如何设计一座500吨/小时的山地岩石骨料厂？

Demand for high-quality crushed stone and manufactured sand in Indonesia's construction market continues to grow. 山岩 is a common local aggregate raw material, but Indonesian project sites present three unique challenges: undulating terrain (many mining areas are located in mountainous and hilly zones), long rainy seasons (high annual precipitation places demands on equipment protection and electrical layout), and unstable power supply (grid stability is limited in some regions).

这三个挑战直接决定了项目的关键设计决策：如何布局场地、如何配置电气控制系统，以及如何选择破碎阶段的数量。

Taking a 450–500 TPH rock aggregate project delivered by ZENITH in Jakarta as a case study, this article details the process configuration and key design decisions of this production line, as well as implementation points worth attention in the early-stage solution design of similar projects in Southeast Asia.

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一、项目基本信息

该项目位于印度尼西亚雅加达，是由ZENITH为当地印度尼西亚及周边国家建筑市场交付的固定式岩石骨料生产线。整个生产线按照“工业化、绿色运营、模块化和智能化”的标准设计与建造。

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主要规格：

· Raw material: 山岩

· Feed size: 0–800 mm, continuous gradation

· Product sizes: 0-5-10-20-30 毫米

· Project capacity: 450–500 TPH, stationary

· Process configuration: F5X振动给料机 + C6X颚式破碎机 + HST圆锥破碎机 + S5X振动筛

· Product applications: Construction sand and crushed stone for the Indonesian local and surrounding national construction markets

第二章 关键项目设计

The designs offering the greatest reference value for similar rock aggregate projects are concentrated at two levels: the modular centralized layout of the secondary and tertiary crushers, and the equipment arranged on three tiers according to terrain plus a two-zone electrical control system positioned close to the energy consumption centers. These two design decisions directly determine the cost, footprint, energy consumption, and maintainability of a 450–500 TPH production line during both construction and operation.

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2.1 二级和三级破碎机的模块化集中布局

整个生产线的二级破碎主机（HST250S单缸液压圆锥破碎机）和两个三级破碎主机（HST250H单缸液压圆锥破碎机）采用集中布局的模块化设计，并结合智能集中控制。

这种布局直接带来三个好处：

· Reduced 皮带输送机 and steel structure consumption — With the secondary and tertiary crushers placed closer together, the number and length of connecting 皮带输送机s decrease accordingly.

· Smaller production line footprint — Multiple main machines are compactly arranged.

· Improved energy consumption and maintenance efficiency — The impact of a single machine's maintenance on the entire line is more controllable.

2.2 三层级沿地形布置 + 两个靠近能耗中心的电气控制区

· Site layout: The complete equipment set is arranged centrally in a modular fashion and distributed across three tiers according to the site terrain.

· Electrical control zoning: 电气控制系统分为两个区域。一个用于初碎的电气控制室，另一个是用于二级/三级破碎和筛分的共用电气控制室。

· Proximity to energy consumption centers: 两个电控室都位于其所服务的能量消费中心附近：初级破碎区控制室负责主破碎机——C6X颚式破碎机；二级/三级破碎与筛分区控制室负责HST二级圆锥破、HST三级圆锥破以及多个S5X振动筛。

直接的好处： 皮带输送机和电控电缆的总长度同时缩短，降低了施工和运行过程中的成本和能耗。这是生产线层面“工业化、绿色运营、模块化和智能化”的具体体现。

第三部分：生产线流程方案

3.1 三段式破碎与闭路生产

Based on process requirements, the project adopts three-stage crushing: primary crushing → secondary crushing → tertiary crushing → screening.

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整个流程围绕两个目标进行组织：

1. Crushing the 0–800 mm continuous-gradation raw ore down to the 0–30 mm finished product specifications in sequence;

2. Through closed-circuit circulation, returning the screen oversize from secondary and tertiary crushing to their corresponding crushing zones, achieving stable classification of multiple finished product sizes: 0–5 mm, 5–10 mm, 10–20 mm, and 20–30 mm.

3.2 进料与主破碎模块

ZENITH F5X 振动给料机： Conveys the 0–800 mm raw ore continuously and steadily; pre-screens out most of the 0–120 mm waste soil through the bar grizzly.

ZENITH C6X 顎式破碎機： The primary crushing main machine, crushing material larger than 120 mm on 顶部 of the bars to a size acceptable for secondary crushing.

Flow: Dump trucks unload the raw ore into the raw material bin → material is conveyed continuously and steadily by the F5X feeder → during feeding, the 0–120 mm waste soil is screened out through the bar grizzly (going directly to the subsequent pre-screening process), while material larger than 120 mm enters the C6X125 颚式破碎机 for primary crushing.

3.3 二次破碎和三次破碎模块

Secondary crushing — ZENITH HST 圆锥破碎机: 二级破碎主机，接收一次破碎的产品。

Tertiary crushing — ZENITH HST 圆锥破碎机: The tertiary crushing main machines, two units in parallel; screen oversize returns to form a closed circuit.

Flow: Material from the primary crushing module is conveyed by 皮带输送机 to the secondary 圆锥破碎机 → secondary crushed material enters the secondary crushing screening; screen oversize larger than 30 mm passes through the steel-structure transfer bin → enters the two parallel tertiary 圆锥破碎机s for crushing → enters the tertiary crushing screening; screen oversize larger than 30 mm from tertiary screening returns once again to the tertiary 圆锥破碎机s, thus forming the closed-circuit crushing and screening loop of the tertiary 圆锥破碎机s.

3.4 筛查模块

ZENITH S5X振动筛执行三项功能：

· Multi-size classification after secondary crushing — screening out the 20–30 mm finished product and feeding the 0–20 mm material to the next screening stage;

· Tertiary crushing screening and closed-circuit circulation;

· Pre-screening of the 0–120 mm waste soil from below the bar grizzly.

3.5 完整的材料路径

Raw material is unloaded by dump trucks → into one C1 raw material bin → vibrating feeder, with a bar gap of 120 mm; material smaller than 120 mm → enters the screening machine, where 0–10 mm waste soil is screened out, and screen oversize larger than 10 mm returns to the discharge 皮带输送机 of the primary 颚式破碎机; material larger than 120 mm on 顶部 of the bars → 颚式破碎机 → transfer bin → secondary 圆锥破碎机 → 振动筛 → 20–30 mm finished product screened out and sent to the finished product storage, 0–20 mm → 振动筛 for finished product screening → finished 产品 of 0-5-10-20 mm screened out and sent to the finished product storage. Finally, screen oversize larger than 30 mm → steel-structure transfer bin → tertiary 圆锥破碎机 → 振动筛 → screen oversize larger than 30 mm → returns once again to the tertiary 圆锥破碎机.

四、值得借鉴的类似岩石骨料项目设计要点

类似的岩石骨料项目，尤其是具有地形高差和为印度尼西亚及周边建筑市场供应的项目，应关注以下设计要点：

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4.1 主要设备的模块化集中布局

当二级和三级破碎主机采用模块化布局集中布置，并进行智能集中控制时，主机之间的输送带传输和钢结构的消耗将直接减少，同时生产线占地面积也得到最小化。

4.2 分层场地设计，遵循地形

对于现场地形高差较大的项目，沿地形呈三级总体布置比大规模场地平整更经济：

· Small material drop — the material drop between tiers is small, reducing the number of 皮带输送机 lifting sections;

· Compressed connecting 皮带输送机 lengths — with the secondary and tertiary crushing modules centrally arranged, the connecting 皮带输送机 lengths between main machines decrease accordingly;

· Clear inspection and maintenance routes — crushing and screening equipment are relatively concentrated.

该项目的三级划分是根据场地坡度和设备规格确定的。对于类似的项目，每台设备的级别数量和级别位置必须由设计人员根据场地坡度、地质条件和设备规格进行核查。

4.3 靠近能源消费中心的双重电力控制区

The direct benefits —

电气控制电缆的总长度减少，电缆成本相应降低；同时，检测点集中，方便故障排查和快速的日常运营响应。整体设计协调电气控制电缆、厂房建筑及其他辅助因素，是确保生产线长期可靠运行的基础。

结论

The 450–500 TPH rock aggregate project delivered by ZENITH in Jakarta, Indonesia, is designed around the positioning of "industrialization, green operation, modularization, and intelligentization" . The complete solution is built around a three-stage closed-circuit crushing process, combined with specific decisions such as the modular centralized layout of secondary and tertiary crushing, achieving integrated coordination from equipment configuration and site design to the electrical control solution.

如果您的项目位于东南亚或具有类似的地形条件，欢迎随时联系我们ZENITH，获取定制方案。

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