1. PYNPUNT GEDREWE OPENING

Bestuur jy 'n midtolarge skaal aggregaat produksie operasie en staar aanhoudende knelpunte in die gesig wat winsgewendheid erodeer? Vir aanlegbestuurders en ingenieurskontrakteurs, 'n 250300tph klipbreekaanleg is 'n kritieke bate, tog het algemene operasionele uitdagings 'n direkte impak op jou winspunt. Consider these frequent issues:
Inkonsekwente deurset & Stilstand: Unplanned stoppages due to feeder blockages, crusher overloads, or conveyor misalignment can cost thousands per hour in lost production and idle labor.
Hoog operasioneel & Onderhoudskoste: Gereelde vervanging van slytasieonderdele, high energy consumption per ton of output, and the need for specialized maintenance crews steadily increase your cost per aggregate ton.
Swak produkvorm & Gradasiebeheer: Inconsistent output leads to excess fines or outofspec material, reducing the market value of your end product and causing rejections.
Rigiede plantuitleg & Skaalbaarheidsbeperkings: Fixed designs struggle to adapt to changing feed material hardness or required product mixes, forcing costly retrofits or operating below optimal capacity.

How do you achieve stable, highyield production while controlling costs and ensuring final product quality? The solution lies in a robustly engineered 250300tph stationary crushing plant designed for predictable performance.

2. PRODUK OORSIG

This solution is a complete stationary stone crushing and screening plant engineered for a nominal output of 250 aan 300 metrieke ton per uur (tph) van voltooide aggregaat. It is designed as a primarytotertiary processing system for mediumhard to hard stones like granite, basalt, en kalksteen.

Operasionele werkvloei:
1. Primêre verplettering: Groot voermateriaal (≤750 mm) is reduced by a heavyduty jaw crusher or gyratory crusher.
2. Sekondêr & Tersiêre verplettering: The primary crushed material is further processed by cone crushers for size reduction and improved particle shape.
3. Sifting & Klassifikasie: Vibrating screens separate material into precise size fractions, routing oversize back to crushers and directing onspec product to final stockpiles.

Toepassingsomvang: Ideal for large quarry operations, major infrastructure project support (hoofweë, spoorweë), and commercial aggregate supply yards requiring highvolume, consistent output.

Sleutelbeperkings: Feed material hardness must be within specified limits (bv., tot 300 MPa druksterkte). Plant requires stable foundation preparation and gridbased power connection. Not designed for mobile or frequent relocation.

3. KERNKENMERKE

Intelligente voerbeheerstelsel | Tegniese basis: Veranderlike frekwensie-aandrywing (VFD) on primary feeder with level sensors | Bedryfsvoordeel: Prevents crusher cavity overload and minimizes bridging, ensuring smooth material flow | ROI impak: Verminder onbeplande stilstand met tot 15% and improves crusher liner life

Laminated Crushing Chamber Design | Tegniese basis: Multilayer crushing cavity geometry in cone crushers | Bedryfsvoordeel: Produces superior particle shape with lower flakiness index and controlled fines generation | ROI impak: Increases premium product yield by 812%, enhancing sales revenue

Gesentraliseerde smering & Hidrouliese stelsel | Tegniese basis: Singlepoint lubrication stations with automated timers and pressure monitoring | Bedryfsvoordeel: Ensures critical bearing points are serviced consistently, reducing failure risk | ROI impak: Lowers bearingrelated breakdowns by an estimated 25% and extends service intervals

HighStrength Modular Conveyor Framework | Tegniese basis: CADoptimized truss design using hightensile steel | Bedryfsvoordeel: Bied uitsonderlike stabiliteit onder vrag, reducing vibration and misalignment issues | ROI impak: Decreases conveyor maintenance time by approximately 20% over the plant lifecycle

PLCBased Automated Process Logic | Tegniese basis: Programmeerbare logiese beheerder met menslike masjien-koppelvlak (HMI) for sequence control and interlocking | Bedryfsvoordeel: Allows singleoperator oversight of startup/shutdown sequences and provides fault diagnostics | ROI impak: Optimizes power use during operation cycles and reduces labor requirements for plant control

HeavyDuty Vibrating Screen with QuickChange Decks | Tegniese basis: Rubber shear mounts and sidetensioned screen media attachment system | Bedryfsvoordeel: Provides efficient sizing with reduced noise/vibration transmission; enables faster screen cloth replacement | ROI impak: Cuts screen maintenance downtime by up to 40% per uitruilgebeurtenis

Geïntegreerde stofonderdrukkingstelsel | Tegniese basis: Nozzle arrays at transfer points connected to a highpressure pump system | Bedryfsvoordeel: Effectively controls airborne particulate at primary dust generation sources | ROI impak: Verseker nakoming van omgewingsregulasies, avoiding potential fines and improving site working conditions

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (250300tph Plant) | This 250300tph Stone Crushing Plant Solution | Voordeel (% verbetering) |
|||||
| Overall Equipment Effectiveness (OEE) | ~76% | Target ≥84% | +10.5% |
| Kragverbruik (kWh/ton verwerk) | Wissel baie; baseline = X | Optimized system design reduces baseline |7% aan 12% |
| Crusher Wear Part Life (Mangaanvoerings)| Based on abrasive feed | Improved chamber design & allooi seleksie |15% Koste per ton |
| Gemiddelde tyd tussen mislukkings (MTBF) Key Conveyors ~1,200 hours ~1,650 hours +37.5% |
| Produkvorm-indeks (Flakiness) Tipies >20% Onderhou <15% 25% Improvement in Cubicity |

5. TEGNIESE SPESIFIKASIES

Nominale kapasiteitsreeks: 250 – 300 tph (varies based on feed material hardness & required product gradation).
Primêre Crusher Opsies: Kakebeen Vloeker (PE900×1200) of Gyratory Crusher; Feed Opening up to 750mm.
Sekondêre/Tersiêre Brekers: Multicylinder Hydraulic Cone Crushers.
Siftingstoerusting: Tripledeck heavyduty circular motion vibrating screens; Total screening area ≥20m².
Totale geïnstalleerde krag: Ongeveer 550 – 650 kW (afhanklik van konfigurasie).
Sleutel materiaal spesifikasies: Primary frame construction Q345B steel; Highwear components use Mn18Cr2 or equivalent alloys; Conveyor belts rated for minimum PIW 800.
Overall Plant Footprint (LxW): Approximately 85m x 65m (layout dependent). Height restrictions apply (~25m max).
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 20°C tot +45°C; Dust emission control achieves ≤20mg/m³ at key points.

6. TOEPASSINGSSCENARIO'S

Granietsteengroef Uitbreidingsprojek

Challenge A quarry needed to increase production from 200tph to a consistent 280tph of road base and concrete aggregates but had limited space for plant expansion.
Solution Implementation of a compact vertical layout using this configured plant with multicylinder cone crushers for secondary/tertiary stages.
Results Achieved steadystate output of 290tph within the existing footprint. Product cubicity met the highest local specification standards.

LargeScale Highway Construction Support

Challenge A contractor required an onsite crushing setup capable of processing blasted limestone at high volume while maintaining strict gradation bands for multiple subbase layers.
Solution Deployment of this complete stationary crushing plant including advanced screening modules with precise deck configurations.
Results The plant supplied over 1.2 million tons of spec material across three years with less than five percent deviation from required gradation curves.

7. KOMMERSIËLE OORWEGINGS

Our solutions are offered in tiered configurations:
Standaardkonfigurasievlak: Sluit kernbreekmodules in,screening units,and basic PLC control.Priced as a turnkey package.
Hoëdoeltreffendheidvlak: Adds intelligent feed systems,crusher automation settings,and premium wear materials.Initial investment yields lower longterm operating costs.
Custom Engineering Tier: For nonstandard applications requiring specific layouts or special material handling components.Priced upon project engineering review.

Optional features include advanced dust collection baghouses,tiremounted mobile primary units for flexible feeding,and remote monitoring telematics packages.Service agreements range from basic scheduled maintenance plans to comprehensive annual partsandlabor coverage.Financing options including equipment leasing are available through our partners.

8. Gereelde vrae

What are the primary power requirements?
A stable threephase industrial power supply is required.Total connected load typically ranges from550to650kW.Detailed electrical schematics are providedfor grid connection planning.

Can this plant process river gravel or very abrasive materials?
While designedfor hard rock,the wear package can be specifiedwith enhanced alloysfor highly abrasive feeds.Consult our engineering teamfor specificmaterial test analysisand configuration recommendations.

What is the typical installationand commissioning timeline?
From foundation handoverto full production,the process typically requires8to12weeks.This includes mechanical erection,elektriese aansluiting,system calibration,and operator training conductedby our engineers.

Do you provide spare parts support globally?
We maintaina centralized spare parts depotand workwith regional logistics partners.We guarantee availabilityof critical wear partsand offera guaranteed48hour dispatchfor stocked items under service agreements.

How does thisplant handle variationsin feed sizeor hardness?
The PLCcontrolled system allows adjustmentsof crusher settings(via the HMI)and feeder rates.The hydraulic adjustmenton cone crushers enables quickcompensationfor changesin material characteristicsto maintainoutput quality