1. PYNPUNT GEDREWE OPENING

Are your iron ore processing margins being squeezed by inconsistent feed, oormatige stilstand, and rising operational costs? Aanlegbestuurders en ingenieurskontrakteurs staar volgehoue ​​uitdagings in die gesig wat 'n direkte impak op die onderste lyn het. Ervaar jy:
Onbeplande stilstand: Gereeld, unpredictable breakdowns in primary crushing due to tramp steel or uncrushable material, stop jou hele verwerkingslyn vir ure.
Deurset-bottelnekke: Inefficient crushing stages causing backlogs, limiting overall plant capacity and failing to meet offtake agreements during peak demand.
Hoë instandhoudingskoste: Constant wear part replacement in abrasive iron ore applications, coupled with laborintensive servicing routines that drain maintenance budgets.
Produk Kwaliteit Veranderlikheid: Inkonsekwente grootte van die finale produk (lump/fines ratio) leading to premium price penalties and customer dissatisfaction.
Energie ondoeltreffendheid: Crushing systems operating at nonoptimal levels, consuming excessive power per tonne of ore processed.

What if your primary crushing stage could become a predictable, highavailability asset instead of a recurring cost center?

2. PRODUK OORSIG

The Bespoke Iron Ore Crushing Plant is a engineered primary and secondary crushing system specifically configured for the highabrasion, hightonnage demands of magnetite or hematite processing. Unlike standard modular plants, each system is designed from the ground up based on your ore characteristics (Abrasion Index, UCS), vereiste kapasiteit, and site logistics.

Operasionele werkvloei:
1. Primêre storting & Voorafskerm: RunofMine (ROM) ore is received at a rugged dump hopper with a grizzly feeder to scalp out oversize material and direct subgrizzly fines to a bypass conveyor.
2. Primêre verplettering: A heavyduty jaw crusher or gyratory crusher reduces the ROM ore to a manageable size for downstream conveying.
3. Sekondêre verplettering & Sifting: Material is conveyed to a secondary cone crusher circuit in closed configuration with sizing screens to ensure precise product control before proceeding to beneficiation.

Toepassingsomvang: Ideal for greenfield sites or major expansion projects requiring 1,500 aan 10,000+ ton per uur kapasiteit. Best suited for operations with consistent longterm mine plans.

Beperkings: Not recommended for smallscale or exploratory operations with rapidly changing ore bodies. Site requires adequate preparation for foundation and crane access.

3. KERNKENMERKE

HeavyDuty Voorskootvoerder | Tegniese basis: Overlapping manganese steel flights driven by rugged tractortype chains | Bedryfsvoordeel: Handles direct dump from 200ton haul trucks without damage, provides even feed regulation to crusher | ROI impak: Eliminates feeder damage downtime; improves crusher cavity fill for up to 15% higher throughput efficiency.

Tramp Metal & Cavity Clearance System | Tegniese basis: Automated hydraulic release and clearing cylinder on primary crusher | Bedryfsvoordeel: Clears blockages or uncrushable material in minutes without manual intervention | ROI impak: Reduces downtime events from hours to minutes, protecting crusher from catastrophic damage.

Liner Life Optimization | Tegniese basis: CADdesigned crushing chamber profiles and alloyed manganese steel liners specific to your ore's abrasiveness | Bedryfsvoordeel: Achieves predictable wear life cycles, allowing for planned maintenance shutdowns | ROI impak: Verleng liner lewe deur 2035% over generic liners; reduces annual consumable cost per tonne.

Gesentraliseerde smering & Toestandsmonitering | Tegniese basis: Automated lubrication system with flow sensors and vibration monitors on critical bearings | Bedryfsvoordeel: Verseker optimale dra gesondheid, verskaf vroeë waarskuwing van moontlike mislukkings | ROI impak: Prevents major bearing failures; reduces manual greasing labor by estimated 80%.

Modular Conveyor Design | Tegniese basis: Bolttogether heavyduty conveyor sections with impact cradles at loading zones | Bedryfsvoordeel: Enables faster installation and future reconfiguration if plant flow needs change | ROI impak: Verkort installasie tyd met tot 30%, reducing timetoproduction.

Stofonderdrukking-integrasie | Tegniese basis: Nozzle system integrated at transfer points, tied into crusher actuation | Bedryfsvoordeel: Significantly reduces airborne particulate from initial crushing stages | ROI impak: Handhaaf regulatoriese nakoming, improves site working conditions and reduces cleanup costs.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (Modulêre aanleg) | Bespoke Iron Ore Crushing Plant Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Plantbeskikbaarheid | 8590% (beplan & onbeplan) | 9496% teiken beskikbaarheid | +510% more productive uptime |
| Tonne/Hour Efficiency| Rated capacity often at ideal conditions| Capacity guaranteed based on your specific ore AI & digtheid| +1015% konsekwente deurset |
| Energieverbruik| Fixed speed drives across motors| HVSI crushers & veranderlike frekwensie aandrywers (VFD's) on feeders/conveyors| Tot 12% laer kWh/ton |
| Wear Cost per Tonne| Generic liner designs standard| Orespecific chamber design & liner metallurgy| 2035% reduction demonstrated |
| Installasie Tydlyn| Sequential assembly on site| Large preassembled skids tested before shipment| 2530% vinniger ingebruikneming |

5. TEGNIESE SPESIFIKASIES

Kapasiteitsreeks: Konfigureerbaar vanaf 1,500 TPH tot verby 10,000 TPH of crushed iron ore.
Primêre Crusher Opsies: Kakebeen Vloeker (1,600mm x 2 000 mm) of Primêre Gyratoriese Breker (60”+). Selection based on feed size and capacity requirement.
Sekondêre Crusher Opsies: Highcapacity cone crushers with hydraulic adjustment and clearing.
Kragvereistes: Total installed power typically ranges from 1.5MW to 6MW+ depending on configuration. Designed for connection to highvoltage mine grid supply (6.6kV/11kV).
Materiaalspesifikasies: Critical wear components utilize premium alloys (bv., TeroTec® manganese steel). Structural steel is Grade S355JR for durability.
Fisiese afmetings: Plant footprint is sitespecific but designed for optimal accessibility around crushers and conveyors for maintenance.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 25°C tot +50°C. Dust encapsulation and insulation/heating packages available for extreme climates.

6. TOEPASSINGSSCENARIO'S

Greenfield Magnetite Project in Pilbara Region

Uitdaging: A new mine required a 4,500 TPH primary crushing plant capable of handling highly abrasive ore with minimal water usage due to arid conditions.
Oplossing: Implementation of a bespoke plant featuring a gyratory primary crusher, dry screening presorting, and fully enclosed conveyors with baghouse filtration.
Resultate: Achieved nameplate capacity within one month of commissioning. Dust emissions maintained below stringent regulatory limits despite dry processing. Wear part life met projected targets within 5%.

Existing Hematite Operation Expansion

Uitdaging: An existing operation needed to debottleneck its process line; the original primary crusher was causing throughput limitations and excessive maintenance shutdowns.
Oplossing: A bespoke secondary crushing circuit was designed downstream of the existing primary stage using highperformance cone crushers in closed circuit with multideck screens.
Resultate: Overall plant throughput increased by 22%. Final product sizing consistency improved significantly (+40%), securing premium lump ore pricing from buyers.

7. KOMMERSIËLE OORWEGINGS

Our bespoke plants are capital investments engineered for longterm operational payback.

Prysvlakke: Quotations are projectspecific based on detailed client specifications (BOM). Budgetary estimates are provided after initial scoping.
Standaard konfigurasie: Sluit kernbreekeenhede in,oplewingsbakke,and basic PLC control.Price range indicative only:$8M $15M USD
Advanced Configuration: Sluit outomatiseringstelsels in,predictive condition monitoring,and advanced dust control.$12M $25M+ USD

Opsionele kenmerke: Aan boord weegstelsels,mobiele monsternemingstasies,crusher cavity vision systems,total turnkey erection services.

Dienspakkette:

Platinum Ondersteuning: Includes remote monitoring,a dedicated service engineer,two scheduled maintenance visits/year,and guaranteed parts delivery within specified timeframe.This package typically adds ~35% CAPEX annually but can reduce unplanned downtime by up to an additional ~50%.

Goud ondersteuning: Scheduled maintenance visits/year plus priority parts support.This package typically adds ~23% CAPEX annually

Onderdele-ooreenkoms: Guaranteed wear parts supply at fixed pricepertonne over an agreed period.This stabilizes operating costs

Finansieringsopsies: We work with major international equipment finance partners offering leasetoown structures operating leases over typical terms

Gereelde vrae

Q1 How do you ensure this bespoke plant will work with our existing downstream processing equipment?
A Our engineering process begins with a comprehensive audit of your entire flow sheet including existing conveyors bin capacities We model the entire system using dynamic simulation software ensuring the new crushing plant integrates without creating bottlenecks elsewhere

Q2 What is the typical implementation timeline from order placement?
A For most projects detailed engineering requires months followed by months manufacturing shipping Site preparation must occur concurrently Commissioning typically takes weeks This timeline varies significantly based on scale complexity permitting requirements

Q3 Can you guarantee performance metrics like throughput energy consumption?
A Yes performance guarantees are contractually stipulated following analysis testing They are based on agreedupon standards such as specific Bond Work Index values Abrasion Index values provided during design phase These guarantees form part of our commercial proposal

Q4 How does financing through your partners work?
A Our finance partners provide capital equipment leasing solutions that preserve your working capital Typical agreements involve monthly payments structured as an operating lease often providing potential tax benefits A formal credit application separate from equipment purchase agreement required

Q5 What training do you provide?
A We provide comprehensive training programs covering normal operation routine maintenance troubleshooting safety procedures Training conducted both during Factory Acceptance Testing FAT commissioning period Documentation includes detailed operation manuals parts lists schematic diagrams