Baichy Basalt Crushing Plant 120t/h Operates Smoothly in South Africa

South Africa’s booming infrastructure and mining sectors demand equipment that is tough, reliable, and cost-effective. Recently, Baichy Heavy Industry successfully launched and smoothly operated a 120 t/h basalt crushing production plant in South Africa. This project stands as a testament to our engineering precision, featuring our advanced C90 Jaw Crusher and CS110 Cone Crusher.

Here is a detailed look at how this project went from a challenge to a resounding success, covering background, design, technology, performance, and feedback.

1. Project Background: The South African Hard Rock Challenge

The client, a prominent aggregate supplier in South Africa, secured a contract to supply high-grade stone for a regional highway project. The raw material? Basalt—one of the hardest and most abrasive stones to process (Mohs hardness 7-8).
The Client's Needs:
   ● Target Output: A stable 120-130 tons per hour.
   ● Material: River Basalt (High silica content, difficult to crush).
   ● Final Product: 0-5mm, 5-13mm, 13-19mm (Strict adherence to road base standards).
   ● Pain Point: Their previous equipment suffered from frequent breakdowns and excessive liner wear. They needed a solution that balanced capacity with durability.

2. Design Challenges and Adaptive Improvements

Designing a line for basalt is different from limestone. The biggest challenge was wear control and flow balance.
   ● The Wear Challenge: Standard impact crushers would wear out in days. Baichy engineers immediately opted for a "Jaw + Cone" configuration.
   ● Space & Power Adaptation: The site in South Africa had limited space and fluctuating voltage. We designed a compact layout that minimized conveyor lengths and integrated soft starters to protect the motors of the C90 and CS110 during power spikes.
   ● Dust Control: Considering South Africa's environmental regulations, we optimized the transfer points to reduce dust emissions during the dry season.

3. Key technological breakthroughs: Three core equipment

The success of this 120t/h  stone crusher line lies in the specific selection of three core machines. This wasn't a generic setup; it was a precision strike.
   ● Primary Crusher: European Jaw Crusher C90
Instead of a traditional PE jaw, we deployed the C90.  It features a "V-shaped" crushing cavity and a heavy-duty movable jaw assembly. The C90 jaw crusher offers a larger feed opening and higher crushing efficiency. It effortlessly handles the initial hard bite of the basalt boulders, ensuring a consistent feed to the secondary stage without blocking.

   ● Secondary Crusher: CS110 Cone Crusher (Symons Type)
This is the workhorse of the plant. The symons cone crusher  CS110 is renowned for its reliability and high-efficiency "lamination crushing" principle.  It produces a uniform, cubical product shape (vital for road construction) while keeping wear costs low. Its spring safety system automatically clears iron or uncrushable material, preventing the downtime that plagued the client's old plant.

   ● Precision Screening: 3YK2160 Vibrating Screen. 

 The 3YK2160 (3 decks, 2.1m x 6.0m) provides ample screening area.  It accurately separates the crushed basalt into the three required final sizes plus the return material. Its high vibration intensity ensures that even wet or sticky fines don't clog the mesh.

4. On-Site Operational Performance

Since commissioning, the data from the South African site has been impressive:
   ● Production Stability: The line consistently runs at 125t/h, slightly exceeding the design target.
   ● Product Quality: The flaky particle ratio is below 10%, meeting the strictest SANRAL (South African National Roads Agency) specifications.
   ● Uptime: The CS110 Cone Crusher has operated for over 2,000 hours with only routine maintenance, proving its stability in hard rock applications.
   ● Efficiency: The seamless integration between the C90 and CS110 means no bottlenecks; the crusher chambers are kept full, maximizing energy efficiency per ton.

5. Client Feedback and Market Impact

"We were skeptical about switching suppliers, but Baichy's C90 and CS110 have proven their worth. The machine build quality handles our basalt effortlessly, and the spare parts support has been excellent." — Site Operations Manager, South Africa.
Market Impact:
This project has become a reference site in the region. It demonstrates that medium-scale quarries (100-150t/h) do not need to compromise on technology. By using high-spec equipment like the C90 and CS110, operators can achieve "big mine" reliability on a smaller budget.

The smooth operation of the 120t/h Basalt Crushing Line in South Africa confirms that the right equipment combination is key to profitability. The smooth operation of the 120t/h Basalt Crushing Line in South Africa proves that Baichy equipment is built to endure the toughest environments. If you are looking for a reliable partner for your next quarry project, follow the lead of our successful South African clients and contact us to get the professional solution with price list now.

FAQ: Questions from South African Clients

Q1: How long does it take to ship the equipment to South Africa?

A: Typically, manufacturing takes about 20-30 days. Shipping from China to major South African ports like Durban usually takes roughly 25-35 days. Baichen handles all logistics to ensure the equipment arrives safely.

Q2: Is the 120t/h line difficult to install?

A: Not at all. Baichen provides a modular design. We send detailed foundation drawings in advance and can arrange for an engineer to guide the installation and commissioning on-site (or via video link) to ensure everything runs smoothly.

Q3: Can I crush other materials with this basalt line?

A: Yes! A "Jaw + Cone" setup is very versatile. Besides basalt, it is excellent for crushing granite, iron ore, river stone, and quartz. It is the ultimate configuration for hard materials.

Q4: Where can I get spare parts (liners/mantles) in the future?

A: Baichy supplies original spare parts globally. We recommend clients order a "safety stock" of essential wear parts (like jaw plates and mantles) with the initial machine purchase to avoid any shipping delays later.