120tph Stone Crusher Plant in Kenya

Here’s a detailed analysis of your proposed 120tph stone crusher plant for aggregate and sand production in Kenya, using the PE-600×900 Jaw Crusher, PSGB-0917 Symons Cone Crusher, and 3YK1545 Vibrating Screen:

1. Equipment Selection & Suitability

a) PE-600×900 Jaw Crusher (Primary Crushing)

• Feed Opening: 600x900mm (24″x35″)
• Max Feed Size: ≤500mm
• Output Size: 65-160mm (adjustable)
• Capacity: 50-120tph (depends on hardness of material)
• Power: 55-75kW
• Suitability: Ideal for primary crushing of hard rocks (granite, basalt). Handles large feed size well and provides stable output for secondary crushing.

b) PSGB-0917 Symons Cone Crusher (Secondary Crushing)

• Type: Standard (PSGB model)
• Max Feed Size: ≤150mm (recommended after jaw crusher)
• Output Size: 16-38mm (adjustable)
• Capacity: 45-91tph
• Power: 75kW
• Suitability: Good for medium-hard to hard stones. Produces well-shaped aggregates for concrete/asphalt. Symons crushers are reliable but require regular maintenance (e.g., liner checks).

c) 3YK1545 Vibrating Screen (Screening)

• Screen Size: 1500x4500mm (3 decks)
• Screen Mesh: Customizable (e.g., 5mm, 10mm, 20mm for sand/aggregate separation)
• Capacity: Up to 150tph
• Power: 15kW
• Suitability: Efficiently separates crushed material into 3-4 grades (e.g., 0-5mm sand, 5-15mm, 15-30mm aggregates). High-frequency vibration ensures low clogging.

2. Flow Design (Simplified)

1. Primary Crushing:
   • Raw material → Vibrating feeder → PE-600×900 Jaw Crusher → Output (65-160mm).
2. Secondary Crushing:
   • Jaw crusher output → Belt conveyor → PSGB-0917 Cone Crusher → Output (16-38mm).
3. Screening:
   • Cone crusher output → 3YK1545 Vibrating Screen → Separated into:
     • 0-5mm (sand),
     • 5-15mm (fine aggregate),
     • 15-30mm (coarse aggregate).
   • Oversize material returns to cone crusher (closed-circuit design).

3. Key Considerations for the Kenya

• Material Hardness: Adjust jaw/cone crusher settings for local rocks (e.g., basalt, andesite).
• Moisture & Stickiness: Use anti-clogging screens for high-humidity conditions.
• Dust Control: Install water spray or dust suppression systems (compliance with local regulations).
• Maintenance: Symons cone crushers require frequent lubrication and liner checks.
• Backup Plan: Include a spare wear parts inventory (jaw plates, cone mantles, screen meshes).

4. Potential Upgrades/Optimizations

• Sand Making: Add a VSI crusher (e.g., Barmac) to improve sand yield and shape.
• Automation: Use PLC control for real-time monitoring of crusher load and screen efficiency.
• Energy Savings: Opt for soft starters or VFDs for cone crusher motors.

5. Estimated Output (120tph)

• Aggregates (5-30mm): ~70-80tph (for concrete/road base).
• Sand (0-5mm): ~30-40tph (may require washing if high clay content).

Conclusion

Your proposed setup is technically viable for 120tph aggregate/sand production. Ensure proper feed size control (≤500mm for jaw crusher) and regular maintenance of the Symons cone crusher. If sand quality is critical, consider adding a sand washer or VSI crusher.

Would you like assistance with layout design or cost estimation?