3 stage 200 tph crusher plant specification

Overview of a 3-Stage 200 TPH Crusher Plant Specification

A 3-stage 200 TPH (Tonnes Per Hour) crusher plant is a comprehensive aggregate production system designed for medium-scale, high-efficiency output of precisely sized stone aggregates. This configuration is engineered to handle hard rock and abrasive materials, breaking them down progressively through primary, secondary, and tertiary crushing stages to achieve superior product shape and gradation control. The "200 TPH" specification defines the plant's designed throughput capacity, while the "3-stage" layout ensures optimal reduction ratios and product flexibility. Such plants are fundamental in supplying quality aggregates for critical construction projects like highways, railways, and concrete batching plants. This article details the typical equipment specifications, flow design, and practical applications of this industry-standard setup.

Plant Configuration & Process Flow
The core principle of a 3-stage plant is sequential size reduction. Run-of-Quarry (ROQ) feed (typically up to 500-600mm) is first reduced by a primary crusher, then screened with oversized material sent to a secondary crusher. The output from secondary crushing is screened again, with middlings directed to a tertiary crusher for final shaping. Each stage allows for better control over the final product's size and cubicity.

Key Equipment Specifications
The exact model selection depends on feed material hardness (e.g., granite, basalt vs. limestone) and desired final products. However, a standard specification range is as follows:

Stage	Crusher Type	Typical Model / Size	Recommended Feed Size	Expected Output Size	Power Rating (Approx.)
Primary	Jaw Crusher	36" x 24" (900x600mm) or similar	Up to 500 mm	150 - 200 mm	110 - 132 kW
Secondary	Cone Crusher	GP220 / HPC200 or similar	Up to 200 mm	40 - 70 mm	160 - 220 kW
Tertiary	Cone Crusher (Short Head) or VSI*	HP200 / VSI-800 or similar	Up to 70 mm	0-5mm, 5-12mm, 12-20mm*	132 - 250 kW

Note: A Vertical Shaft Impactor (VSI) is often chosen for the tertiary stage when superior cubical shape for manufactured sand and fine aggregates is the priority.

Supporting Equipment:

• Screens: Vibrating screens (2-3 decks) are critical at each stage. Primary screen sizes ~50-80mm; secondary screen sizes ~20-40mm; final product sizing screens with multiple decks.
• Feeders & Conveyors: Apron feeder for primary hopper; belt conveyors connecting all units with widths typically from 650mm to 800mm.
• Bins & Chutes: Surge bins between stages ensure smooth material flow and crusher choke-fed operation.

Real-World Project Case Study: Highway Construction in Southeast Asia
A project requiring over 2 million tons of high-quality aggregate for asphalt and concrete work utilized a tailored 3-stage 200 TPH plant.

• Challenge: Process hard granite to produce specified blends of sub-base (0-40mm), coarse aggregates (10-20mm, 20-30mm), and manufactured sand (0-5mm).
• Solution: The plant was configured as:
  1. Primary: A single-toggle jaw crusher.
  2. Secondary: A multi-cylinder hydraulic cone crusher set for a medium-fine setting.
  3. Tertiary: A VSI crusher fed with the secondary screen's mid-size fraction to produce in-spec cubical sand, reducing reliance on natural sand.
• Outcome: The plant consistently met the 200 TPH output target. The use of the VSI in the tertiary stage was crucial in achieving the required particle shape index for the highway's top asphalt layer, enhancing durability while optimizing yield from every ton of raw material.

---

Frequently Asked Questions (FAQ)

1. Why choose a 3-stage design over a simpler 2-stage layout for a 200 TPH plant?
A 2-stage plant (Jaw + Cone) is more economical but offers less control over product gradation and shape, especially for producing fine aggregates or sand. The third stage (tertiary cone or VSI) allows for closed-circuit grinding and precise shaping of particles. For hard rock where multiple spec products are needed simultaneously—particularly including high-quality manufactured sand—the 3-stage design provides superior flexibility, higher overall yield of saleable products, and better product shape.

2. Can this plant configuration produce manufactured sand?
Yes, effectively. This is one of its key advantages when equipped with either:

• A cone crusher in closed circuit with fine screens.
• Preferably,a Vertical Shaft Impactor (VSI) as the tertiary crusher.A VSI crushes via rock-on-rock impact,yielding optimally shaped,cubical fine aggregate that meets international standards(like IS:383)for plasteringandconcretework,solving both supplyandqualityissueswithnaturalsand.

3.What arethe main factors that can cause actual productionto fall belowthe designed 200 TPH?
Several operational factors can affect throughput:

• Feed Material Hardness:Harder rock(e.g.,granite)reducescrushersthroughputcomparedtosofterrock(e.g.,limestone).
• Feed Gradation & Fines Content:*Excessive finesor clayin feedmaterialcanchokecrushersandscreens.
• Desired Product Size:Producingmorefineaggregates(especially<10mm)slowsdownoveralltonnagecomparedtoproducingonlycoarseaggregates.
• Equipment Maintenance:Dullcrusherlinersorblinded screensignificantlyreduceefficiency.Regularmaintenanceisessentialtosustaindesigncapacity.

4.Is thisa portable/skid-mountedorstationaryplant?
A 200 TPH,3-stageplantis typicallyengineeredasastationaryorsemi-stationarysetupdue toitssizeandweight(primarycrushers,vibratingscreens,bulkysurgebins).However,mobiletrack-mountedplantscanbeconfiguredinthreecrushingstagesbutusuallyatalowerscale(up to~150TPH).Forlong-termprojects(>2years),astationaryplantoffersloweroperationalcostsandhigherstability.

5.Whatisthetypicalpowerrequirementfortheentireplant?
Totalinstalledpowerto driveallcrushers,screens,andconveyorsforahardrock(granite)applicationtypicallyrangesbetween550kWto700kW.Thisdoesnotincludepowerforauxiliarieslikedustsuppressionsystemsorelectrostaticprecipitators.Detailedengineeringalwaysrequiresaspecificloadcalculationbasedontheexactequipmentmodelsselected