USED CONE CRUSHERS
Information and illustrations of cone crushers, links to other resources including used cone crushers and plant design considerations
DESIGNING A CRUSHING PLANT
WEBPAGE TRANSLATION TOOL


ILLUSTRATIONS OF PLANT DESIGNS

PICTURES OF CRUSHING AND SCREENING PLANTS
Designing a crushing plant to obtain the lowest cost per ton produced, and meet your market needs, requires balancing the entire process.
  • Starting with the best method to extract the raw material and deliver it to the crushing plant
  • Designing the crushing plant to be able to process that raw feed and then produce the final marketable products
  • Choosing the equipment so all components work together efficiently
Designing a crushing plant is similar to designing a manufacturing production line. All components must work together to create a smooth flow, consistent production, and as uniform final products as possible. The raw material can change during the life of the operation, weather can influence the operation, and normal wear can affect the production and quality of the output of the plant. The plant operator must be constantly adapting the operation to reflect these changes. In the end, crushing is an art rather than an exact science.

There are some basic principles that if followed will help you obtain the greatest production with the least capital investment and lowest operating costs.
  •    The raw feed needs to be as uniform in gradation, type, and feed rate as possible.       
  •    Remove all rock that is already smaller than your discharge setting prior to feeding each crusher.
  •    Using grizzlies and screens to reduce the amount of material that needs to be crushed will save you capital costs and operating costs.
Primary crushing is normally done by horizontal shaft impactors, gyratory crushers, or jaw crushers, and sometimes cone crushers.

Secondary crushing can be accomplished by using a jaw crusher, horizontal shaft impactor, or a cone crusher.

Tertiary crushing is normally done using a fine, shorthead, or Gyradisk cone crusher, and vertical shaft impactor.

Roll crushers are used both for secondary crushing or when fewer fines are wanted, such as producing "chips".

For more information on the various types of rock crushers, their method of crushing, and the average reduction ratios they produce, please go to
CRUSHER TYPES.

For more information on various crushers go to CONE ILLUSTRATIONS. For pictures of some aggregate plants
see below.

ALL CRUSHING IS BASED UPON STARTING WITH A RAW RESOURCE AND TRANSFORMING IT INTO FINAL PRODUCTS OR A FORM FROM WHICH YOU CAN EXTRACT VALUE FROM. IT IS IMPORTANT TO KNOW WHAT YOU ARE STARTING WITH, AND WHAT YOU WANT TO END WITH. IT IS THAT INFORMATION THAT IS USED TO DETERMINE WHAT EQUIPMENT YOU WILL NEED. 

Basic information needed includes:
1. What are the physical characteristics of the rock? Type of rock? Hardness of rock? Chemical composition of the rock? Weight per unit of measure (such as pounds per cubic foot or kilograms per cubic meter)? Is the rock abrasive? Average moisture content? 
2. Gradation of the rock? What are the average percentages of each size range?
3. Source of the rock? Is it from a sand and gravel deposit, or a shot rock quarry?
4. How many tons per hour can you supply the plant?
5. What is your market demand? What is the demand for certain size ranges?
6. How many different products will you need to produce? What is the size range of each product?
7. Do you want to have your operation stationary or portable? Portable equipment costs more to purchase, to ship, and to maintain.
8. Do you want equipment that is simple in design, easy to trouble-shoot and repair, and built to last.
9. Do you want equipment that uses high technology such as electronic sensors, computers, control consoles, and designed for high production but short useful life. 
 

The following are examples of matching the crushing and processing equipment to produce the final products processing a sand and gravel deposit and in a rock quarry. Notice how the use of appropriate screening greatly increases the production capacity of the crushers. By changing the input gradation, screen size, crusher size and discharge setting, various configurations can be compared to come up with the one best suited to meet your objectives.        

 

 
EXAMPLES OF PLANT FLOW PROCESS IN DESIGNING A CRUSHING PLANT
1.
USING A 3' STANDARD CONE TO PRODUCE 3 FINAL PRODUCTS AT 175 TONS PER HOUR
EQUIPMENT USED:

SURGE HOPPER WITH FEED CONVEYOR
SINGLE DECK SCALPING SCREEN
SYMONS 3' STANDARD CONE CRUSHER
TWO DECK SCREEN

Loading sand and gravel into a feed hopper. Raw material is fed to a scalping screen with 1 1/2" top screen cloth. Material 1 1/2" to 6" delivered to the 3' standard head cone crusher set at 3/4" closed side discharge setting. All materials now go to a two deck screen with 3/4" top deck and 3/8" bottom deck. In this design, all material that is already the final product sizes bypasses the cone. The cone is only used to crush rock larger than 1 1/2", reducing the wear on the manganese, and greatly increasing the production capacity of the plant. While the Symons 3' standard cone is only rated for an average production of 100 tons per hour set at 3/4" discharge setting, this plant is able to produce 175 tons per hour by using only one cone crusher.



2.
USING A 17X42 JAW CRUSHER WITH 45" CONE CRUSHER TO PROCESS 230 TONS PER HOUR OF QUARRY ROCK
TO MAKE 4 FINAL PRODUCTS

EQUIPMENT USED:

Kue Ken 17X42 jaw crusher
Allis Chalmers 45" cone crusher
2 each 5X16 three deck incline screens
4X12 single deck scalping screen




3.
USING A 30X42 JAW CRUSHER WITH A 4' STANDARD CONE CRUSHER TO PROCESS 250 TONS PER HOUR OF
SAND AND GRAVEL AND MAKE 3 SEPARATE FINAL PRODUCTS


EQUIPMENT USED:

Vibratory grizzly feeder
30X42 jaw crusher
48" standard cone crusher
6X20 three deck vibratory screen




4.
USING A 30X42 JAW CRUSHER WITH A 4' STANDARD CONE CRUSHER TO PROCESS 350 TONS PER HOUR OF
SAND AND GRAVEL AND MAKE ONE FINAL PRODUCT; BASE ROCK

EQUIPMENT USED:

Vibratory grizzly feeder
30X42 jaw crusher
48" standard cone crusher
Single deck vibratory scalping screen

This illustrates well the difference using a different screen, and discharge settings on the jaw and cone, can make in the production capacity of the same crushers. In the above illustration the customer wanted to maximize their 1/4" to 1" rock, their most popular size range. If you wanted to make a 1 1/2" base rock and not separate it into different products the capacity could be increased by over 30%.




5.
USING A 10X36 JAW CRUSHER AND TWO SCREENS TO MAKE 3 DIFFERENT PRODUCTS AT 80 TONS PER HOUR
PROCESSING A SAND AND GRAVEL DEPOSIT 


EQUIPMENT USED:

2 DECK HORIZONTAL SCREEN
10X36 JAW CRUSHER
2 DECK INCLINE SCREEN


This is a good starter plant for a low budget. A jaw crusher is simpler to operate and maintain than a cone crusher, and also costs less. This arrangement will also require less electricity to operate. A cone crusher can be added in the future that will greatly increase your production. An illustration of that is below.

To get the maximum production capacity it is important to not run any material through the jaw that is already smaller than your largest size of final product. In this configuration it would be easy to close-circuit the jaw and return its discharged material back to the primary scalping screen. By trying different discharge settings on the jaw you can produce even more final products. By returning the discharged material from the jaw you can increase the discharge opening until you reach the optimum opening for maximum production.






6.
USING A 10X36 JAW CRUSHER, 36" STANDARD CONE CRUSHER, AND TWO SCREENS TO MAKE 3 DIFFERENT PRODUCTS AT 200 TONS PER HOUR PROCESSING A SAND AND GRAVEL DEPOSIT 

EQUIPMENT USED:

2 DECK HORIZONTAL SCREEN
10X36 JAW CRUSHER
36" STANDARD CONE CRUSHER
  3 DECK INCLINE SCREEN

This illustrates how the adding of a 3' cone crusher can increase production from 80 tons per hour to 200 tons per hour. Even though the cone crusher is only rated for 83 tons per hour of average production at this discharge setting, the addition of it to the circuit can increase production by 120 tons per hour. This is because of the effective use of the screens.

Screens and conveyors cost less to purchase, operate, and maintain than crushers. They are very effective in getting the greatest production possible out of your crushers.




7.
USING A 42X48 JAW CRUSHER, A 7' STANDARD CONE CRUSHER, AND TWO SCREENS TO MAKE ONE PRODUCT
AT 550 TONS PER HOUR FOR A GOLD MINE

 
EQUIPMENT USED:

APRON FEEDER
HEAVY DUTY SCALPING SCREEN
(A VIBRATORY GRIZZLY FEEDER COULD BE SUBSTITUTED)
42X48 JAW CRUSHER
SYMONS 7' STANDARD CONE CRUSHER
  2 EACH TWO DECK INCLINE SCREENS

This was an attempt to find the best configuration for processing gold ore.





8.
USING A 30X42 JAW CRUSHER, 5 1/2' STANDARD CONE CRUSHER, 5 1/2' SHORTHEAD CONE CRUSHER AND TWO SCREENS TO MAKE ONE PRODUCT AT 270 TONS PER HOUR
FOR A GOLD MINE USING A BALL MILL

 
EQUIPMENT USED:

APRON FEEDER
HEAVY DUTY SCALPING SCREEN
(A VIBRATORY GRIZZLY FEEDER COULD BE SUBSTITUTED)

42X48 JAW CRUSHER
SYMONS 5 1/2' STANDARD CONE CRUSHER
SYMONS 5 1/2' SHORTHEAD CONE CRUSHER
  2 EACH THREE DECK INCLINE SCREENS

The goal was to take 24" and minus quarry produced rock and produce as many tons per hour of 1/2" minus final product. 



9.
USING A 42X48 JAW CRUSHER, 5 1/2' STANDARD CONE CRUSHER, 5 1/2' SHORTHEAD CONE CRUSHER AND TWO SCREENS TO MAKE ONE PRODUCT AT 500 TONS PER HOUR
OF 1" MINUS MATERIAL WITH APPROXIMATELY 50% BEING 1/2" AND SMALLER
 
EQUIPMENT USED:

VIBRATORY GRIZZLY FEEDER
30X42 JAW CRUSHER
SYMONS 5 1/2' STANDARD CONE CRUSHER
SYMONS 5 1/2' SHORTHEAD CONE CRUSHER
  2 EACH THREE DECK INCLINE SCREENS






 
10.
USING A 12X36 JAW CRUSHER, BEING FED SAND AND GRAVEL, IN CLOSE CIRCUIT,
TO PRODUCE 90 TPH OF FINAL PRODUCTS

An illustration of what a single 12X36 jaw crusher can produce by combining it with two screens. In this configuration it can produce three final products. The final sizes and percentages of each size can be varied by changing the discharge setting on the jaw (CSS) and the opening sizes of the screen cloth.



 
11.
USING A 12X36 JAW CRUSHER COMBINED WITH A 3' SHORTHEAD CONE CRUSHER, TO PRODUCE 150 TONS PER HOUR OF 3/4" AND MINUS MATERIAL
The tons per hour could be increased substantially if larger sizes of final products wanted to be produced. By adding a 2 deck screen three final products could be produced. For an estimate of what is possible please contact us.





 
CRUSHING AND SCREENING PLANT PICTURES

 

Typical hard rock quarry using rock trucks to deliver the raw material to the crushing plant. This shows the "rock box" where the trucks dump their material, which then is fed to the jaw by a vibratory grizzly. Rocks that are too big for the jaw crusher, or become stuck in the jaw opening can be broken into smaller pieces by the hydraulic pedestal mounted breaker. The material that bypassed the crusher with the use of the grizzly feeder are then deposited on the jaw crusher discharge belt. Notice the control house where the plant operator can oversee the entire operation,including the trucks feeding the rock box.
 
 


 

 

USING A SCREENING PLANT WITH A WHEEL LOADER TO MAKE SEVERAL PRODUCTS.

 

SHOT ROCK QUARRY WITH PRIMARY JAW CRUSHER WITH PEDESTAL MOUNTED HYDRAULIC BREAKER WITH ROCK BOX AND VIBRATORY GRIZZLY FEEDER,CONE CRUSHER, AND INCLINE VIBRATORY SCREEN FOR FINAL SEPARATION OF CRUSHED ROCK.
 
 

Combining a portable screening plant with a portable cone crusher for crushing the oversize material. Plant is being fed from a sand and gravel deposit.
 

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