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This production line has a design capacity of 200 tons per hour, adopting a streamlined short-process configuration with fewer main equipment units, low initial investment, and simple operation and maintenance. It simultaneously produces calcium carbonate powder, manufactured sand, and multi-specification aggregates, meeting diverse market demands in building materials, chemical fillers, desulfurization agents, and feed additives.
The line has completed environmental upgrades, with fully enclosed structures throughout combined with a high-efficiency baghouse dust collection system, achieving dust-free operation at the production site with emission concentrations meeting national and international environmental standards. Under optimized conditions, actual capacity can exceed 200 tons per hour, helping customers achieve production targets ahead of schedule.
Core Pain Points: First, small-to-medium calcium carbonate mines have limited investment budgets, and traditional multi-stage lines require numerous equipment units, large land areas, and long payback periods; second, calcium carbonate powder production generates large dust volumes, with non-compliance risks of production suspension and rectification; third, low-capacity lines have high unit operating costs, with per-ton energy consumption and labor costs remaining persistently high.
Solution Highlights: The PCZ heavy hammer crusher serves as the primary crushing equipment, completing both coarse and medium crushing in a single machine – streamlining the process and reducing equipment count by over 50%. The large reduction ratio and high one-pass formation rate reduce per-ton energy consumption by approximately 25% compared to traditional jaw + impact crusher solutions. The full line is equipped with pulse-jet baghouse dust collectors and fully enclosed casings, keeping workshop dust concentration below 10mg/m³. The screening configuration is flexible, allowing adjustment of powder, sand, and aggregate output ratios as needed.
Stage 1 – Feeding: Calcium carbonate run-of-mine is evenly fed into the primary crusher by a vibrating feeder, with variable frequency control of feed rate to match downstream processing capacity.
Stage 2 – Primary Crushing and Shaping: The PCZ heavy hammer crusher reduces feed ≤600mm to below 50mm in a single pass, utilizing high-speed hammer impact principles for high reduction ratio without the need for a preceding jaw crusher.
Stage 3 – Classification Screening: Crushed material enters a multi-deck circular vibrating screen, where it is separated by particle size into powder (<5mm), manufactured sand (0-5mm), small aggregate (5-15mm), and coarse aggregate (15-30mm). Oversized material automatically returns to the hammer crusher for recirculation.
Stage 4 – Dust Collection and Recovery: All dust-generating points at crushing, screening, and transfer stations are equipped with collection hoods, connected via ducting to a pulse-jet baghouse dust collector. Collected powder is recovered as finished product, with clean air discharged in compliance with standards.
Stage 5 – Conveying and Storage: Finished products of each grade are conveyed by sealed belt conveyors to corresponding silos, equipped with automatic material distribution and weighing/loading systems.
Scheme Design: Based on mine reserves, calcium carbonate grade (CaCO3 content), target product structure, and investment budget, we customize crusher selection and dust collection solutions, providing 3D line layout and ROI calculations.
Equipment Manufacturing: Core equipment (heavy hammer crusher, vibrating screens, dust collectors, conveyors) are self-developed and self-manufactured, with each machine tested and inspected before delivery, accompanied by performance test reports.
Installation and Commissioning: Engineers provide on-site guidance for civil works and equipment installation, conducting integrated commissioning until the line achieves 72 hours of full-load compliance, while simultaneously completing operator training.
Operation and Maintenance Outsourcing: Optional O&M packages covering regular inspections, spare parts supply, dust collection system maintenance, and remote technical support.
Malaysia Perak Calcium Carbonate Powder and Aggregate Processing Project. The customer is a local calcium carbonate powder processing company whose mine previously focused on lump ore exports with low added value and profit margins. Zhongyu Dingli designed and delivered one 200-ton/hour calcium carbonate crushing and powder production line.
Since commissioning, actual capacity has reached 220 tons/hour, with powder (200-325 mesh) accounting for approximately 35% and manufactured sand and aggregates approximately 65%. After the fully enclosed dust collection system was put into operation, workshop dust concentration fell below 8mg/m³, passing Malaysia's DOE environmental acceptance on the first attempt. Compared to the previous outsourcing model, the customer's comprehensive production costs decreased by approximately 30%.
Client Feedback: "Zhongyu Dingli's line investment was within our budget. From installation to commissioning took only 4 months, and the dust collection performance far exceeded expectations – environmental approval passed on the first try. The line has run stably ever since, and we are very satisfied with the ROI."
Q1: What is the approximate total investment for a 200TPH line, and what is the payback period?
A: Depending on configuration, main equipment investment is typically within a reasonable range, with full EPC investment varying based on site and auxiliary facilities calcium carbonate production system. Based on the Malaysia case reference, under normal calcium carbonate powder and aggregate market conditions, the payback period is approximately 2-3 years.
Q2: Can the line simultaneously produce powder of different fineness grades?
A: The base version produces <5mm powder-sand mixture. For 200-800 mesh fine powder, additional Raymond mills or vertical roller mills can be added to form a grinding and classification system, calcium carbonate manufacturing line enabling on-demand allocation of powder, sand, and aggregate.
Q3: Is the dust collection system easy to maintain? How long do filter bags last?
A: The pulse-jet baghouse dust collector uses PLC automatic cleaning with simple maintenance procedures. Under calcium carbonate operating conditions, filter bag service life is approximately 12-18 months, with low replacement costs and the ability to replace bags individually without production shutdown.
Q4: How many operators does the 200TPH line require?
A: The line operates automatically, requiring only 3-4 people per shift (including central control operator, patrol inspector, and loader operator).
Q5: Does Zhongyu Dingli have localized service in Malaysia?
A: The company maintains a regional office and spare parts warehouse in Kuala Lumpur, high volume calcium carbonate plant providing spare parts delivery within 48 hours and engineer on-site service within 72 hours. Over 30 production lines have been deployed across Southeast Asia.
Get Your Custom Calcium Carbonate Line Solution | Contact Zhongyu Dingli Engineer Team
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Main Product:
Mobile Crusher,
Sand Making Equipment,
Screening Equipment,
Feeding Equipment,
Mining Conveyor,
Crushing Equipment
