Project Introduction:

The Philippines’ “Build! Build! Build!” program is entering an advanced phase. Major infrastructure projects, including those in Metro Manila, the Clark Economic Zone, the Subic Bay Free Port, and the Central Luzon Expressway network, are fully underway, leading to a sustained surge in demand for high-quality, large-scale aggregates. In this context, a quarry owner located in the limestone-rich region of Central Luzon, Philippines, invested in establishing a 450 metric tons per hour (TPH) limestone crushing and manufactured sand production line. The project utilizes an advanced “Three-Stage Crushing + High-Efficiency Screening” process. Through the synergistic operation of a Jaw Crusher, a Single-Cylinder Hydraulic Cone Crusher, and a Symons Cone Crusher, the line ensures the output of aggregates with superior particle shape, continuous gradation, and stable quality. The facility aims to become the highest-standard manufactured sand production base in the Northern and Central Philippines, providing a solid material foundation for the nation’s infrastructure development.

Core Equipment and Process Flow

To meet the client’s stringent requirements for high output, low flakiness and elongation, and strict gradation control, the project innovatively adopted a “Coarse Crushing → Medium Crushing → Fine Crushing → Screening” three-stage crushing process. This design maximizes the optimization of the material stage-by-stage, significantly enhancing finished product quality and system stability.

Main Equipment Configuration:

• Jaw Crusher (Heavy-duty PE Series):
  • Serves as the Primary Coarse Crushing unit, responsible for processing raw limestone with a maximum feed size of up to 800 mm.
  • Designed with a high crushing ratio, it reduces large rocks to the 150-200 mm range, ensuring uniform feeding and protecting downstream equipment.
  • Equipped with a heavy-duty Vibrating Feeder that includes a pre-screening function to initially remove soil and fines.
• Single-Cylinder Hydraulic Cone Crusher (HST Series):
  • The core unit for Secondary Medium Crushing, performing highly efficient crushing on the material pre-processed by the jaw crusher.
  • Features hydraulic discharge opening adjustment, high automation, stable operation, and controls the output size to 40-60 mm.
  • The laminated crushing principle provides initial shaping of the material, serving as an ideal feed for the tertiary fine crushing stage.
• Symons Cone Crusher (Spring-type Standard/Short Head):
  • Serves as the Tertiary Fine Crushing and Final Shaping unit, undertaking the task of precision crushing.
  • Utilizes the mature spring-loaded safety system, providing strong tramp iron release capability, which is particularly suitable for raw materials in the Philippines that may contain impurities due to complex geological conditions.
  • Produces fine output size (0-35 mm), with significantly reduced flakiness and elongation index (＜8%). The cubic particle shape greatly improves concrete workability and strength.
• Large Multi-Layer Vibrating Screen (3YK3073 or Larger Model):
  • Configured with three or four screen decks to efficiently classify the material from the Symons cone crusher, producing:
    • 0-5 mm: Manufactured sand raw material or finished manufactured sand (after washing);
    • 5-10 mm, 10-20 mm, 20-31.5 mm: Multiple specifications of crushed stone aggregate, meeting various concrete grade requirements.
  • Features a closed-circuit design: Oversized material is returned to the Symons cone crusher for re-crushing, ensuring consistent finished product size.

Process Flow Summary:

• Coarse Crushing: Raw material is fed by the vibrating feeder into the Jaw Crusher for primary crushing.
• Medium Crushing: Coarse-crushed material is conveyed to the Single-Cylinder Hydraulic Cone Crusher for secondary crushing.
• Fine Crushing/Shaping: The medium-crushed product enters the Symons Cone Crusher for precision crushing and final shaping.
• Screening: The crushed material is classified by the Multi-Layer Vibrating Screen.
• Products: Qualified finished products are stored by size; fines enter the sand-making system.
• Supply: All aggregate products are supplied to local batching plants, precast component factories, and national infrastructure projects.

System Features:

• Three-Stage Crushing for Superior Quality: Sequential crushing ensures rounded particle shape and reasonable gradation, making it ideal for high-grade concrete and asphalt pavements.
• High Capacity and Reliability: Designed for 450 TPH, with an annual output exceeding 3 million tons; strong system stability through the dual-cone synergy.
• Strong Adaptability: The Symons cone crusher handles raw materials well, suitable for the variable geological conditions in the Philippines.

Intelligent and Eco-Friendly: Equipped with a PLC control system.

Positive Impact on the Local Philippine Community

1. • Ensuring Material Supply for “Build! Build! Build!”：
     The project directly provides stable, high-quality aggregates for key projects like the Manila-Clark Railway, Subic-Clark Expressway, and the New Kaliwa Dam, alleviating the “sand and stone shortage” and safeguarding project schedules and quality.
   • Driving Technological Upgrade in the Philippine Aggregate Industry:
     The introduction of the advanced three-stage crushing process breaks away from the traditional “Jaw + Impact Crusher” or “Single Cone” model, setting a new industry benchmark and guiding the Philippine aggregate sector towards high-end, intensive development.
   • Reducing Illegal Quarrying and Protecting the Environment:
     The large-scale production of manufactured sand substitutes natural river sand and sea sand, effectively curbing illegal quarrying activities in river basins like the Pasig and Pampanga Rivers, preventing riverbed erosion, bridge foundation exposure, and coastline erosion, thus protecting the ecological security of Luzon.
   • Creating Jobs and Promoting Local Economy:
     The project directly creates 120+ technical jobs and drives the development of supporting industries such as transportation, power, and equipment maintenance, providing stable income for local residents and aiding rural revitalization.
   • Improving Domestic Building Material Quality and Competitiveness:
     High-quality aggregates enhance the overall quality of Philippine concrete and precast components, strengthening the competitiveness of domestic construction material enterprises in the international market and reducing reliance on imported materials.
   • Supporting Sustainable Urban Development:
     Premium aggregates extend the service life of buildings, reducing resource waste and carbon emissions from maintenance and reconstruction, helping the Philippines achieve green building and sustainable development goals.