What is the Capacity of Common Stone Crushers?

Stone crushers are indispensable machinery in the mining and construction industries, serving a critical function in the production of high-quality aggregates and various crushed materials for infrastructure and industrial applications. When selecting a stone crusher, one of the most vital factors to evaluate is its processing capacity—the volume of material it can efficiently crush within a specific timeframe. This parameter directly impacts operational efficiency, production timelines, and overall project economics. Below is a detailed breakdown of typical capacity ranges for the most common types of stone crushers:

1. Jaw Crushers: 1-1000 tph

Jaw crushers are primary crushers used for coarse crushing of hard and medium-hard stones (e.g., granite, limestone, andesite). Their capacity is primarily determined by the size of the feed opening and the crusher’s power.

- Small jaw crushers (for small-scale operations):
- Feed opening: 150×250 mm to 250×400 mm
- Capacity: 1– 30 tons per hour (tph)
- Common uses: Quarries, construction sites, small mining operations.

- Medium jaw crushers (for medium-scale production):
- Feed opening: 400×600 mm to 600×900 mm
- Capacity: 50 – 300 tph
- Suitable for crushing hard stones in quarries or aggregate plants.

- Large jaw crushers (for large-scale projects):
- Feed opening: 800×1000 mm or larger
- Capacity: 300 – 1,000+ tph
- Used in mining and large aggregate production lines.

2. Cone Crushers: 10 - 2000tph

Cone crushers are secondary or tertiary crushers, ideal for fine crushing of hard materials (e.g., granite, basalt, andesite) to produce uniform, cubic aggregates. Their capacity depends on the cone diameter, eccentric throw, and rotational speed.

- Small cone crushers (small quarries):
- Cone diameter: 400 – 700 mm
- Capacity: 10 – 100 tph

- Medium cone crushers (most common in aggregate plants):
- Cone diameter: 800 – 1,300 mm
- Capacity: 100 – 500 tph
- Example: A 1,200 mm cone crusher handling andesite can achieve 300 – 400 tph (like the Baichy plant in Indonesia).

- Large cone crushers (mining or high-capacity projects):
- Cone diameter: 1,500 mm or larger
- Capacity: 500 – 2,000+ tph

3. Impact Crushers: 10 - 1000 tph

Impact crushers use high-speed impact force to crush materials, suitable for medium-hard stones (e.g., limestone, dolomite) and producing well-shaped aggregates. They are divided into horizontal shaft impact (HSI) and vertical shaft impact (VSI) crushers.

- HSI Impact Crushers:
- Small models: 10 – 100 tph
- Medium models: 100 – 500 tph
- Large models: 500 – 1,500 tph

- VSI Crushers (for shaping and fine crushing):
- Small models: 5 – 50 tph
- Medium models: 50 – 300 tph
- Large models: 300 – 1,000+ tph

4. Roll Crushers: 1 - 300 tph

Roll crushers use two rotating rolls to crush materials, suitable for soft to medium-hard stones (e.g., coal, limestone). They have lower capacity compared to jaw or cone crushers.

- Small roll crushers: 1 – 50 tph
- Large roll crushers: 50 – 300 tph

5. Hammer Crusher: 10 - 300tph

Hammer crushers are a high-speed impact crusher that uses rotating hammers to shatter and crush materials into smaller pieces. It is ideal for soft to medium-hard materials like limestone, coal, gypsum, and brittle minerals.

- Capacity Range: 10–300 TPH

- Common Use: Small to medium-sized crushing for softer materials

Key Factors Affecting Capacity

- Material properties: Harder, more abrasive materials reduce capacity due to increased wear and slower processing.
- Feed size and uniformity: Overly large or uneven feed can lower efficiency.
- Crushing setting: Narrower discharge settings (for finer products) reduce capacity.
- Maintenance: Poorly maintained crushers (e.g., worn liners) operate at reduced capacity.

In summary, the capacity of common stone crushers varies significantly based on their type, size, design, and the material being crushed (hardness, moisture content, etc.). Common stone crushers range from 1 tph (small jaw/roll crushers) to 2,000+ tph (large cone or impact crushers), with most industrial-scale operations using models in the 100 – 500 tph range.