When constructing a 500-ton-per-hour crushed stone production line, equipment selection and process design must be closely aligned with raw material characteristics and finished product requirements. The following details core equipment configurations, typical process flows, and key optimization measures, supplemented with specific data and case studies to enhance practicality:
I. Core Equipment Configuration Plan
1. Primary Crushing Stage
Jaw Crusher
Application Scenario: Processing large raw material chunks (feed size ≤930mm), particularly suited for medium-hardness materials like limestone and bluestone (Mohs hardness 3-5).
Data Support: Taking the C6X jaw crusher as an example, it achieves a processing capacity of 400-800 tons/hour, with a motor power of 220kW and a crushing ratio of 6:1, efficiently completing primary crushing tasks.
Case Study: A highway project in Gansu utilized C6X jaw crushers, with a single unit processing over 6,000 tons daily to meet the requirements of a 500-ton-per-hour production line.
Gyratory Crusher Alternative
Suitable Applications: Processing high-hardness materials like granite and basalt (Mohs hardness ≥7).
Data Comparison: Conical crushers offer 30% higher capacity than jaw crushers but require 20%-30% higher initial investment. For example, a granite quarry using an H7800 conical crusher achieved 650 tons per hour, though the equipment weighed over 200 tons and required heavy-duty foundations.
2. Medium and Fine Crushing Stage
Impact Crusher
Advantages: Produces cubical-shaped final products with ≤8% needle and flake content, suitable for concrete aggregate production.
Cost Analysis: Taking the CI5X impact crusher as an example, the unit price is approximately ¥800,000, 40% lower than cone crushers, but wear part lifespan is only one-third that of cone crushers.
Cone Crusher
Technical Parameters: Multi-cylinder hydraulic cone crushers (e.g., HPT300) handle 200-500 tons/hour. The layer compression crushing principle extends wear part lifespan to over 8,000 hours.
Case Study: The HST315 single-cylinder cone crusher deployed in the Shanxi Lüliang diabase project produces five aggregate specifications (5-10mm, 10-20mm, etc.), with needle and flake content ≤5%.
3. Screening and Shaping Stage
Vibrating Screen
Classification Efficiency: The 3YZS2460 vibrating screen handles 300-600 tons/hour with 95% screening accuracy and recirculation rate controlled below 15%.
Closed-loop Design: Achieves multi-stage screening via the S5X3075 screen, simultaneously producing five finished grades: 0-5mm, 5-10mm, 10-20mm, 20-30mm, and 30-40mm.
Sand Maker
VSI6X Vertical Shaft Impact Crusher: Utilizes “stone-on-stone” and “stone-on-iron” composite crushing. Produces sand with a modulus of fineness 2.8-3.2 and powder content ≤8%, meeting Class II sand standards.
Energy Consumption Comparison: 20% more energy-efficient than traditional sand makers, with power consumption of only 3.5 kWh per ton.
II. Analysis of Typical Process Flows
1. Limestone Production Line
Process Design:
Feeder → Jaw Crusher (primary crushing) → Impact Crusher (secondary crushing) → Vibrating Screen (grading) → Recirculated crushing → Sand Maker shaping → Sand Washer (optional) → Finished product.
Case Data:
The Gansu project employs C6X jaw crusher + CI5X impact crusher + S5X screening, achieving 520 tons per hour with 98% qualified product particle shape. It supplied over 2 million tons of aggregate for the Lanhai Expressway.
2. Granite/Basalt Production Line
Process Optimization:
Jaw crusher coarse crushing → Cone crusher medium/fine crushing → Multi-stage screening → Sand maker shaping → Dust removal system → Finished product.
Case Highlights:
The Lüliang, Shanxi project achieved “one crusher replacing two” using HST315 cone crushers, reducing equipment units and lowering comprehensive energy consumption by 18%, with an annual aggregate output of 1.5 million tons.
III. Key Optimization Measures
1. Pre-screening and Iron Removal
Bar Feeder: Achieves 85% pre-screening efficiency, separates particles ≤50mm, and reduces overload risk for jaw crushers.
Magnetic Separator Configuration: Permanent magnet separators with ≥1.2T magnetic induction strength remove over 95% of ferrous impurities, protecting downstream equipment.
2. Energy-Saving Design
European-style jaw crusher (PEW860): Features deep-chamber crushing design, reducing energy consumption by 15% compared to traditional jaw crushers, with motor power optimized to 110kW.
Hydraulic cone crusher: Hydraulic discharge opening adjustment minimizes downtime, lowering overall power consumption by 12%.
3. Environmental Protection Features
Enclosed Structure: Crushing workshops enclosed with color-coated steel panels reduce noise by over 20dB.
Pulse Dust Collection System: Dust removal efficiency ≥99%, dust emission concentration ≤10mg/m³, meeting national environmental standards.
IV. Data Support and Industry Trends
Market Data: China's crushed stone production line equipment market reached ¥12 billion in 2024, with 500-ton-per-hour lines accounting for over 40% of the market.
Technological Trends: Intelligent control systems (e.g., SCADA) enable remote equipment monitoring, achieving 90% accuracy in fault prediction and reducing downtime by 30%.
Through these configurations and optimizations, the 500-ton-per-hour crushed stone production line achieves efficient, low-consumption, and environmentally friendly operation, providing stable, high-quality aggregate support for infrastructure construction projects.
