Quarry rock crusher system with a capacity of 100 tons per hour (tph) represents an intermediate-scale crushing solution suitable for medium-sized mining operations, aggregate production, or construction projects. This analysis examines the equipment configuration, operational considerations, and technical specifications for such a system, particularly focusing on hard rock applications like granite processing.
System Configuration
For processing hard materials like granite, a well-designed 100 tph crushing plant typically includes three-stage crushing:
1. Primary Crushing – Jaw Crusher
- Function: First-stage reduction of large quarry rock (typically ≤800mm feed size)
- Output: Approximately 200-300mm particle size
- Equipment: Robust jaw crusher (e.g., PE600×900) with 180mm feed opening
2. Secondary Crushing – Cone Crusher
- Function: Intermediate reduction to smaller aggregate sizes
- Output: 30-50mm particles
- Equipment: Hydraulic cone crusher (HPT200 or similar) with 75-100kW motor
3. Tertiary Crushing – Impact Crusher/VSI
- Function: Final shaping and production of high-quality aggregates
- Output: 5-20mm graded products
- Equipment: VSI crusher or multi-cylinder hydraulic cone crusher for finer products
Technical Specifications
| Parameter | Specification |
|---|---|
| System Capacity | 100 tph |
| Feed Size | ≤800mm |
| Final Product Sizes | 0-5mm, 5-10mm, 10-20mm, 20-30mm |
| Power Consumption | 220-280 kW (total system) |
| Plant Footprint | ~50×30 meters |
| Operation Mode | 2-3 shift continuous operation |
Operational Considerations
- Material Characteristics: The system must be specifically configured for hard rock (250-350 MPa compressive strength) with proper wear-resistant materials in crushing chambers.
- Dust Control: Requires integrated dust suppression system with water spray nozzles at transfer points and crusher inlets/outlets.
- Maintenance Schedule:
- Daily: Lubrication checks, wear part inspection
- Monthly: Liner replacement assessment
- Yearly: Major component overhaul
- Production Optimization: Proper feeder speed regulation and crusher parameter adjustment to maximize throughput while maintaining product gradation.
Economic Analysis
- Capital Cost: $300,000-$500,000 for complete system
- Operating Cost: $5-$8 per ton (including power, wear parts, labor)
- ROI Period: Typically 18-36 months for medium-scale quarry operations
A properly configured 100 tph quarry rock crushing system offers an optimal balance between production capacity and capital investment for medium-scale operations. The three-stage crushing approach ensures efficient size reduction while maintaining product quality. System selection should prioritize robust primary crushing equipment matched with precise secondary/tertiary crushers to handle the specific material characteristics of the operation.