1. PYNPUNT GEDREWE OPENING

Managing a stone quarry crushing plant involves constant pressure to balance output, cost, en betroubaarheid. Staan jy voor hierdie aanhoudende uitdagings?
Ongeskeduleerde stilstand: Bearing failures or component wear in primary crushers can halt your entire production line for days, costing tens of thousands in lost revenue per hour of stoppage.
Inkonsekwente produkgradering: Fluctuations in feed size or worn crushing chambers lead to offspec aggregate, resulting in product rejection, recrushing costs, en ontevrede kliënte.
Hoë bedryfskoste: Rising energy consumption from inefficient crushing processes and the frequent need for manual adjustment and maintenance directly erode profit margins.
Veiligheid & Arbeidsintensiteit: Routine inspections and clearing of jammed material in critical zones expose personnel to risk and divert skilled labor from proactive maintenance tasks.

What if your primary crushing stage could deliver more predictable throughput, verminder jou koste per ton, and improve site safety? The solution lies in selecting a robust, intelligently engineered primary jaw crusher station.

2. PRODUK OORSIG

This product description details our Stationary Primary Jaw Crusher Plant, a complete, preengineered module designed for the first stage of rock reduction in a quarry crushing circuit. It forms the critical foundation for your entire mineral processing operation.

Operasionele werkvloei:
1. Voerinname: RunofQuarry (ROQ) material is dumped by haul trucks directly into a rugged vibrating grizzly feeder (VGFF VGF).
2. Voorafskerm & Bypass: The VGF removes natural fines and bypasses subsize material to a conveyor, reducing unnecessary wear on the crusher.
3. Primêre vermindering: Oversize material is directed into the deep crushing chamber of a heavyduty jaw crusher, where it is compressed between a fixed and a moving jaw plate.
4. Ontslag & Transport: Crushed product is discharged at the specified CSS (Geslote kant-instelling) onto a main product conveyor for transport to secondary crushing or stockpiling.

Toepassingsomvang: Ideal for processing hard rock types like granite, basalt, and limestone. Engineered for continuous, hoëtonnage-bedrywighede.
Beperkings: Nie ontwerp as 'n selfstandige voltooide produk-aanleg nie; requires secondary and tertiary stages for most aggregate specifications. Feed size is limited by the physical dimensions of the crusher opening.

3. KERNKENMERKE

Modulêre BoltTogether-ontwerp | Tegniese basis: Prefabricated structural steel sections with machined connection interfaces | Bedryfsvoordeel: Verminder veldinstallasietyd met tot 40% versus traditional weldedonsite plants, enabling faster commissioning. | ROI impak: Lower labor costs and earlier production start translate to quicker capital payback.

HeavyDuty Vibrerende Grizzly Voeder (VGFF VGF) | Tegniese basis: Highstrength steel deck with replaceable grizzly bars; adjustable eccentric shaft drives | Bedryfsvoordeel: Effectively scalps fines and evenly distributes feed across the full crusher inlet, preventing chokefeeding on one side. | ROI impak: Protects crusher from abrasive wear caused by fines, extends liner life by an estimated 1520%, and improves overall energy efficiency.

Hydrostatic Jaw Crusher Drive | Tegniese basis: Directdrive system with variablespeed hydraulic motors instead of traditional Vbelts and sheaves | Bedryfsvoordeel: Provides reversible operation to clear blockages and allows precise control of crusher speed to match feed conditions dynamically. | ROI impak: Eliminates belt maintenance costs and downtime; velddata toon a 30% reduction in time spent clearing jams.

Integrated PLCBased Control System | Tegniese basis: Centralized programmable logic controller with touchscreen HMI monitoring motor amps, laer temperature, and hydraulic pressure | Bedryfsvoordeel: Gives operators realtime visibility into plant health and allows remote start/stop sequencing from a safe location. | ROI impak: Enables predictive maintenance scheduling based on trend data, preventing catastrophic failures.

WalkAround Maintenance Platforms & Access Ladders | Tegniese basis: OSHAcompliant platforms with nonslip grating provide safe 360degree access to all service points. | Bedryfsvoordeel: Your maintenance crew can perform routine checks, smering, and liner changes safely and efficiently. | ROI impak: Reduces risk of workplace incidents and lowers insurance premiums while improving mean time to repair (MTTR).

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard | Our Primary Jaw Crusher Plant Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Beskikbaarheid (Optyd)| ~9294% (geskeduleer & ongeskeduleerde stop) |>96% (based on 24month field data) |>24% verhoog |
| Liner ChangeOut Tyd| 1824 hours for similar capacity units| <12 hours with hydraulic assist tools| ~3350% faster |
| Energieverbruik per ton| Baseline set at 100% for comparable plants| Average reduction to ~92% via efficient drive & optimal kinematics| ~8% lower kWh/ton |
| Installasie & Commissioning Duration| 810 weeks from delivery start| 56 weeks due to modular design| ~30% faster |

5. TEGNIESE SPESIFIKASIES

Crusher Model: JC5460 HeavyDuty Jaw Crusher
Voer opening: 54" x 60" (1372 mm x 1524 mm)
Maksimum voergrootte: 48" (1220 mm) knop
Geslote kant-instelling (CSS) Reeks: 6" 14" (150 mm 355 mm)
Kapasiteitsreeks: 550 1,500 STPH (500 1,360 MTPH), afhanklik van voermateriaal en CSS.
Totale geïnstalleerde krag: Ongeveer. 600 HP (450 kW) combined for crusher drive,VGFF VGF,en vervoerbande.
Main Structure Material: ASTM A36 Steel with abrasionresistant wear liners at impact points.
Overall Module Dimensions (LxBxH): Ongeveer. 65' x 25' x 22' (19.8m x 7.6m x 6.7m).
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 20°C tot +50°C (4°F tot +122°F). Dust suppression system connections are standard.

6. TOEPASSINGSSCENARIO'S

Uitbreiding van granietsteengroef | Uitdaging: An existing operation needed to increase primary throughput by 35% without expanding their truck dump footprint or primary conveyor infrastructure.| Oplossing: Replacement of an older jaw plant with our highcapacity modular JC5460 plant featuring an optimized feeder geometry.| Resultate: Achieved the required 35% throughput increase within the same footprint.Product gradation consistency improved,customer rejections fell by 12%.

HighAbrasion Basalt Processing | Uitdaging:Liner wear costs in the primary stage were excessive,causing liner changes every 6 weeks at significant cost in parts,arbeid,and lost production.| Oplossing: Implementation of our jaw plant with proprietary manganese steel jaw plates paired with the efficient material flow from the heavyduty VGF.| Resultate:Liner life extended to an average of 9 weke,a 50% improvement in changeout frequency,yielding an annual savings of over $85k in direct wear part costs.

7.KOMMERSIËLE OORWEGINGS

Our stationary primary jaw crusher plants are offered in three core configurations:
Basisvlak: Includes crusher,VGFF VGF,motor dryf,basic walkways,and control panel.Focused on essential functionality.
Prestasievlak (Mees algemene): Adds integrated dust suppression spray systems,hydraulic setting adjustment for the crusher,and enhanced guarding packages.
Premium vlak: Incorporates advanced condition monitoring sensors(online lubrication,temperatuur,vibrasie),extended service platforms,and premium wear liners with guaranteed MTBF(Gemiddelde tyd tussen mislukking).

Optional features include magnet systems,tramp iron relief systems,and custom conveyor lengths.Service packages range from basic commissioning support to comprehensive multiyear maintenance agreements with guaranteed parts availability.Financing options include capital lease agreements tailored to match projected cash flow from increased production.

8.Gereelde vrae

V:What if my haul trucks deliver slightly larger rock than your maximum specified feed size?
A:The heavyduty design includes reinforced components,but consistently exceeding max feed size risks damage.We offer optional oversized feed protection solutions such as hydraulic rock breakers mounted on the feeder deck frame.

Q.How does this plant integrate with my existing secondary cone crushers?
A.The discharge conveyor is sized based on your required peak capacity.The control system can be configured via standard protocols(Modbus,Ethernet/IP)to communicate with your existing PLCs.All electrical interfaces are clearly documented for your engineering team.

Q.What is the expected operational impact on my power consumption?
A.Field data typically shows stable or reduced specific energy consumption(kWh/ton)due to efficient drive systems.Optional softstart controls further mitigate peak demand charges during startup.

Q.Are spare parts readily available?
A.We maintain regional inventory hubs globally.Critical wear parts like jaw plates are stocked based on predictive models derived from thousands of operating hours.Customers under service agreements receive priority allocation.

Q.What commercial terms are available?
A.We offer ExWorks,FOB Port,and Delivered Duty Paid(DDP) incoterms.Payment structures typically involve progress payments tied to manufacturing milestones.Please inquire about current lead times which vary based on configuration complexity