This stationary modular limestone crushing and screening production line has a capacity of 1,000–1,300 tons per hour, with a peak capacity of 1,400 tons per hour. It features a total installed power of approximately 1,500 kW and is designed to process high-hardness raw materials such as limestone and gypsum. Suitable for large aggregate supply bases, ready-mix concrete plants, asphalt pavement, and railway ballast production in countries such as Saudi Arabia, the United Arab Emirates, and Oman. Designed for continuous operation of over 20 hours per day and capable of withstanding high-temperature environments exceeding 45°C.
Key Challenges: Traditional lines consume over 0.85 kWh of electricity per ton of material, resulting in high costs; jaw and hammer plates require replacement every 2–3 months, leading to frequent downtime; lack of intelligent early warning systems relies on manual operation; long spare parts lead times in the Middle East disrupt continuous production.
Solution Highlights: Power consumption per ton of material does not exceed 0.38 kWh, achieving 55% energy savings compared to traditional lines; core wear-resistant components made of NM650 ultra-high-strength steel (620-650 HBW) extend service life by 4.5 times; compatible with the Mine AI management platform, enabling one-click intelligent production adjustment within 3 days; Modular design reduces costs by 15%-20% compared to custom solutions, with a 30-day shorter delivery cycle.
Limestone Crushing Plant Process Flow
Dump truck unloading → GZD2200×9000 heavy-duty vibrating feeder (1500 t/h, double-eccentric shaft excitation) → PE1800×2200 jaw crusher for primary crushing (Feed opening 1500 mm, motor 400 kW, compressive strength ≤320 MPa) → PF2225 impact crusher for medium and fine crushing (rotor diameter 2200 mm, capacity 1100–1400 t/h) → 3YK3675 intelligent circular vibrating screen for grading (screen area ≥21 m², efficiency 92%, optional fourth layer) → Oversize material is returned to the impact crusher in a closed-circuit system, while qualified products are sent to the finished product stockpile. The finished product has a flake and needle content below 6% and a powder content not exceeding 3%, meeting the high-standard aggregate specifications for the Middle East. The entire line operates with variable-frequency synchronized control; feeders, crushers, and screens automatically adjust speed based on load to eliminate idling, and are equipped with dust collection and spray dust suppression systems.
Limestone Crushing Plant EPC Service Scope
Design: Customized 3D layout based on core compressive strength and abrasion index; optimized belt angles and elevation differences at transfer points to reduce dust generation and energy consumption
Equipment Manufacturing: NM650 wear-resistant steel plates + Cr26 ceramic-embedded high-manganese steel castings; motors and bearings designed for 55°C ambient temperature with Class F insulation and automatic lubrication; control cabinets equipped with industrial air conditioning
Installation and Commissioning: On-site engineers supervise foundation work and installation; procedures include single-unit no-load testing → system no-load testing → trial operation with material → 72-hour production capacity acceptance testing
Operation and Maintenance Management: Real-time cloud-based monitoring of vibration, temperature, and current, accessible via mobile devices; quarterly on-site inspections to assess wear part life and belt misalignment; 24-hour emergency spare parts shipping from warehouses in Dubai and Riyadh; 7-day on-site training covering central control operation, fault diagnosis, and hammer plate replacement
Limestone Crushing Plant Project Case Study
Limestone Project for a Major Building Materials Group in Riyadh, Saudi Arabia: Raw material compressive strength 120–150 MPa, silica content 8%–12%. Designed capacity 1,100 t/h, actual stable operation at 1,250 t/h. 8,000 hours of continuous operation without downtime due to wear part failures; measured power consumption of 0.36 kWh per ton of material; annual electricity savings of approximately 13 million kWh (equivalent to $570,000) based on 5,800 operating hours; finished product complies with Saudi SASO 2829:2020 standards, with 5.2% needle and flake content and 2.8% powder content. The service life of wear parts is three times that of the previously used European brand, and AI early warning alerts users to replace liners one week in advance. The project was completed from contract signing to commissioning in 105 days, 40 days ahead of schedule.
Limestone Crushing Plant FAQ
1. Will the equipment frequently overheat and shut down during the local summer heat of 50°C?
No. All motors feature Class F insulation rated for 155°C. Main bearings are equipped with automatic lubrication and forced air cooling, and control cabinets are fitted with industrial air conditioning. Limestone processing plant for the Middle Eastern Lines of the same model have been operating stably in the UAE and Qatar for over three years without any shutdowns due to high temperatures.
2. Is it difficult to replace NM650 wear-resistant steel plates on-site?
We provide prefabricated, modular, bolt-fastened wear liners that eliminate the need for on-site welding custom aggregate processing solution. An engineer will be on-site for the first replacement to guide the use of a torque wrench; replacing a set of jaw plates takes approximately 8 hours.
3. Will high-clay limestone clog the screen mesh?
A double-layer bar vibrating screen can be installed at the feed end to pre-screen out soil. Screen options include polyurethane anti-clogging plates combined with a high-pressure spray system. Please provide data on the raw material’s moisture content and clay content, and we will customize a tailored solution.
5. Does the control system support Arabic?
The central control touchscreen supports one-click switching between Arabic, English, and Chinese. Remote monitoring data can be deployed on a local intranet server or an Alibaba Cloud node in Saudi Arabia, complying with local data sovereignty requirements.Impact Crusher Aggregate Production Line
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