A Comprehensive Guide to 200tph Iron Ore Crushing Plants

For mining operations and processing iron ore, a 200TPH (tons per hour) crushing plant is a strategic investment for mid-to-large mining operations. Designed to handle the hardness and abrasiveness of iron ore (Mohs hardness 4-5.5), this plant balances high throughput with precise particle sizing—critical for downstream processing like beneficiation and pelletizing. Below, we explore the key components, design considerations, and benefits of a 200TPH iron ore crushing plant, tailored to meet mining industry demands.

About 200TPH Iron Ore Crushing Plant

A 200TPH iron ore crushing plant is a integrated system engineered to reduce raw iron ore (lumps up to 800mm) into uniform, saleable products—typically 0-10mm, 10-20mm, and 20-40mm fractions. Unlike general-purpose stone crushing plants, it’s specialized to handle iron ore’s unique properties: high density, abrasiveness, and the need to minimize fines (which reduce ore quality for smelting). The plant’s workflow ensures consistent throughput of 200 tons per hour, making it ideal for mines producing 1,500-2,000 tons daily (based on 8-10 hour shifts).

Core Equipment Configuration

To achieve 200TPH efficiency with iron ore, the plant relies on a multi-stage crushing process. Here’s the optimal setup:

1. Primary Crushing: Jaw Crusher

The first stage uses a large jaw crusher (e.g., PE900×1200 or C125) to break raw iron ore lumps from the mine (max feed size 750mm) into 150-200mm chunks. Key features:
-High manganese steel jaw plates: Resist abrasion from iron ore, lasting 30-50% longer than standard steel.
-Hydraulic adjustment: Quickly fine-tune the discharge gap to control output size, reducing downtime during material changes.
-Capacity: 160-300 TPH, perfectly matching the 200TPH target when paired with downstream equipment.

2. Secondary Crushing: Cone Crusher

After primary crushing, a cone crusher (e.g., HP300 or CS250) processes the 150-200mm ore into 20-60mm particles. Cone crushers are preferred for iron ore due to:
-Compression crushing: Produces cubical particles with minimal fines (critical for iron ore, as fines require extra processing in beneficiation).
-High reduction ratio: Efficiently breaks hard iron ore without excessive energy use.
-Capacity: 180-250 TPH, ensuring the plant maintains 200TPH even during peak loads.

3. Tertiary Crushing (Optional): Fine Cone Crusher

For operations requiring finer iron ore (e.g., 0-10mm for pelletizing), a tertiary cone crusher (e.g., HP200) further reduces material to the desired size. This stage is optional but adds value for mines supplying steel mills.

4. Screening & Conveying

-Vibrating Screen: A 3-deck circular vibrating screen (e.g., 3YK2460) separates crushed ore into 3 grades (0-10mm, 10-20mm, 20-40mm). Oversized material returns to the cone crusher via a closed-loop system, ensuring no waste.
-Belt Conveyors: 1000mm-wide belts with rubber linings (resistant to iron ore’s abrasiveness) transport material between stages at 1.2-1.5m/s, matching the 200TPH throughput.

Designing the Flow: Open Circuit vs. Closed Circuit

• Open Circuit: The material passes through the crusher only once. Simpler but offers less control over product size. Less common for precise iron ore requirements.

• Closed Circuit: The crushed material is screened; the oversize is fed back (recirculated) to the crusher for further crushing. This is the standard for most iron ore plants as it ensures optimal efficiency and consistent product size control, maximizing yield.

Sample 200TPH Iron Ore Crushing Plant Flow Design

A standard two-stage, closed-circuit design is highly effective:

• Feed: ROM iron ore (0-1000mm) is dumped into a hopper.
• Vibrating Grizzly Feeder: Scalps off natural fines (e.g., -50mm) and evenly feeds the jaw crusher.
• Primary Jaw Crusher: Crushes ore to ~250mm.
• Conveyor Belt: Transports crushed material to a primary screen.
• Primary Screen (Vibrating Screen): Separates the material. Oversize (>50mm) is sent to the secondary cone crusher. Undersize (<50mm) is the product or is combined with the cone crusher output.
• Secondary Cone Crusher: Further reduces the oversize from the screen to the desired product size.
• Conveyor Belt: Returns the cone crusher output to the same primary screen for re-classification (forming a closed circuit).
• Product Conveyor: The final, correctly sized material (e.g., 0-50mm) is conveyed to a stockpile for the next stage of processing.

A 200tph iron ore crushing plant is a significant investment, but with careful planning and the right equipment selection, it becomes a highly profitable asset. By focusing on robust machinery, intelligent circuit design, and proactive maintenance, you can build a operation that delivers reliable tonnage for years to come.

Ready to design your optimal 200tph iron ore crushing circuit? Consult with a experienced crushing equipment supplier to tailor a solution that matches your ore properties and production goals perfectly.