Here’s a detailed flow chart explanation for a 200 TPH stone crusher plant, designed to optimize crushing efficiency and ensure smooth material processing:
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Flow Chart of a 200 TPH Stone Crusher Plant
# 1. Feeding Stage
The process begins with raw material being loaded into a vibrating feeder or dump hopper. The feeder ensures consistent material flow to the primary crusher, preventing blockages and maintaining uniform feed size (typically ≤500mm).
# 2. Primary Crushing (Jaw Crusher)
The vibrating feeder directs the material to a primary jaw crusher, which reduces large stones into smaller fragments (approx. 150–200mm). The jaw crusher’s rugged design handles hard rocks like granite or basalt efficiently.
# 3. Secondary Crushing (Cone Crusher/Impact Crusher)
Crushed material from the primary stage is conveyed to a secondary cone crusher or impact crusher for further reduction (output size: 20–50mm). A cone crusher is preferred for abrasive materials, while an impact crusher suits softer rocks like limestone.
# 4. Screening Stage (Vibrating Screen)
The crushed aggregate passes through a vibrating screen to separate it into desired sizes (e.g., 0–5mm, 5–10mm, 10–20mm). Oversized particles are returned to the secondary crusher via conveyor belts for re-crushing (closed-circuit system).
# 5. Tertiary Crushing (Optional VSI Crusher)
For producing high-quality sand or finely shaped aggregates, a tertiary Vertical Shaft Impactor (VSI) may be added. This stage refines particles to ≤10mm, ideal for concrete or asphalt production.
# 6. Material Washing (Sand Washer – Optional)
If the project requires clean aggregates, a sand washer removes dust and impurities from the final product, enhancing its market value.
# 7. Stockpiling & Dispatch
Processed materials are stored in segregated stockpiles based on size. Loaders or conveyors transfer the finished products to trucks for transportation to construction sites or customers.
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Key Components & Their Roles
- Vibrating Feeder: Regulates feed rate to prevent overload.
- Crushers: Jaw (primary), cone/impact (secondary), VSI (tertiary).
- Screens: Classify aggregates into precise grades