500t/h Limestone Crusher Plant

Capacity:

500 ton / hour

Output size:

0-5mm, 5-10mm,10-25mm, 25-40mm

Material:

Limestone

Configuration:

Vibrating Feeder ZSW1349, Jaw Crusher PE900x1200, Multi Cylinder Cone Crusher HPC500, Impact Crusher PFW1315, Vibrating Screen YK2460, Belt Conveyor System

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High-Yield 500 t/h Limestone Crushing and Screening Plant

Project Overview

This case study examines the design and implementation of a large-scale 500 ton per hour limestone crushing and screening plant. Built to supply major infrastructure projects, this plant required a robust and flexible configuration to produce high-quality aggregates at an industrial scale. The solution integrates primary, secondary, and tertiary crushing stages using a PE900x1200 Jaw Crusher, an HP500 Cone Crusher, and two PF1315 Impact Crushers, along with efficient 2YK2460 Vibrating Screens for precise classification.

Challenge:

Achieving a consistent output of 500 tons per hour required equipment with high capacity and minimal risk of bottlenecking.Certain applications required perfectly cubic aggregates (best from a cone crusher), while others needed well-shaped, slightly rougher particles (ideal from an impact crusher). Managing a stone crusher plant of this scale demanded high automation, ease of maintenance, and low downtime to ensure profitability.

The 500t/h Limestone Crusher Plant Configuration

The plant was designed as a three-stage crushing circuit with advanced screening for maximum efficiency and product control.

1. Primary Crushing Station:

PE900×1200 Jaw Crusher: As the primary workhorse, this heavy-duty jaw crusher processes raw limestone up to 750mm, reducing it to 0-200mm. Its robust construction and deep crushing chamber ensure reliable performance under continuous heavy loads.

2. Secondary Crushing Stage:

HP500 Cone Crusher: This advanced hydraulic cone crusher handles intermediate reduction, producing well-shaped particles between 0-60mm. Its automated setting adjustment and overload protection maintain consistent output quality.

3. Tertiary Crushing Stage:

Dual PF1315 Impact Crushers are deployed in parallel. This configuration provides several benefits:
● High Capacity: Two units share the load, enabling high processing rates for the final product shaping.
● Excellent Product Shape: Impact crushers are renowned for producing a well-graded, high-quality product shape with a high percentage of fines, ideal for asphalt and concrete mixes.

● Flexibility: This setup allows the plant to fine-tune the final product characteristics by adjusting the crusher settings.

4. Screening System:

Dual 2YK2460 Vibrating Screens: These heavy-duty screens with dual decks ensure precise product separation into multiple specifications, with oversize material efficiently recirculated to appropriate crushers.

Key Advantages of 500tph Limestone Crusher Plant

1. Massive Production Capacity: The combination of large, high-capacity machines reliably achieves the target of 500 tons per hour.
2. Superior Product Quality: The multi-stage process (Jaw + Cone + Impact) ensures excellent control over particle size and shape, producing premium aggregates for the most demanding applications.
3. High Flexibility and Control: The parallel use of two impact crushers and two screens allows operators to easily adjust the product mix to meet changing market demands.
4. Optimized Efficiency: The circuit is designed to minimize recirculation load and reduce energy consumption per ton of material produced, leading to lower operating costs.

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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.Why is a three-stage crushing process used for 500tph stone crusher?

A three-stage process (Primary, Secondary, Tertiary) is essential for high-capacity plants to achieve proper size reduction gradually. It prevents overloading any single machine, allows for better control over the final product's shape and size, and significantly improves the overall efficiency and yield of the plant.

2. How is the feed regulated to prevent overloading the crushers?

A well-designed crushing plant of this scale includes sophisticated material handling systems. This involves surge piles or hoppers with vibrating feeders that ensure a consistent and regulated flow of material to each crusher. Level sensors and automation systems work together to prevent overfilling and ensure smooth, continuous operation.

3. What is the benefit of using both cone crusherand impact crusher?

This combination leverages the strengths of both technologies. The cone crusher provides a consistent, well-shaped base product with high reduction ratios. The impact crushers then further refine the material, creating an excellent particle shape and generating the necessary fine sand content. It offers the best of both worlds: cubicity and high yield.

4. Why are two screens used instead of one larger one?

Using two 2YK2460 screens in parallel offers redundancy and operational flexibility. If one screen requires maintenance, the plant can still operate at a reduced capacity. It also provides a larger total screening area, which is critical for handling 500 t/h of material efficiently, ensuring accurate sizing without bottlenecks.

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