500 TPH Basalt Crushing Plant Configuration & Flowchart

500 TPH Basalt Crushing Plant: Configuration & Process Flow Analysis

Reading Time: 3 mins

Basalt is the premier choice for premium aggregates used in high-end infrastructure (such as highways, high-speed railways, and bridge tunnels) due to its high strength, superior wear resistance, and strong corrosion resistance.

However, with a Mohs hardness of 6–7, basalt is highly abrasive and challenging to crush, placing extreme demands on equipment wear life.

The Solution: This article provides a field-proven, streamlined 500 TPH (tons per hour) basalt crushing plant configuration and process flow designed to ensure maximum uptime and eliminate operational bottlenecks in harsh rock conditions.


I. Core Configuration (Scientific Selection for Hard Rock)

This plant follows the core engineering logic of "efficient primary crushing, precise secondary/tertiary sizing, and high-quality shaping." The configuration focuses on maximizing wear-part longevity and output stability under heavy-duty conditions.

1. Complete Equipment List

Processing Stage

Equipment Name & Specification

Qty

Role & Edge in Hard Rock Application

Feeding

1350 Linear Vibrating Feeder

1 unit

Ensures continuous and uniform feeding. Features a pre-screening grizzly section to remove dirt and fines early on, drastically reducing unnecessary wear on downstream crushers.

Primary Crushing

CJ125 European Type Jaw Crusher

1 unit

Coarse crushing of large blast-muck basalt. Engineered with a deep crushing chamber and aggressive kinematics for massive crushing force while preventing material choking.

Secondary Crushing

500-Model Multi-Cylinder Hydraulic Cone Crusher

2 units

Parallel Circuit. Medium crushing. Utilizes inter-particle (lamination) crushing for high efficiency. Equipped with a hydraulic tramp-iron release system to protect the mantles from uncrushable objects.

Tertiary Crushing

500-Model Single-Cylinder Hydraulic Cone Crusher

2 units

Parallel Circuit. Fine crushing. Features an optimized chamber design with real-time hydraulic CSS (Closed Side Setting) adjustment to precisely control output sizes, relieving the burden on the shaper.

Shaping & Sand

1145 Vertical Shaft Impact Crusher (VSI)

2 units

Parallel Circuit. Shaping and cubical sand production. Employs the "rock-on-rock" crushing principle, maximizing cubical particle shape while heavy-duty premium alloy wear parts handle high abrasiveness.

Screening

2YK3070 / 4YK2470 Vibrating Screen

2 units

High-frequency accurate sizing. Ensures strict segregation of finished product sizes without cross-contamination. Oversized aggregates are automatically recirculated.

Auxiliary System

Belt Conveyors, Pulse Bag Dust Catchers, PLC System

1 lot

Features heavy-duty, tear-resistant belts. The entire line is automated via a centralized intelligent PLC system for real-time monitoring and safe remote operation.

2. Core Advantages of the Plant

Maximum Wear Resistance

All critical crushing zones utilize top-tier wear-resistant alloys (high-manganese and high-chromium). This significantly extends the replacement cycle of wear parts, solving the industry's biggest headache regarding basalt's high abrasiveness and lowering operational costs (OPEX).

Stable and Seamless Output

By utilizing parallel configurations for secondary crushing, tertiary crushing, and shaping stages, the line eliminates single-machine bottlenecks. The entire circuit runs smoothly like water—fluid traffic up front, zero bottlenecks behind.

Customized Environmental Compliance

The entire plant features a fully enclosed structure paired with an optimized pulse dust collection system, engineered completely according to the environmental regulations of the project's local jurisdiction.

II. Standardized Production Process Flow

This 500 TPH basalt line utilizes a highly efficient closed-circuit process loop. Experienced operators and buyers can grasp the system's efficiency at a single glance:

Plaintext

[ Raw Material ]
        │
        ▼
 1350 Linear Vibrating Feeder ──────(Pre-screening / Removes Dirt & Fines)
        │
        ▼
 CJ125 European Jaw Crusher ────────(Primary Coarse Crushing to ≤300mm)
        │
        ▼
 500-Model Multi-Cylinder Cone ─────(Parallel Medium Crushing to ≤50mm)
        │
        ▼
 500-Model Single-Cylinder Cone ────(Parallel Fine Crushing to ≤15mm) <───┐
        │                                                                │
        ▼                                                                │ (Oversize
 1145 VSI Crusher (立冲) ───────────(Rock-on-Rock Shaping/Sand Making)   │  Recirculation)
        │                                                                │
        ▼                                                                │
 2YK3070 / 4YK2470 Screens ──────────────────────────────────────────────┘
        │
        ├─► [Finished Aggregates: 20-40mm]
        ├─► [Finished Aggregates: 10-20mm]
        ├─► [Finished Aggregates: 5-10mm]
        └─► [Manufactured Sand: 0-5mm]

Technical Support & Consultation

By stripping away rigid, brand-specific model codes, this layout highlights pure engineering logic and optimal equipment balancing—providing international mining contractors and commercial quarry owners with a highly reliable, zero-headache hard rock solution.

Direct Corporate Contact Information

Official Business Email

ht6234nibin@gmail.com

Corporate Website

https://hengtai-global.com/

Instant WhatsApp Communication

+86 18288664797