Stationary Stone Crushing Plant
Stationary Stone Crushing Plant
A Stationary Crushing Plant (Fixed Stone Crushing and Screening Plant) is a permanent, high-capacity industrial installation designed to process blasted rock boulders, mined ores, and river gravel into classified aggregate fractions and manufactured sand. Erected on reinforced concrete foundations in commercial quarries and large-scale open-pit mines, stationary plants utilize a multi-stage closed-circuit flow consisting of Primary Crushing (Jaw Crusher), Secondary & Tertiary Crushing (Cone Crusher or Impact Crusher), and Multi-Deck Vibrating Screening.
Capacity available: 50 to 1000 tph
Crusher: Jaw crusher, Cone crusher, Impact crusher or Hammer crusher can be used as per your stone
Control system language available: Chinese; English; Russian; French; Spanish.
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PRODUCT DESCRIPTION
A Stationary Crushing Plant (Fixed Stone Crushing and Screening Plant) is a permanent, high-capacity industrial installation designed to process blasted rock boulders, mined ores, and river gravel into classified aggregate fractions and manufactured sand. Erected on reinforced concrete foundations in commercial quarries and large-scale open-pit mines, stationary plants utilize a multi-stage closed-circuit flow consisting of Primary Crushing (Jaw Crusher), Secondary & Tertiary Crushing (Cone Crusher or Impact Crusher), and Multi-Deck Vibrating Screening.
Compared with mobile units, stationary plants deliver significantly higher continuous throughput (up to 1,000+ TPH), superior mechanical stability, lower operating costs per ton, and maximum flexibility to tailor finished aggregate gradations for high-grade concrete, asphalt pavements, and railway ballast.
Henan Shengmao Machinery Co., Ltd. designs and manufactures complete turnkey stationary stone crushing and screening plants with production capacities ranging from 50 TPH to 1,000 TPH. Capable of handling raw rock feed sizes up to 1,300 mm, our stationary plants are engineered to deliver maximum reduction ratios, consistent aggregate grading (0–360 mm output range), and outstanding energy efficiency across diverse hard and soft rock applications:
Hard & Abrasive Rock Lines (Granite, Basalt, River Cobblestone, Quartz, Iron Ore): Utilizes a heavy-duty Primary Jaw Crusher + Secondary/Tertiary Hydraulic Cone Crusher configuration to minimize wear-part consumption and provide high-pressure lamination crushing.
Soft to Medium-Hard Rock Lines (Limestone, Dolomite, Calcite, Sandstone, Gypsum): Configured with a Primary Jaw Crusher + Secondary Impact Crusher for high reduction ratios and premium cubic particle shape with low fines generation.
Manufactured Sand Lines: Integrated with a Vertical Shaft Impact (VSI) Crusher (Sand Maker) and high-efficiency sand washing equipment.
PARAMETERS
|
Engineering Parameter |
Standard Specification / Value |
|
Production Capacity Range |
50 – 1,000 TPH (Customizable:50, 100, 200, 300, 400, 600, 1,000 TPH) |
|
Maximum Feeding Size |
≤1,300 mm≤1,300 mm |
|
Finished Aggregate Sizes |
0 – 360 mm (Standard: 0–5mm, 5–10mm, 10–20mm, 20–31.5mm, 31.5–60mm) |
|
Applicable Raw Materials |
Granite, Basalt, Limestone, River Pebble, Dolomite, Andesite, Quartz, Iron Ore |
|
Primary Crushing Unit |
Heavy-Duty Jaw Crusher (PE / PEW Series) |
|
Secondary Crushing Unit |
Hydraulic Cone Crusher or High-Efficiency Impact Crusher |
|
Tertiary / Shaping Unit |
Fine Cone Crusher or VSI Vertical Shaft Impact Crusher |
|
Screening Efficiency |
≥95% (Multi-deck circular vibrating screen) |
|
Particle Shape Quality |
Cubic shape with Flakiness & Elongation ratio <10%<10% |
|
Control System |
Central PLC automated cabinet with manual/automatic interlock |
|
Global Project Proof |
Proven turnkey projects (e.g., 400 TPH crushing plant in the Philippines) |
CORE PARAMETERS
Capacity available: 50 to 1000 tph
Crusher: Jaw crusher, Cone crusher, Impact crusher or Hammer crusher can be used as per your stone
Control system language available: Chinese; English; Russian; French; Spanish.
CORE SELLING POINT
High Continuous Throughput & Large Feed Intake (100–1,000 TPH)
Wide Production Range: Standard and custom plant lines deliver continuous, stable output from 100 TPH up to 1,000 TPH to meet large commercial quarry and mining demands. Massive Feed Size Acceptance: Heavy-duty primary jaw crushers accommodate raw blasted boulders up to ≤1,300 mm≤1,300 mm, minimizing the need for secondary blasting and pre-breaking at the quarry face.
Rock-Tailored Flowsheet Engineering (Optimized for Hard vs. Soft Rocks)
For Hard & Abrasive Rocks (Granite, Basalt, River Cobblestone, Quartz, Iron Ore): Configured with Primary Jaw Crusher + Secondary/Tertiary Hydraulic Cone Crusher. Utilizes high-pressure laminated crushing principles to minimize wear-part consumption and provide high continuous reduction. For Soft & Medium-Hard Rocks (Limestone, Dolomite, Sandstone, Gypsum): Configured with Primary Jaw Crusher + Secondary High-Efficiency Impact Crusher. Maximizes single-stage reduction ratios with lower power consumption per ton. For High-Grade Manufactured Sand: Integrates Vertical Shaft Impact (VSI) Sand Makers and spiral/wheel bucket sand washing units.
Superior Aggregate Particle Shape (Highway & High-Strength Concrete Grade)
High Cubicity & Low Flakiness: Optimized crushing cavity geometry and closed-circuit recirculation keep finished aggregate flakiness and elongation ratios below 10%. Accurate Fractional Classification: High-amplitude circular vibrating screens sort aggregates into exact commercial fractions (e.g., 0–5mm, 5–10mm, 10–20mm, 20–31.5mm) with screening efficiency ≥95%≥95%.
Heavy-Duty Build Quality & Low Operating Cost per Ton
Extended Wear Life: High-manganese steel jaw plates, high-chromium alloy blow bars, and forged alloy cone mantles deliver extended service intervals under abrasive operating conditions. Centralized Automated Control: Central PLC electrical cabinet with motor interlocks, thermal overload protection, and emergency stop systems safeguards continuous operations. 4-Step Customized Engineering Design Shengmao formulates the exact plant configuration based on 4 client inputs:
4-Step Customized Engineering Design
Shengmao formulates the exact plant configuration based on 4 client inputs: Raw Material Type & Hardness (e.g., Limestone vs. Granite) Maximum Feeding Size (e.g., ≤600 mm≤600 mm or ≤1,300 mm≤1,300 mm) Required Hourly Output (e.g., 200, 400, or 600 TPH) Finished Aggregate Sizes & Proportions (e.g., 0–5mm, 5–10mm, 10–20mm, 20–31.5mm)
RECOMMENDED USAGE SCENARIOS
Commercial Quarrying & Bulk Aggregate Production
Operating Context: Dedicated commercial stone quarries processing raw blasted rock to supply regional construction, building, and infrastructure markets.
Processed Materials: Limestone, dolomite, sandstone, granite, basalt, and river pebbles.
Shengmao Solution: High-capacity multi-stage crushing lines (100 to 1,000 TPH) accommodating raw boulder feed sizes up to ≤1,300 mm≤1,300 mm, sorting materials into 3–5 commercial fractions simultaneously (e.g., 0–5mm, 5–10mm, 10–20mm, 20–31.5mm).
Commercial Value: Maximizes hourly output while minimizing wear cost per ton through material-matched crushers (impact crushers for limestone; cone crushers for granite).
Highway, Expressway & High-Speed Railway Construction
Operating Context: National infrastructure projects requiring high-specification aggregates with strict limits on particle shape (high cubicity), flakiness, elongation, and cleanliness.
Processed Materials: Basalt, granite, and hard limestone for asphalt surface courses (Stone Mastic Asphalt / SMA) and railway ballast.
Shengmao Solution: Jaw Crusher + Multi-Cylinder Hydraulic Cone Crusher + Multi-Deck Vibrating Screen (Closed Circuit) keeping finished aggregate flakiness and elongation ratios below 10%.
Commercial Value: Produces high-strength cubic aggregate and ballast that strictly pass national highway and railway engineering audits.
Ready-Mix Concrete Batching & Manufactured Sand Plants
Operating Context: Aggregate and sand supply lines integrated directly with commercial concrete batching plants and asphalt mixing facilities.
Processed Materials: Sandstone, limestone, river cobblestones, and quarry tailings.
Shengmao Solution: Integrates Vertical Shaft Impact (VSI) Sand Makers and spiral or wheel bucket sand washing machines to produce high-grade 0–5mm manufactured sand with controlled fineness modulus and low silt content (<1%<1%).
Commercial Value: Optimizes cement consumption in concrete mixtures and enhances compressive strength (C50–C80 high-performance concrete).
Hydroelectric Dams, Bridges & Airport Runway Mega-Projects
Operating Context: Remote, large-scale civil engineering projects requiring continuous, high-volume on-site aggregate processing over multi-year build cycles.
Processed Materials: Massive alluvial river gravel, hard granite, and quartz deposits.
Shengmao Solution: Heavy-duty continuous plants (400–1,000 TPH) on reinforced concrete foundations with automated central PLC interlocking for reliable 24/7 round-the-clock operations.
Commercial Value: Guarantees uninterrupted aggregate supply on-site, eliminating reliance on third-party commercial suppliers and cutting remote transportation logistics costs.
Mining & Mineral Beneficiation Pre-Crushing
Operating Context: Open-pit and underground mines requiring primary and secondary ore size reduction before feeding ball mills or flotation circuits.
Processed Materials: Iron ore, copper ore, gold ore, bauxite, and quartz sand.
Shengmao Solution: Heavy-duty cast steel frame Jaw Crushers (PE/PEW Series) paired with high-crushing-force Hydraulic Cone Crushers, reducing raw ore from ≤1,000 mm≤1,000 mm down to ≤15−25 mm≤15−25 mm feed sizes.
Commercial Value: Lowers total energy consumption across the comminution circuit under the proven "more crushing, less grinding" operational principle.
FAQ
Q1:How do I choose between a Cone Crusher and an Impact Crusher for secondary crushing?
A1:
Choose a Hydraulic Cone Crusher if your rock is hard and abrasive (such as granite, basalt, river cobblestone, quartz, iron ore, or andesite with compressive strength >150 MPa>150 MPa). Cone crushers utilize high-pressure laminated compression, significantly reducing wear-part replacement costs in abrasive conditions.
Choose an Impact Crusher if your rock is soft to medium-hard (such as limestone, dolomite, sandstone, calcite, or gypsum with compressive strength <150 MPa<150 MPa). Impact crushers deliver higher single-stage reduction ratios and produce superior cubic particle shapes with lower initial capital cost.
Q2:What information is needed for Shengmao engineers to design a custom crushing line?
A2:
To provide an optimized flowsheet layout, equipment selection, and factory direct quotation, we require four core parameters:
Raw Material Type & Hardness (e.g., Granite, Limestone, River Stone; Mohs hardness)
Maximum Feeding Size (Maximum boulder dimensions in mm, up to ≤1,300 mm≤1,300 mm)
Required Production Capacity (Target output in metric tons per hour, e.g., 100, 200, 400, 600, or 1,000 TPH)
Finished Product Sizes & Fractions (e.g., 0–5mm, 5–10mm, 10–20mm, 20–31.5mm)
Q3:What is the maximum boulder size that the primary crusher can accept?
A3:
Shengmao’s heavy-duty primary jaw crushers (PE / PEW Series) feature deep, symmetrical crushing cavities capable of handling blasted rocks and river boulders up to ≤1,300 mm≤1,300 mm, eliminating the need for expensive secondary blasting at the quarry face.
Q4:What production capacities can Shengmao provide for stationary plants?
A4:
We engineer turnkey stationary crushing and screening plants with throughput capacities ranging from 100 TPH to 1,000 TPH (popular standard configurations include 100, 200, 300, 400, 500, 600, 800, and 1,000 TPH).
Q5:How does the plant ensure high cubicity and low flakiness in the finished aggregate?
A5:
High aggregate quality is achieved through laminated crushing cavity design in our hydraulic cone crushers (promoting inter-particle rock-on-rock crushing) and closed-circuit screening recirculation, keeping the finished aggregate flakiness and elongation ratio below 10%.
Q6:What civil foundation work is required for a stationary stone crushing plant?
A6:
Stationary crushing lines require reinforced concrete foundations designed to absorb dynamic operational vibrations. Shengmao provides complete civil engineering foundation drawings, anchor bolt layouts, and dynamic loading diagrams tailored to your site topography and soil bearing capacity prior to equipment delivery.
Q7:How long does it take to install and commission a complete crushing plant?
A7:
For a standard 100–400 TPH crushing line, installation and mechanical/electrical commissioning typically take 30 to 45 days after concrete foundations have cured. Larger multi-stage lines (500–1,000 TPH) typically require 45 to 60 days.
Q8:What wear-resistant materials are used in Shengmao crushers?
A8:
Jaw Crushers: High-manganese steel jaw plates and side cheek plates (Mn13Cr2 / Mn18Cr2).
Impact Crushers: High-chromium alloy blow bars (Cr26 / Cr27) and high-strength alloy impact liners.
Cone Crushers: Heavy-duty forged alloy manganese mantles and concave bowl liners.
Vibrating Screens: Wear-resistant high-manganese woven wire mesh or modular polyurethane screen panels.
Q9:Does the plant come with automated lubrication and safety interlocks?
A9:
Yes. Hydraulic cone crushers feature centralized lubrication monitoring oil temperature, pressure, and flow rates. The central PLC electric cabinet features automated motor interlocking and thermal overload emergency shutdown.
Q10:Can the electrical system be customized for different international power grids?
A10:
Yes. All electric motors, transformers, and PLC control cabinets can be customized to match your country’s industrial electrical grid, including 380V/50Hz, 220V/60Hz, 440V/60Hz, or 480V/60Hz, with optional soft starters or Variable Frequency Drives (VFD).
Q11:How is the equipment shipped internationally?
A11:
Standard modular components, conveyors, and vibrating screens are shipped in 40ft High Cube (40HQ) and Open Top (OT) containers, while heavy crusher mainframes and cone assemblies are transported via Flat Rack (FR) platforms or Breakbulk vessels.
Q12:What after-sales and on-site engineering services does Shengmao provide?
A12:
On-Site Installation Supervision: Dispatching experienced mechanical and electrical engineers to guide erection, wiring, trial runs, and local staff training.
Lifetime Spare Parts Support: OEM genuine replacement wear parts in stock with expedited worldwide dispatch.
Warranty: 12 months standard warranty on all major mechanical equipment from the date of commissioning (or 18 months from shipment).
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