Production line overall configuration with jaw crusher tutorial

Production line overall configuration with jaw crusher tutorial

Jaw crusher serves as the primary crushing equipment in aggregate, ore, and construction waste production lines. It breaks large raw stones into medium-sized particles for secondary crushing by cone crusher / impact crusher. This tutorial introduces complete production line configuration principles, typical schemes, equipment matching, layout notes and common troubleshooting.

1. Core Design Principles

  1. Match feeding size: Jaw crusher inlet size ≥ maximum raw material block size.
  2. Capacity matching: The processing capacity of the subsequent crusher shall be ≥ the output of jaw crusher to avoid material accumulation.
  3. Material characteristics: Hard rock (granite, basalt) → jaw + cone; brittle stone (limestone) → jaw + impact crusher.
  4. Site condition: Consider foundation space, transportation, power supply, dust collection and drainage.

2. Typical Complete Production Line Configuration

Scheme 1: Small Aggregate Line (50–100 t/h, limestone, construction rubble)

  • Feeding: Vibrating feeder
  • Primary crushing: Jaw crusher
  • Screening: Vibrating screen
  • Secondary crushing: Impact crusher
  • Conveying: Belt conveyors
  • Auxiliary: Dust removal system, electric control cabinet

Process flow: Raw material bin → vibrating feeder → jaw crusher → belt conveyor → vibrating screen

  • Oversized stones return to impact crusher for re-crushing
  • Qualified finished aggregates are separated into different grades

Scheme 2: Hard Rock Production Line (150–300 t/h, granite, basalt)

  • Feeding: Heavy-duty vibrating feeder
  • Primary crushing: Large jaw crusher
  • Secondary crushing: Cone crusher
  • Screening: Multi-layer vibrating screen
  • Conveying: Belt conveyors
  • Auxiliary: Iron remover, dust collector, central control system

Process flow: Raw material bin → vibrating feeder (with iron remover) → jaw crusher → belt conveyor → cone crusher → vibrating screen

  • Oversized materials loop back to cone crusher
  • Multiple finished stone grades output

Scheme 3: Mobile Jaw Crushing Line (flexible site, construction waste)

  • Integrated unit: Vibrating feeder + jaw crusher + mobile chassis + belt conveyor
  • Optional matching: Mobile cone / impact crushing station Suitable for frequent site relocation, no fixed foundation required.

3. Key Equipment Matching Rules

  1. Vibrating feeder: Uniformly feed raw material, pre-screen fine soil and impurities to improve jaw crusher efficiency.
  2. Jaw crusher: Primary crushing, discharge gap adjustable to control the primary output particle size.
  3. Belt conveyor: Connect each device, inclined angle and belt width must match hourly throughput.
  4. Magnetic iron remover: Install before jaw crusher to remove steel debris, prevent crushing cavity damage.
  5. Vibrating screen: Classify finished materials; screen layers are determined by finished product specifications.

4. Site Layout & Installation Requirements

  1. Raw material bin is set at the high position to realize gravity feeding and save power.
  2. Leave maintenance space around jaw crusher: At least 1–1.5m on both sides for jaw plate replacement.
  3. Arrange dust collection points at feeding mouth, discharge mouth and transfer points of conveyors.
  4. Electrical control cabinet should be placed in dry, dust-free area with interlock protection to realize sequential start-stop.
  5. Ground foundation must be reinforced with concrete, equipped with shock absorption pads to reduce vibration.

5. Operation & Maintenance Points

  • Pre-start: Check jaw plate wear, tightness of bolts, lubrication of eccentric shaft bearing.
  • Operation: Feed materials evenly; forbid metal blocks entering crushing chamber.
  • Shutdown: Stop feeding first, wait until all materials inside jaw crusher are completely discharged then stop the machine.
  • Regular maintenance: Replace worn jaw plates, check lubricating oil, fasten loose bolts.

6. Common Matching Mistakes

  1. Subsequent crusher capacity smaller than jaw crusher → material blockage.
  2. Ignoring iron remover → metal entering jaw cavity causing equipment damage.
  3. Insufficient maintenance space → difficult to replace wear parts.
  4. Improper belt conveyor angle → material slipping.