UNIQUEMAC × Reliance Industries: 250–300TPH Coal Crushing Plant Project Case Study

Project Background

In India’s industrial sector, coal is still one of the most important raw materials for power generation and large-scale manufacturing. For companies operating continuous production lines, the stability of coal preparation has a direct impact on the entire downstream process.

In this project, Reliance Industries was expanding its production capacity and found that the existing coal crushing system was no longer performing consistently under higher load conditions. The main issue was not that the system completely failed, but that it became difficult to maintain stable output during long hours of operation.

Feed fluctuations, uneven particle sizes, and occasional bottlenecks in material handling started to affect overall production efficiency.

To solve this, the client required a new crushing system with a capacity of 250–300 tons per hour, but more importantly, they needed a system that could run continuously with stable performance and minimal operator intervention.

After technical discussions and evaluation of different solutions, the project was awarded to UNIQUEMAC for full system design and equipment supply.

Real Site Challenges

Coal crushing sounds simple on paper, but in real operation, the conditions are quite unpredictable.

One of the first issues observed was the inconsistency of raw coal feed. The material coming from different mining batches had very different sizes. Some loads contained large lumps, while others were mostly fine particles mixed with moisture. This kind of variation creates unstable pressure inside the crushing chamber.

Another issue was moisture content. Depending on weather conditions and stockpile storage time, coal can become sticky and difficult to handle. This often leads to material buildup at transfer points, especially around feeding equipment.

The third challenge was system continuity. In a plant like this, the crushing section is not an isolated unit. Any interruption in crushing directly affects conveyor systems, downstream screening, and overall plant scheduling.

So the key requirement was not just capacity — it was operational stability over long continuous running periods.

System Design Approach

Instead of starting with equipment selection, the engineering team first studied how material flows through the system.

In coal crushing plants, instability usually starts at the feeding stage. If the feed is uneven, even a high-performance crusher will struggle to maintain steady output.

For this reason, the design approach focused on one main principle:

stabilize material flow before crushing.

The final layout was built around a controlled feeding system paired with a primary jaw crusher. The goal was to make sure the crusher always operates under a consistent load, rather than reacting to sudden surges or drops in material input.

The system was arranged to maintain a smooth transition from storage hopper to feeder, then into the crusher, and finally into the discharge conveyor without interruptions or sudden load changes.

Key Equipment Selection

PE900×1200 Jaw Crusher

The PE900×1200 jaw crusher was selected as the primary crushing unit because it provides a good balance between capacity and operational stability in large-scale coal applications.

In this project, its role was not just to reduce material size, but to act as the central load-handling unit of the system.

With a capacity range of 186–398TPH, the crusher has enough flexibility to handle variations in feed volume while still maintaining stable operation within the required 250–300TPH range.

In real operation, this margin is important. Coal feed is never perfectly constant, so having extra capacity allows the system to absorb fluctuations without causing overload or unstable operation.

Structurally, the crusher uses high-manganese steel wear parts designed for long service life under abrasive conditions. While coal is not as hard as rock, it often contains impurities that can accelerate wear over time.

Another important aspect is the crushing chamber design. The internal structure helps material move more evenly through the crushing process, which reduces sudden impact loads and helps stabilize power consumption during operation.

From a maintenance perspective, the design allows key components to be accessed more easily during scheduled shutdowns, which is important for plants that run continuously.

Heavy-Duty Apron Feeder

In this project, the apron feeder plays a much more important role than simply transporting material.

Its main function is to regulate how coal enters the crusher. Without proper feed control, even a well-designed crusher can experience unstable loading conditions.

The apron feeder used here is built with a reinforced chain and pan structure, capable of handling large lump coal and uneven material distribution without deformation.

In actual operation, its most important function is consistency. It converts irregular, batch-loaded material from the hopper into a steady and controlled flow.

The variable speed control system allows operators to adjust feed rate depending on crusher load conditions. This helps keep the crusher running in a stable working range instead of constantly switching between overload and underload conditions.

In practice, this is what makes the entire system feel “stable” from an operator’s point of view.

Project Execution Process

The project was carried out in several stages, following a standard engineering workflow.

The first stage involved site analysis and material behavior study. This included understanding feed size distribution, moisture variation, and available installation space.

Once the layout was confirmed, equipment manufacturing and testing were carried out in the factory. Each major component was tested under working conditions to ensure it could operate reliably before shipment.

After delivery to the site, UNIQUEMAC engineers were involved in installation supervision. This included equipment alignment, structural positioning, and integration between the feeder and crusher system.

One of the most important steps during commissioning was load balancing. This is where feeder speed and crusher capacity are adjusted together until the system reaches stable operation. It usually takes several iterations to achieve the right balance.

Training was also provided to local operators, focusing on daily operation procedures and basic maintenance practices.

Operational Performance

After commissioning, the system started stable operation within the target range of 250–300TPH.

One of the most noticeable improvements compared to the previous setup was stability. The system no longer experienced frequent fluctuations caused by inconsistent feeding conditions.

Another improvement was reduced downtime. With more stable load distribution, mechanical stress on the crusher and feeder system became more balanced, which reduced unexpected stoppages.

Energy consumption also became more predictable. Instead of fluctuating power peaks, the system operated within a more consistent load range, which improved overall efficiency.

From an operational perspective, the plant became easier to manage on a day-to-day basis, especially during long continuous runs.

Client Feedback

Engineers from Reliance Industries noted that the biggest improvement was not just output, but control.

The system became easier to operate and required fewer adjustments during long production cycles. This reduction in manual intervention had a direct impact on overall plant efficiency.

They also highlighted the importance of installation support, especially during commissioning, where small adjustments had a significant impact on system stability.

Final Summary

This project is a good example of how crushing system performance is not determined by a single machine, but by how the entire material flow is designed and controlled.

By focusing on feed stability first and then matching the crusher performance to that condition, the system achieved a more reliable and predictable operation.

For large-scale industrial users, this kind of system-level thinking is often more important than individual equipment specifications.