一、Introduction to Stationary Stone Crusher Plants

A fixed stone crusher plant, also known as a stationary stone crushing plant, is a permanent installation designed to break down large stones into smaller, more manageable sizes. Its core function is to process various types of rocks and ores, including granite, limestone, and basalt, into aggregates of different specifications. These aggregates are essential raw materials for a wide range of industries.

In the mining industry, stationary stone crusher plants are used to extract valuable minerals from ore bodies. They crush the mined ore into smaller pieces, making it easier to transport and further process. In the construction sector, these plants play a crucial role in producing high – quality building aggregates for concrete production, road construction, and building foundations. They ensure that the aggregates meet the strict quality standards required for these applications.

MINGYUAN is a well – recognized brand in the field of stationary stone crusher plants. With years of experience, it has established a strong brand positioning as an innovative and reliable provider. The company’s products are known for their advanced technology, high efficiency, and durability. MINGYUAN’s industry influence is evident in its wide customer base, which includes large – scale mining companies and major construction projects. Its commitment to quality and customer service has made it a preferred choice for many businesses looking to set up stationary stone crusher plants.

二、Pre-Project Preparation

1．Market Research & Demand Analysis

Before setting up a stationary stone crusher plant, comprehensive market research and demand analysis are essential.

Region	Annual Aggregate Demand (tons)	Major Customer Types
Region A	500,000	Concrete mixing plants, small – scale road construction contractors
Region B	800,000	Large – scale infrastructure projects, high – end real – estate developers
Region C	300,000	Local building construction companies

The target market has a significant demand for aggregates. Concrete mixing plants need high – quality aggregates for producing concrete, while road construction contractors require specific – sized aggregates for road base and surface layers. The competition in the market varies by region. In some areas, large established players dominate, while in others, there is room for new entrants.

When it comes to investment, the expected return on investment can be high, given the consistent demand. However, risks such as fluctuating raw material prices and new market entrants should be considered.

2．Site Selection & Layout Design

Selecting the right site for a stationary stone crusher plant is crucial for its long – term success. There are several key indicators to consider during site selection.

• Raw Material Transportation Distance: A shorter distance between the raw material source and the plant reduces transportation costs. For example, if the quarry is far from the plant, the cost of hauling large stones will be substantial.
• Water and Electricity Supply: Adequate water is needed for dust suppression and equipment cooling, while a stable electricity supply is essential for the operation of crushers, conveyors, and other equipment.
• Terrain Slope: A relatively flat terrain is preferred as it simplifies the construction of the plant and the installation of equipment. A steep slope may require additional earth – moving work and can pose challenges for equipment operation.

Regarding the layout design of the plant, different functional areas should be clearly defined.

• Raw Material Area: This area should be close to the entrance for easy unloading of raw materials. It should have sufficient space for stockpiling large stones.
• Crushing Area: The crushing equipment should be arranged in a logical sequence to ensure a smooth flow of materials. There should be enough space for maintenance and operation.
• Finished Product Area: This area should be located near the exit for convenient loading of finished aggregates onto trucks for delivery.

3．Regulatory Compliance & Permits

To legally operate a stationary stone crusher plant, several core permits and approvals must be obtained.

• Environmental Impact Assessment: This involves evaluating the potential environmental impact of the plant, including dust emissions, noise pollution, and waste disposal. The assessment report needs to be submitted to the relevant environmental protection department for approval.
• Mining License: If the plant is directly connected to a quarry, a mining license is required. This license allows the extraction of raw materials from the designated area.
• Safety Production License: Ensuring the safety of workers and the operation of the plant, this license is issued after meeting strict safety standards and regulations.

MINGYUAN offers comprehensive compliance support services. The general approval process is as follows:

• Submit application materials to the relevant government departments.
• Wait for the departments to review and conduct on – site inspections.
• Make necessary modifications according to the feedback from the departments.
• Obtain the final permits after meeting all requirements.

三、Equipment Selection & Configuration

1．Core Components of a Stationary Plant

A stationary stone crusher plant consists of several key components, each with its own unique function and selection logic.

• Jaw Crusher: It is usually the primary crusher in a plant. Its main function is to break large stones into smaller pieces. The jaw crusher operates by compressing the material between two jaws. When selecting a jaw crusher, factors such as the maximum feed size and the required output size are considered. It is suitable for hard and abrasive materials like granite.
• Cone Crusher: As a secondary or tertiary crusher, the cone crusher further refines the crushed material. It works by squeezing the material between an eccentrically gyrating cone and a fixed wall. Cone crushers are ideal for medium – hard to hard materials such as basalt.
• Sand Making Machine: Also known as a vertical shaft impact crusher, it is used to produce high – quality artificial sand. It shapes the particles through high – speed impact. This machine is suitable for materials with relatively low hardness like limestone.
• Screening Machine: Its function is to separate the crushed materials into different sizes. By using different mesh sizes, it can classify the aggregates according to customer requirements.

Equipment Model	Processing Capacity (tons/hour)	Energy Consumption (kWh/ton)	Suitable Materials
MY – J100	50 – 150	0.8 – 1.2	Granite, basalt
MY – C200	80 – 200	0.6 – 1.0	Limestone, sandstone
MY – S300	30 – 100	1.0 – 1.5	Limestone
MY – SC400	100 – 300	0.5 – 0.8	Various aggregates

2．MINGYUAN’s Equipment Advantages

MINGYUAN’s stationary stone crusher plant equipment comes with several notable technical advantages.

The company’s equipment is equipped with an intelligent control system. This system can monitor the operation status of the equipment in real – time, including parameters such as temperature, pressure, and vibration. For example, if the temperature of a crusher exceeds the normal range, the system will automatically issue an alarm and adjust the operation mode to prevent equipment damage.

In terms of materials, MINGYUAN uses high – quality wear – resistant materials. The crushing chamber of the crusher is made of special alloy steel, which can withstand the impact and abrasion of hard materials for a long time. This significantly extends the service life of the equipment.

The low – noise design is another highlight. Through advanced noise – reduction technology, the noise generated during the operation of the equipment is effectively reduced. For instance, the noise level of MINGYUAN’s crushers is generally 10 – 15 decibels lower than that of similar products in the market.

In addition to the excellent product performance, MINGYUAN also provides comprehensive after – sales services. The company offers on – site installation guidance to ensure that the equipment is installed correctly. And it has a large inventory of spare parts, which can be quickly delivered to customers when needed, minimizing the downtime of the equipment.

3．Customized Configuration Solutions

MINGYUAN provides customized configuration solutions based on the characteristics of raw materials and production capacity requirements.

• For Hard and Dry Raw Materials with High – Capacity Demand (e.g., 500 tons/hour): A combination of a large – scale jaw crusher, a multi – stage cone crusher, and a high – efficiency screening machine can be used. The estimated total investment for this configuration is approximately $800,000.
• For Medium – Hard and Moist Raw Materials with Medium – Capacity Demand (e.g., 200 tons/hour): A medium – sized jaw crusher, a sand – making machine, and a medium – sized screening machine are recommended. The total investment for this configuration is about $350,000.
• For Soft and Dry Raw Materials with Low – Capacity Demand (e.g., 100 tons/hour): A small – sized jaw crusher and a simple screening machine can meet the needs. The estimated total investment is around $150,000.

Configuration Type	Equipment List	Total Investment Estimate
High – capacity, hard raw materials	Large – scale jaw crusher, multi – stage cone crusher, high – efficiency screening machine	$800,000
Medium – capacity, medium – hard raw materials	Medium – sized jaw crusher, sand – making machine, medium – sized screening machine	$350,000
Low – capacity, soft raw materials	Small – sized jaw crusher, simple screening machine	$150,000

四、Installation & Commissioning Process

1．Foundation Construction

The construction of the equipment foundation is a critical step in setting up a stationary stone crusher plant. Strict construction standards must be adhered to ensure the stability and safety of the equipment.

Concrete strength is a key factor. Generally, the concrete for the foundation should have a compressive strength of at least C25 – C30 according to engineering specifications. This high – strength concrete can withstand the heavy load and vibration generated by the crushers and other equipment during operation.

The accuracy of embedded bolts is also crucial. The position deviation of embedded bolts should be controlled within a very small range, usually within ± 2mm in the horizontal direction and ± 5mm in the vertical direction. This ensures that the equipment can be accurately installed on the foundation.

Geological surveys play an important role in foundation design. If the geological conditions are poor, such as soft soil or uneven ground, additional foundation treatment measures may be required. For example, pile foundations may need to be used to improve the bearing capacity of the foundation. A detailed geological survey report can provide valuable information for engineers to design a suitable foundation structure.

2．On – Site Equipment Installation

MINGYUAN follows a well – defined installation process to ensure the proper setup of the stationary stone crusher plant.

1. Equipment Positioning: First, mark the installation positions of each equipment on the foundation according to the layout design. Use precise measuring tools to ensure the correct alignment of crushers, conveyors, and other components. For example, the crushers should be placed in a straight line to ensure the smooth flow of materials.
2. Component Assembly: Assemble the main components of the equipment. This includes installing the crushing chambers, motors, and transmission systems. During assembly, follow the manufacturer’s instructions carefully. For instance, when installing the crusher’s crushing chamber, ensure that all bolts are tightened to the specified torque to prevent loosening during operation.
3. Calibration and Debugging: After assembly, calibrate the equipment to ensure its normal operation. Check the alignment of rotating parts, the tension of belts, and the clearance between moving components. Then, conduct a trial run of the equipment at a low speed. During the trial run, monitor the operation parameters such as temperature, vibration, and noise. Make necessary adjustments to ensure that the equipment operates stably.

The installation team should have relevant professional qualifications. They should be familiar with the structure and operation principles of stone crusher plants and have rich installation experience. MINGYUAN requires its installation teams to have certificates in mechanical installation and electrical installation to ensure the quality of installation.

3．Testing & Performance Validation

After the on – site equipment installation, comprehensive testing and performance validation are necessary to ensure that the stationary stone crusher plant meets the design requirements.

| Test Item | Standard Requirement | Actual Measurement | Result |

| —- | —- | —- | —- |

| Processing Capacity | 200 tons/hour | 195 tons/hour | Pass (within acceptable error range) |

| Finished Product Grain Shape | Cubical shape, less than 15% needle – shaped particles | 12% needle – shaped particles | Pass |

| Energy Consumption | 0.8 kWh/ton | 0.82 kWh/ton | Pass (within acceptable error range) |

The processing capacity is a key parameter. The plant should be able to achieve the designed hourly output. By continuously feeding raw materials and measuring the output of finished products, the actual processing capacity can be determined.

The grain shape of the finished product is also important. High – quality aggregates should have a cubical shape, which is beneficial for concrete production and road construction. Use a sieve analysis and visual inspection to evaluate the grain shape.

Energy consumption is another aspect to be verified. Monitor the power consumption of the crushers, conveyors, and other equipment during operation. Compare the actual energy consumption with the design value to ensure energy – efficient operation.

During the debugging process, some common problems may occur. For example, abnormal vibration may be caused by unbalanced rotating parts or loose bolts. In this case, check and balance the rotating parts and tighten the bolts. Blockages may happen in the feeding system or the crushing chamber. Clear the blockages and adjust the feeding speed to prevent recurrence. Record these problems and their solutions in a test report for future reference.

五、Operational Management & Maintenance

1．Staff Training Program

MINGYUAN offers a comprehensive staff training program to ensure the efficient and safe operation of stationary stone crusher plants.

• Equipment Operation Training: This module teaches operators how to start, stop, and adjust the various components of the plant, such as crushers, conveyors, and screening machines. They learn to optimize the production process for different raw materials and output requirements.
• Fault Diagnosis and Troubleshooting: Trainees are educated on identifying common equipment failures, such as abnormal vibrations, unusual noises, and power malfunctions. They are trained to take immediate corrective actions to minimize downtime.
• Safety Regulations: This part emphasizes the importance of safety in the workplace. Operators learn about the proper use of personal protective equipment (PPE), emergency procedures, and safety protocols to prevent accidents.

The training is delivered through a combination of on – site practical training and online courses. On – site training allows trainees to gain hands – on experience, while online courses provide flexibility for continuous learning.

2．Routine Maintenance Plan

Regular maintenance is crucial for the long – term performance of a stationary stone crusher plant. MINGYUAN recommends the following maintenance schedule:

• Daily Inspection: Operators should conduct a quick check of the equipment before starting work. This includes inspecting the lubrication levels, checking for loose bolts, and examining the conveyor belts for wear.
• Monthly Maintenance: A more in – depth monthly maintenance involves cleaning the equipment, checking the alignment of rotating parts, and testing the safety devices. Lubrication of critical components should also be carried out according to the manufacturer’s recommendations.
• Annual Overhaul: Once a year, a comprehensive overhaul is necessary. This includes disassembling the major components for a thorough inspection, replacing worn – out parts, and performing a complete calibration of the equipment.

MINGYUAN’s original spare parts are of high quality and are specifically designed for its equipment. Using these parts ensures optimal performance and extends the service life of the plant. The company maintains a large inventory of spare parts, enabling quick replacement when needed.

3．Safety & Environmental Management

Safety and environmental protection are top priorities in the operation of a stationary stone crusher plant.

• Safety Regulations: All employees must wear appropriate PPE, such as helmets, safety glasses, and earplugs. The plant should be equipped with safety guards and emergency stop buttons on all moving equipment. Regular emergency drills should be conducted to ensure that employees know how to respond in case of an accident.
• Environmental Protection Measures: Dust is a major environmental concern in stone crushing plants. MINGYUAN provides dust collection systems, such as bag filters and wet dust suppression systems, to reduce dust emissions. Noise pollution is also addressed through the use of noise – reducing enclosures around the crushers and other noisy equipment.

MINGYUAN’s environmental protection equipment is designed to meet strict environmental standards. The company offers customized solutions based on the specific requirements of each plant, ensuring that the operation is both safe and environmentally friendly.

六、MINGYUAN’s Success Case Study

1．Project Background & Objectives

In a recent project, MINGYUAN collaborated with a well – known construction company aiming to establish a stationary stone crusher plant. The raw materials for this project were mainly granite, a hard and abrasive rock commonly used in high – quality construction aggregates. The design capacity of the plant was set at 300 tons per hour to meet the large – scale demand of the customer’s construction projects.

The customer required a plant that could produce aggregates with strict quality standards, including a cubical shape and specific particle size distribution, suitable for high – end concrete production. However, the project faced several challenges. The site had limited space, which made the layout design and equipment installation more difficult. Additionally, there was a tight construction schedule due to the upcoming peak construction season. MINGYUAN had to find solutions to these problems while ensuring the plant met all the technical requirements.

2．Implementation Process Highlights

1. Equipment Configuration: Based on the characteristics of granite and the required production capacity, MINGYUAN selected a combination of a large – scale jaw crusher for primary crushing, followed by a cone crusher for secondary crushing, and a high – efficiency screening machine. This configuration was optimized to ensure high – quality aggregate production and efficient operation.
2. Site Adaptation: Considering the limited site space, MINGYUAN’s engineers redesigned the plant layout. They used a more compact arrangement of equipment while still maintaining proper functionality and safety clearances.
3. Installation and Commissioning: The installation team from MINGYUAN quickly mobilized to the site. They first completed the foundation construction according to strict standards. Then, they installed the equipment precisely as per the layout design. During the commissioning process, they conducted multiple rounds of calibration and adjustment to ensure stable operation.
4. Customer Collaboration: Throughout the project, MINGYUAN maintained close communication with the customer. They listened to the customer’s suggestions and feedback in a timely manner, and made necessary adjustments to meet the customer’s needs.

3．Post – Operation Results & Feedback

After the plant was put into operation, it achieved remarkable results. The production capacity reached 305 tons per hour, with a capacity compliance rate of over 100%, far exceeding the design requirement of 300 tons per hour. In terms of energy consumption, the actual energy consumption was 0.75 kWh/ton, which was 12.5% lower than the design value of 0.86 kWh/ton, indicating significant energy – saving effects.

The customer was highly satisfied with the performance of the plant. The high – quality aggregates produced by the plant fully met the requirements of their high – end construction projects, and the stable operation of the plant ensured a continuous supply of materials. The customer’s satisfaction rate reached 95%, as indicated by a post – project survey.

This project also provided strong validation for MINGYUAN’s technology. The successful operation of the plant demonstrated the effectiveness of MINGYUAN’s equipment configuration, intelligent control system, and low – noise and energy – saving design. It further enhanced MINGYUAN’s reputation in the market and provided valuable experience for future projects.