Project Overview

A mining owner in Java, Indonesia, possessing abundant high-quality limestone reserves, invested in a high-performance crushing line to meet growing demand for construction aggregates and cement raw materials while enhancing product value.

Production Line Configuration

The line adopts a classic “Jaw Crusher + Impact Crusher” two-stage crushing system with efficient screening and feeding equipment:

  1. Vibrating Feeder
    • Model: GZD-1500×6000 or equivalent
    • Role: Uniformly feeds limestone (≤750 mm) into the jaw crusher, preventing blockages.
    • Feature: Grizzly screen pre-removes soil/fines, boosting primary crushing efficiency.
  2. Jaw Crusher (Primary Crushing)
    • Model: PE-1200×1500
    • Role: Reduces limestone to ≤200 mm.
    • Feature: High crushing ratio, robust structure, and 500 t/h capacity.
  3. Impact Crushers (Secondary Crushing)
    • Model: Two × PF-1315
    • Role: Further crushes material to ≤31.5 mm using high-speed blow bars.
    • Feature: Produces cubical aggregates ideal for premium applications.
  4. Circular Vibrating Screens
    • Model: Two × 3YA-2460
    • Role: Screens crushed material into 0–5 mm, 5–10 mm, 10–20 mm, and 20–31.5 mm grades.
    • Feature: Multi-layer design separates multiple specs; oversized material (>31.5 mm) returns to impact crushers.
  5. Belt Conveyors
    • Role: Connects equipment (e.g., B1000/B1200 widths) for seamless material flow.

Process Flow

  1. Feeding: Excavator loads raw limestone into silo → Vibrating feeder delivers material uniformly.
  2. Primary Crushing: Jaw crusher reduces size to ≤200 mm.
  3. Transfer: Conveyor 1 moves crushed material to buffer silo/secondary stage.
  4. Secondary Crushing: Impact crushers process material to ≤31.5 mm.
  5. Screening: Conveyor 2 transports material to vibrating screens.
  6. Grading & Recycling:
    • Qualified products (0–5 mm, 5–10 mm, etc.) discharge to stockpiles.
    • Oversized material returns via conveyor 3 for re-crushing (closed loop).
  7. Storage: Finished aggregates stored in designated yards.

Key Advantages

  • High ROI: In-house production cuts long-term costs and boosts profits.
  • Production Flexibility: Adjustable screen meshes adapt to market demands.
  • Superior Particle Shape: “Jaw + Impact” combo ensures cubical aggregates.
  • Reliable Operation: Proven equipment minimizes downtime.

Client Value

This customized 500 t/h limestone crushing line integrates efficiency, eco-friendliness, and intelligence, empowering the owner to maximize resource value and dominate Indonesia’s aggregate market.