200t/h Limestone Crushing Plant in Indonesia

This case study details the successful implementation of a 200t/h limestone crushing plant in Indonesia, engineered and supplied by SBM. Designed to meet the robust demands of the local construction and infrastructure sector, the plant utilizes a streamlined configuration of PE Series Jaw Crusher and CS Series Cone Crusher. This project exemplifies how tailored equipment selection and robust engineering can deliver high-capacity, consistent output for critical raw material production, supporting Indonesia's rapid development.

1. Project Background and Market Demand

Indonesia is currently undergoing a massive surge in infrastructure development, ranging from the construction of the New Capital City to the expansion of provincial road networks. Limestone, as a primary raw material for high-quality aggregate and cement production, is in high demand.

For Indonesian quarry operators, the challenge lies in balancing high throughput with product shape quality and low operational costs. This 200t/h plant was designed specifically to address these needs, providing a robust solution for medium-hard limestone processing.

2. Raw Material and Requirements

• Material: Limestone (Medium hardness, low abrasiveness)
• Input Size: mm
• Output Size: 0-5mm, 5-10mm, 10-20mm, 20-30mm (Adjustable)
• Capacity: 200 Tons Per Hour (t/h)
• Application: Road construction, high-grade concrete, and building materials.

3. Core Equipment Configuration

After a thorough analysis of the feed material characteristics and the client's production goals, SBM engineers proposed a classic yet highly efficient two-stage crushing circuit. This configuration is renowned for its balance of high throughput, excellent product shape control, and operational simplicity.

Primary Crushing: SBM PE Jaw Crusher

Function: As the primary crusher, its role is to accept the run-of-quarry limestone (with a maximum feed size typically up to 500-600mm) and perform the initial, coarse reduction.

Key Features & Benefits:

• Robust Construction: The crusher's frame, swing jaw, and eccentric shaft are built from high-quality cast steel, ensuring longevity under the high-stress conditions of primary crushing.
• Deep Crushing Chamber & High Reduction Ratio: This design allows for larger feed size and produces a consistent output of 150-200mm, optimally preparing the material for secondary crushing.
• Reliability: Known for minimal maintenance requirements and ease of wear part replacement, a critical factor for maintaining uptime in remote quarry locations.

Secondary Crushing: SBM CS Cone Crusher

Function: It receives the primary-crushed material and further reduces it to the final product sizes (e.g., 0-5mm, 5-10mm, 10-20mm, 20-31.5mm). The cone crusher is essential for achieving the desired particle shape and gradation.

Key Features & Benefits:

• Layered Crushing Principle: The CS Series' unique crushing cavity design and high rotational speed enable inter-particle crushing. This results in a higher yield of perfectly cubic end products, which are superior for high-strength concrete.
• Hydraulic Control System: Allows for easy adjustment of the discharge setting (CSS) to fine-tune product size without stopping the crusher. It also provides automatic overload protection, safeguarding the machine from tramp metal or uncrushable material.
• Energy Efficiency: Advanced crushing dynamics translate to lower power consumption per ton of output compared to older cone crusher designs.

Supporting System: The plant is completed with a SBM vibrating feeder for even material distribution, vibrating screens for precise product sizing, and a comprehensive belt conveyor system. Dust suppression units are integrated at key transfer points to ensure environmental compliance.

4. Process Flow Description

The production line follows a streamlined, automated logic:

• 1. Feeding:  Raw limestone is fed into a Vibrating Feeder. Fines are bypassed to prevent unnecessary wear on the primary crusher.
• 2. Primary Stage:  The PE Jaw Crusher performs the initial break.
• 3. Transfer:  Material is transported via belt conveyor to the CS Cone Crusher.
• 4. Secondary Stage:  The Cone Crusher reduces the material to the target sizes.
• 5. Screening:  A Vibrating Screen (usually 3-deck or 4-deck) separates the material into the four required fractions.
• 6. Recirculation:  Any oversize material (+30mm) is returned to the Cone Crusher for a closed-circuit re-crushing, ensuring 100% product compliance.

5. Performance Metrics and Operational Outcomes

Since commissioning, the plant has consistently met and exceeded performance expectations:

• Capacity: Steadily achieves and often surpasses the designed 200 t/h output, with product yield optimized for the local market's most in-demand sizes.
• Product Quality: The combination of the jaw crusher's coarse reduction and the cone crusher's fine, layered crushing produces aggregates with excellent particle shape (high cubicity) and consistent gradation. This meets stringent Indonesian national standards (SNI) for concrete and road construction aggregates.
• Uptime & Reliability: The robust design of SBM equipment and the simplicity of the two-stage layout have resulted in operational availability exceeding 92%. Planned maintenance is straightforward, with critical wear parts like jaw plates and cone mantles easily accessible and replaceable.
• Economic Impact: For the client, the plant has enabled a significant increase in market share, allowing them to secure contracts for major infrastructure projects. The efficiency of the setup has also translated to a lower cost per ton produced, enhancing profitability.

6. Why This Configuration for Indonesia?

I. Climate Resilience

Indonesia’s high humidity and tropical rainfall can make limestone "sticky." The combination of the PE Jaw and CS Cone handles high-moisture content better than impact crushers, which are prone to clogging in the crushing chamber during the monsoon season.

II. Energy Efficiency

The CS Cone Crusher is designed for high efficiency with low power consumption per ton of produced material. In a market where electricity or diesel costs are a major factor in the "Cost Per Ton," this efficiency provides a competitive edge.

III. Product Quality

Indonesian national standards (SNI) for road aggregates are increasingly strict regarding the "flakiness" of the stones. The CS Cone Crusher ensures a high-quality, cubical aggregate that meets all local building codes for high-strength concrete.

The 200 t/h limestone crushing plant in Indonesia stands as a testament to effective engineering solutions in the aggregate production industry. By deploying a optimized circuit centered on the reliable SBM PE Jaw Crusher and CS Cone Crusher, the client has gained a durable, high-performance asset that is directly contributing to Indonesia's infrastructure development.