150tph Mobile Crusher Plant in Lebanon

150tph Mobile Crusher Plant for Basalt Processing in Lebanon

Project Overview:

A leading Lebanese construction company was contracted for a major highway development project. The project required a massive supply of high-quality basalt aggregates. To meet this demand directly at the project site, the company invested in a advanced 150-ton-per-hour mobile crushing plant, designed to process hard basalt into precise, single-specification aggregates efficiently and reliably.

The Challenge:

Basalt has a Mohs hardness of 6-7, making it a tough material to crush. Conventional single-stage or two-stage crushing lines often struggle with low efficiency and frequent wear-part replacement. The end-use (high-grade road base) required strict control over particle size—no oversize or undersize materials were allowed, demanding precise crushing and screening coordination. Finally we sugget to use two mobile crushing plants with three stage crushing process to meet requirement.

The Solution: A Custom Two-Unit, Three-Stage Mobile Crushing Line

The innovative solution was a two-unit mobile plant that performs three stages of crushing. This configuration eliminates the need for a fixed, complex setup while delivering exceptional performance.

1. Primary & Tertiary Crushing Unit: Three-Combination Mobile Station

This integrated unit handles the first and third stages of crushing.
● Vibrating Feeder: Evenly feeds raw basalt (0-600mm) into the crusher, preventing blockages and ensuring a steady flow.
●Jaw Crusher PE600x900 (Primary Crushing): This robust jaw crusher is the workhorse of the primary stage. It takes the large raw basalt rocks and reduces them to a smaller size (approx. 0-150mm). Its strong structure is ideal for the high compressive strength of basalt.
●Spring Cone Crusher PYB900 (Tertiary Crushing): In a unique configuration, this cone crusher acts as the tertiary crusher. It takes the precisely screened material from the secondary unit and performs the final shaping and crushing to the required 0-31.5mm specification, ensuring a high-quality, cubical end product.

2. Secondary Crushing & Screening Unit: Two-Combination Mobile Station

This unit is the heart of the closed-circuit system, ensuring product quality.
●Symons Cone Crusher CS160 (Secondary Crushing): This larger cone crusher receives the output from the primary jaw crusher. It performs the secondary crushing, further reducing the material size and beginning the process of shaping the aggregates.

●Vibrating Screen 2YK1860 (Screening & Classification): This double-deck screen is critical. It sorts the material from the secondary crusher:
Oversize Material (>31.5mm): Sent back to the secondary cone crusher CS160 for re-crushing.
Correctly Sized Material (0-31.5mm): Sent to the tertiary PYB900 cone crusher on the first unit for final shaping.
Undersize Material (0-5mm, Crusher Dust): Can be stockpiled as a separate by-product.

Key Advantages of This Mobile Crushing Plant

1. Unmatched Mobility: The two mobile stations can be repositioned quickly, keeping pace with the moving construction front.

2. Optimal Product Shape: The three-stage crushing process, featuring two different cone crushers, ensures a perfectly cubical product that is ideal for road base compaction and asphalt adhesion.

3. High Efficiency & Low Wear: The closed-circuit design with the screen ensures that crushers only process material that needs to be crushed, reducing unnecessary wear on the PYB900 and saving energy.

4. Simplified Logistics: Only two main units need to be transported and set up, drastically reducing time and costs compared to a three-unit system.

Baichy Machinery Service Support in Lebanon

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 use a three-stage process with only two mobile units?

This innovative "cross-circuit" design is highly efficient. By placing the tertiary crusher on the same unit as the primary crusher, it simplifies the plant layout and reduces the number of inter-unit conveyors needed, lowering both cost and setup time without compromising the final product quality.

2. How is the circuit balanced between the two mobile stations?

The primary station handles coarse crushing, while the secondary station performs intermediate crushing and final sizing. The capacity is balanced through precise equipment selection and process optimization, ensuring smooth material flow throughout the system.

3. What are the maintenance requirements for this configuration?

Daily maintenance includes routine inspections and lubrication. Jaw crusher wear parts require replacement every 800-1000 hours, while cone crusher liners need change every 600-800 hours. Regular screen mesh inspection and replacement is also essential.

4. How is the final product size controlled?

The product size is primarily controlled by the closed-side setting (CSS) of the tertiary PYB900 cone crusher and the screening efficiency of the 2YK2160 vibrating screen. Adjusting the CSS allows for fine-tuning of the final output.

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