project report for tph 200 ne crusher

Project Report for 200 TPH Cone Crusher

1. Introduction

This project report outlines the design, installation, commissioning, and operational details of a 200 TPH (Tonnes Per Hour) Cone Crusher plant. The cone crusher is designed for medium-hard to hard rock crushing applications in mining, quarrying, and aggregate production.

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2. Project Scope

Objectives:

• Install a high-capacity cone crusher capable of producing 200 TPH output.
• Ensure efficient crushing with optimal power consumption.
• Minimize downtime through robust design and maintenance features.
• Comply with environmental and safety regulations.



Key Specifications:

| Parameter | Details |
|———–|———|
| Crusher Type | Hydraulic Cone Crusher |
| Capacity | 200 TPH |
| Feed Size | Up to 250 mm |
| Output Size Range | 10–40 mm (adjustable) |
| Power Requirement | ~150–200 kW |
| Drive System | Electric Motor with VFD Control |

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3. Technical Details

Crusher Selection:

A secondary or tertiary cone crusher (e.g., Metso HP300, Sandvik CH440, or equivalent) is selected based on:

• Feed size distribution
• Required product size
• Rock hardness (e.g., granite, basalt)
• Closed Side Setting (CSS) adjustment capability

Supporting Equipment:

1. Feeder: Vibrating Grizzly Feeder (~500 mm x 1500 mm)
2. Screen: Multi-deck vibrating screen (~6×16 ft)
3. Conveyors: Belt conveyors for feed and discharge
4. Dust Suppression System: Water spray nozzles at transfer points
5. Control Panel: PLC-based automation for monitoring & adjustments

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4. Plant Layout & Flow Diagram

`
[Feed Hopper] → [Vibrating Feeder] → [Jaw Crusher] → [Cone Crusher] → [Screen] → [Final Product]
(Optional Primary Crushing Stage)
`
(Note: If raw material exceeds cone crusher feed size, a primary jaw crusher may be required.)

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5. Installation & Commissioning

Steps:

1. Site preparation (foundation design for static & dynamic loads).
2. Erection of crusher, feeder, screens, and conveyors.
3. Electrical wiring & control system setup.
4. Trial run with empty load → gradual feeding → full-load testing.
5. Calibration of CSS and optimization of throughput.

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6. Performance Metrics

| Metric | Target Value |
|——–|————–|
| Production Rate | 180–220 TPH |
| Power Consumption | ≤0.8 kWh/tonne |
| Availability (%) | ≥95% |
| Maintenance Interval | Every 500 hours |

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7. Operational Challenges & Solutions

1. Wear Parts Life: Use high-quality manganese liners (~800–1000 hours).
2. Dust Control: Implement water sprays + bag filters.
3. Overload Protection: Hydraulic tramp release system.
4. Uneven Feed: Ensure proper feeder speed regulation.

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8. Environmental & Safety Compliance

• Noise levels below 85 dB(A) with acoustic enclosures.
• Dust emissions controlled per EPA/ISO standards.
• Emergency stop buttons and guarding around moving parts.

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9. Cost Estimation (Approx.)

| Component | Cost (USD) |
|———–|————|
| Cone Crusher Unit | $250,000 – $400,000 |
| Auxiliary Equipment | $100,000 – $150,000 |
| Installation & Civil Work | $50,000 – $80,000 |
| Total Project Cost | ~$400,000 – $630,000 |

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10 Conclusion

The 200 TPH cone crusher plant ensures efficient rock crushing with minimal downtime while meeting production targets sustainably.

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Prepared by:
[Your Name]
[Company Name]
[Date]

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