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Zhongxin Heavy Industrial Machinery Co.,Ltd.
Browse proven fixed stone crushing production lines installed across global quarrying and mining operations. Each case study features comprehensive equipment lineups—including heavy-duty jaw crushers, hydraulic cone crushers, impact crushers, and VSI sand makers—complete with capacity specs, site layouts, and HD working videos.
Jiaozuo Zhongxin Heavy Industry, a leading manufacturer specializing in crushing, screening, grinding, and mineral processing production lines, has officially completed the engineering, delivery, and on-site commissioning of a 500 TPH iron ore crushing and screening plant in Mindanao, Philippines. Engineered to process abrasive, high-hardness raw iron ore under demanding tropical conditions, this project highlights Zhongxin’s turnkey capabilities in supplying reliable, high-capacity iron ore processing lines across Southeast Asia.
As infrastructure development and mineral export demand continue to expand across the Philippines, mining contractors require heavy-duty crushing plants capable of sustained high-tonnage output without frequent unplanned downtime. Before partnering with Zhongxin, the client faced several operational challenges common to hard-rock mining sites:
◎High Material Hardness and Abrasiveness: Run-of-mine (ROM) iron ore exhibits high compressive strength and silica content, causing accelerated wear on conventional impact-style crushers.
◎Strict Output Gradation Requirements: The client needed precise particle size distribution to supply both metallurgical export feed and commercial construction aggregates simultaneously.
◎Tropical Climate Adaptability: High humidity, seasonal heavy rainfall, and continuous multi-shift operation demanded robust structural sealing, reliable electrical protection, and efficient material screening to prevent screen blinding.
To address these requirements, Zhongxin’s engineering team designed a stationary, multi-stage, closed-circuit crushing and screening production line optimized for durability, low cost-per-ton operation, and easy maintenance.
Project Location: Mindanao, Philippines
Raw Material: High-Hardness Iron Ore / Hard Mineral Rock
Design Capacity: 500 Tons Per Hour (500 TPH)
Plant Configuration: Stationary Multi-Stage Closed-Circuit System
Core Equipment Supplied by Zhongxin:
Heavy-Duty Vibrating Grizzly Feeder
Primary Jaw Crusher (Coarse Crushing Stage)
Compound Cone Crushers (Secondary & Fine Crushing Stage)
Multi-Deck Circular Vibrating Screens (Sizing & Classification Stage)
Heavy-Duty Belt Conveyors & Automated Control System
End Product Applications: Metallurgical iron ore feed, railway ballast, highway sub-base, and structural concrete aggregates
To maintain a consistent throughput of 500 TPH while maximizing wear part service life, the plant follows a systematically balanced four-stage workflow:
1. Primary Feeding and Coarse Crushing Stage
Run-of-mine iron ore boulders are transported by haul trucks and dumped into the raw material hopper. A heavy-duty vibrating grizzly feeder regulates material flow evenly into the Primary Jaw Crusher, while simultaneously scalping out natural fines and dirt through its grizzly bars. Engineered with a deep symmetrical crushing chamber, heavy-duty forged eccentric shaft, and high-manganese steel jaw plates, the primary jaw crusher reduces large feed boulders down to manageable intermediate sizes with high crushing ratios and minimal energy loss.
2. Secondary and Fine Crushing Stage
Crushed material discharged from the primary stage is transported via main belt conveyors to a surge bin feeding the Compound Cone Crushers. Selected specifically for hard and abrasive minerals, Zhongxin’s compound cone crushers utilize laminated crushing principles—allowing rock-on-rock interparticle attrition inside the crushing chamber. This mechanism delivers two major benefits: it produces uniform, cubical finished particles with low flakiness, and it significantly reduces direct metal-to-rock abrasion on the mantle and concave liners.
3. Multi-Stage Screening and Size Classification
The crushed iron ore is conveyed to high-frequency Multi-Deck Vibrating Screens for accurate separation. Equipped with heavy-duty eccentric block exciters and wear-resistant screen meshes, the vibrating screens efficiently stratify materials into multiple finished size fractions despite high ambient moisture.
4. Closed-Circuit Recirculation Loop
Qualified finished products meeting target specifications are routed directly to designated stockpiles via radial discharge conveyors. Oversized particles retained on the top screen deck are automatically transferred back to the compound cone crushers via a return belt conveyor. This closed-circuit configuration guarantees strict product size control and eliminates waste.
For mining operators evaluating a 500 TPH iron ore crushing plant, total cost of ownership (TCO) is determined by liner lifespan, mechanical availability, and power efficiency. Zhongxin’s plant design provides measurable operational advantages:
◎Extended Wear Part Lifespan: High-manganese alloy steel castings in both the jaw crusher and compound cone crushers resist severe abrasion, extending replacement intervals and lowering spare parts expenditure per ton of ore processed.
◎Reliable Overload Protection: The compound cone crushers incorporate a heavy-duty spring release system that automatically allows uncrushable tramp iron to pass safely through the chamber without damaging the main shaft or frame.
◎Modular Steel Structure & Easy Maintenance: Elevated steel support platforms and maintenance walkways around the crushers and vibrating screens allow technicians to inspect bearings, check belt tension, and replace wear liners rapidly, maximizing daily operating hours.
◎Energy-Efficient Drive Systems: Precisely matched high-efficiency electric motors and V-belt drives minimize power draw per ton, reducing operating costs in regions with high industrial electricity tariffs.
Optimize your mineral beneficiation circuit with our high-recovery mineral processing equipment. We manufacture heavy-duty grinding ball mills, spiral classifiers, hydrocyclones, froth flotation machines, and magnetic separators designed for processing gold, copper, iron, and manganese ores. Engineered for continuous duty and maximum mineral extraction efficiency, our machinery ensures reduced wear, lower power consumption, and improved concentrate grades across all hard-rock mining operations.
Discover custom-engineered mineral processing lines and complete aggregate production plant solutions tailored to your capacity and ore characteristics. From turnkey gold ore processing plants (CIP/CIL & flotation) and copper extraction lines to high-capacity sand-making and aggregate crushing circuits, we provide end-to-end flowsheets—integrating crushing, wet grinding, classification, and slurry dewatering. Partner with us for optimized plant layout design, factory-direct equipment supply, and maximum ROI.
This section is designed to address the most pressing inquiries customers may have regarding the daily operation, maintenance, product advantages, and after-sales service of our cone crushers. Our aim is to help you gain a comprehensive understanding of our overall capabilities and enable you to make informed decisions for your projects.
Choosing Zhongxin genuine wear parts reduces downtime and significantly boosts your mining operation's ROI.
We help clients develop maintenance plans to solve issues before wear affects production.
We offer customized parts for materials like granite or gold ore, increasing wear resistance by 30%.
Leveraging our optimized supply chain, we promise the fastest delivery of parts to global sites.
