120t/h Limestone Crusher Plant in Kyrgyzstan

Capacity:

80-120 ton / hour

Output size:

0-6mm,6-15mm,15-31.5mm

Material:

Limestone

Configuration:

Vibrating Feeder ZSW8530, Jaw Crusher PE500x750, Symons Cone Crusher CS75, Vibrating Screen YK1548, Sand Washing Machine XSD2610, Belt Conveyor System

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Efficient 120 t/h Limestone Crusher Plant in Kyrgyzstan

Project Overview:

A leading construction company in Kyrgyzstan sought to capitalize on the nation's growing infrastructure and building materials market. The goal was to establish a reliable 120 tons per hour limestone crushing plant to produce high-quality sand and aggregates. This plant was designed to be a model of efficiency and productivity, supplying essential materials for local construction projects.

Challenge:

The raw limestone from the quarry contained a mix of large, hard boulders and finer, clay-contaminated sections, requiring a robust and flexible crushing circuit. Maximizing output while minimizing downtime, energy consumption, and wear part costs was critical for the plant's profitability. The plant layout needed to be compact yet allow for smooth material flow and easy access for maintenance.

The Solution: Two-stage Stone Crushing And Washing Circuit

The designed two-stage crushing and washing circuit is optimized for limestone processing. The key components of this aggregate production line are:

1. Primary Crushing: PE500x750 Jaw Crusher

The PE500x750 Jaw Crusher serves as the primary crusher. Its robust design features a 500x750mm feed opening, capable of handling large-sized raw limestone directly from the quarry. It performs the initial size reduction, breaking down rocks to a size suitable for the secondary crusher, ensuring stable and efficient primary crushing.

2. Secondary Crussed Crushing: CS75 Cone Crusher

For secondary crushing, the CS75 Cone Crusher is employed. This crusher is ideal for producing a well-shaped, cubicle end product. It crushes the pre-screened material from the jaw crusher through compression, which is superior for achieving the particle shape required for high-value construction applications.

3. Screening & Classification: 3YK1548 Vibrating Screen

The triple-deck 3YK1548 vibrating screen separates the crushed material into specific sizes. This efficient screening process allows the plant to produce three different aggregate grades simultaneously (e.g., 0-5mm, 5-20mm, 20-31.5mm). Oversized material is recirculated back to the cone crusher in a closed-circuit system, maximizing overall efficiency.

4. Sand Washing: XSD2610 Sand Washer

To meet the high standard for manufactured sand, the XSD2610 Sand Washer is integrated into the line. It cleans the 0-5mm sand by removing fine dust, clay, and other impurities. This results in a premium, clean sand that enhances the strength and workability of concrete and mortar.

Key Advantages of 120tph Limestong Crusher Plant

1. Optimized Particle Shape: The "Jaw Crusher + Cone Crusher" combination ensures the final aggregates have excellent cubicity, increasing their value in the market.

2. High Efficiency and Automation: The streamlined flow with integrated screens and conveyors minimizes bottlenecks, allowing for continuous 120 t/h limestone processing.

3. Versatile Product Output: The plant can flexibly produce up to four different specification-grade products, maximizing return on investment.

4. Low Operational Costs: The selected equipment is known for its durability and low maintenance needs, contributing to a lower cost per ton of material produced.

Baichy Machinery Service Support in Kyrgyzstan

Crushing Solutions Design

Baichy Machinery can customize a crushing plant for you based on the specific conditions of your project: such as the construction site, hardness of the raw materials, output, output size, budget, etc.

On-site Installation & Training

Our team provides on-site installation and thorough training to ensure safe operation of the crushing plant.

Quality Control & Global Delivery

Rigorous quality checks ensure compliance with standards, and we handle worldwide delivery to your location.

After-Sales Support

Baichy Machinery provides you with spare parts supply, project transformation, investment return analysis, etc.

Crushing Solutions Design

On-site Installation & Training

Quality Control & Global Delivery

After-Sales Support

Frequently Asked Questions (FAQs)

Find answers to the most common questions about Baichy Machinery. If you can’t find what you’re looking for here, please contact us.

1. 1. Why choose a two-stage crushing process (Jaw + Cone) for limestone?

A two-stage process is highly efficient for medium-hard rock like limestone. The jaw crusher handles the primary, heavy-duty breaking, while the cone crusher performs secondary crushing, which is crucial for achieving a well-shaped, high-quality aggregate ideal for concrete production.

2. What is the main difference between a jaw crusher and a cone crusher?

A jaw crusher is used for primary crushing, designed to handle the largest feed material and break it down into coarse rubble. A cone crusher is used for secondary or tertiary crushing; it takes the pre-crushed output from the jaw crusher and refines it into smaller, more uniform, and well-shaped aggregates.

3. What is the role of the 3YK1548 vibrating screen in a crushing plant?

The vibrating screen acts as a control point to classify materials by size. It ensures each product fraction meets precise specifications. Oversized material is sent back for re-crushing (creating a closed circuit), which optimizes the entire production line's efficiency and product quality.

4. When is a sand washer like the XSD2610 necessary in an aggregate plant?

A sand washer is essential when producing manufactured sand from crushed rock. It removes harmful fine dust, clay, and impurities, resulting in "clean" sand. This significantly improves the quality of concrete and mortar, making it necessary for projects with high quality standards.

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