For soft rock crushing projects with an hourly output of 100 tons, it is essential to fully leverage the inherent characteristics of soft rock—specifically its low hardness and ease of crushing—to minimize both equipment investment and operational energy consumption.
The preferred solution involves utilizing a single-stage heavy-duty hammer crusher. This type of equipment integrates both primary and secondary crushing functions, capable of directly reducing large raw materials to a finished product size of less than 25 millimeters. It produces an excellent particle shape with controllable fines content. Since the compressive strength of soft rock typically falls below 100 MPa, a single-stage crushing process is sufficient to meet the requirements for construction aggregates or cement raw materials, thereby eliminating the need for the traditional two-stage "jaw crusher + impact crusher" workflow. This approach not only reduces the number of required machines and intermediate conveyor belts but also significantly decreases the plant's footprint and electricity consumption.
In terms of process flow, raw materials are fed uniformly into the heavy-duty hammer crusher via a vibrating feeder. The crushed material is then transported by conveyor belt to a vibrating screen for classification. Finished products meeting the required specifications are sent directly to storage, while oversized particles are returned to the crusher for further processing, establishing a closed-circuit loop that ensures stable output and consistent quality. If extremely stringent requirements exist regarding the content of needle-like or flaky particles, a shaping machine may be added at the final stage; however, this is generally not necessary for typical soft rock applications.
Furthermore, environmental protection measures are indispensable. Given that soft rock crushing operations tend to generate significant dust, it is necessary to install enclosed hoods at the feed inlet, discharge outlet, and screening points, and to integrate a pulse-jet bag filter system. This configuration offers a simple structure, ease of maintenance, and a short return-on-investment period, making it the most cost-effective choice for soft rock processing.
