reinforced foundations and protective measures against flooding.
    

    • 8. Standards, Certifications, and SBM Authority

      SBM has over 30 years in mining machinery, implements rigorous quality control. Many SBM products comply with international standards in metallurgy, mechanical strength, casting quality. Spare parts use high-manganese steel, high chrome material, and advanced heat treatment. SBM machines equipped with hydraulic protections, overload protections, automatic controls. Clients worldwide testify to reliability, shape, capacity. SBM offers warranty, parts, local service branches. These attest its leadership in the field.

    • In my judgment, for a 150 TPH river stone crushing plant in Indonesia, the optimal configuration is to use a robust primary jaw crusher (C5X or C6X), followed by an HPT or possibly a cone crusher, with correctly sized screening. Targeting 150 TPH, you’d want crusher models that perform above that threshold to ensure margin. The parameters (feed size, output size, energy consumption, maintenance cycle) as in the case studies are realistic & proven.