Local sandstone (Mohs hardness 3–4, medium brittleness)—abundant in Saudi Arabia. This case study presents the application of a 200-ton-per-hour Mobile Impact Crusher plant for a sandstone quarrying operation in Saudi Arabia. The project's key requirement was a simple, highly efficient crushing circuit to process soft to medium-hard sandstone into two specific aggregate sizes for construction and sub-base applications. The solution utilized a mobile impact crusher in a primary crushing role, demonstrating a streamlined and cost-effective approach.
The client needed a crushing solution for a sandstone deposit that was relatively soft and non-abrasive. The primary goals were to keep the initial investment and operational costs low while achieving a high output of 200 tph. The requirement for only two final product sizes allowed for a simplified process. A traditional two-stage setup (Jaw + Impact) was considered unnecessary for the material characteristics, prompting the search for a more efficient alternative.
The optimal solution was a mobile unit featuring a powerful impact crusher used in a primary crushing role. This configuration eliminates the need for a separate primary jaw crusher, simplifying the entire flow, reducing equipment costs, and minimizing fuel consumption. The natural friability of sandstone makes it perfectly suited for impact crushing, which excels at producing a well-graded, cubical product.
The entire operation is handled by a single mobile unit:
Equipment: The mobile plant integrates a heavy-duty vibrating feeder and the PF1315 impact crusher.
Function: Large sandstone blocks (up to ~700mm) are directly fed by an excavator into the unit's vibrating feeder. The feeder steadily conveys the raw material into the PF1315 impact crusher.
rocess: The PF1315 impact crusher acts as the primary and only crusher. Its high-speed rotor hammers the sandstone blocks, causing them to break upon impact against the aprons. This single impact action efficiently reduces the large raw material to the required sizes in one step.
The crushed material is then discharged onto an integrated onboard vibrating screen. The screen precisely separates the output into the two specified product sizes: 0-20mm and 20-40mm.
Any oversized material is recirculated back into the impact crusher for further processing (closed-circuit operation), ensuring high efficiency and consistent product gradation.
1. Simplified Circuit & Lower Investment: By using the impact crusher for primary crushing, the need for a separate jaw crusher unit was eliminated. This resulted in significantly lower initial capital expenditure and reduced operational costs (e.g., less equipment to maintain and fuel).
2. High Efficiency for Soft Rock: The impact crushing principle is ideal for sandstone, achieving high reduction ratios and the target capacity of 200 tph with ease.
3. Excellent Product Shape: The impact crusher produces aggregates with a superior, cubical shape, which is highly desirable for providing better compaction and strength in construction applications.
4. Exceptional Mobility & Quick Setup: The single-unit design offers ultimate mobility. The plant can be relocated and set up for operation very quickly, allowing it to follow the quarry face and minimize truck haulage distances.
5. Operational Flexibility: The discharge gap of the PF1315 impact crusher can be easily adjusted hydraulically, allowing operators to fine-tune the final product sizes if market demands change.
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.
Our team provides on-site installation and thorough training to ensure safe operation of the crushing plant.
Rigorous quality checks ensure compliance with standards, and we handle worldwide delivery to your location.
Baichy Machinery provides you with spare parts supply, project transformation, investment return analysis, etc.
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