1. PYNPUNT GEDREWE OPENING

Are escalating operational costs and unpredictable downtime eroding your iron ore processing margins? Plant managers and engineering contractors face persistent challenges in primary crushing stages that directly impact downstream efficiency and profitability. Algemene pynpunte sluit in:
Oormatige dra & Onderhoudskoste: Abrasive iron ore rapidly degrades crusher liners, leading to frequent shutdowns for replacement, high spare parts expenditure, and lost production.
Unplanned Downtime from Tramp Metal: Hidden scrap metal or uncrushable material in feed causes catastrophic damage to crusher internals, resulting in days of unscheduled downtime and sixfigure repair bills.
Inconsistent Feed Size & Capacity Bottlenecks: Poorly sized feed from the mine or an inefficient primary crusher creates choke points, limiting throughput and preventing the plant from reaching its designed capacity.
Hoë energieverbruik per ton: Older crushing technology often operates at low mechanical efficiency, making energy one of the largest variable costs with poor ROI on power spend.
Stof Emissie & Safety Compliance: Inadequate containment at primary crushing points creates hazardous work environments, triggers regulatory noncompliance risks, and represents valuable product loss.

Is your current primary crushing solution a reliable asset or a constant source of cost and delay? The right engineered Chinese Iron Ore Crushing Plant addresses these challenges directly.

2. PRODUK OORSIG

This solution is a heavyduty, stationary primary crushing station engineered specifically for the volumetric reduction of runofmine (ROM) ystererts. It is centered on a robust gyratory or jaw crusher designed for maximum reliability and throughput in highabrasion applications.

Operasionele werkvloei:
1. ROM iron ore is dumped into a reinforced hopper by haul trucks.
2. A vibrating grizzly feeder (VGFF VGF) removes fine material (100mm) via a bypass chute while evenly feeding oversize material to the primary crusher.
3. The core primary crusher reduces the ore to a nominal product size of 150250mm through compressive force.
4. Crushed material is discharged onto a main conveyor system for transport to secondary crushing or stockpiling.

Toepassingsomvang: Ideal for greenfield mine development or brownfield plant expansion requiring highcapacity (2,000 10,000+ TPH), continuousduty primary reduction of magnetite, hematiet, or other ironbearing ores.

Beperkings: Not suitable for portable or semimobile applications without significant structural modification. Requires stable foundational concrete works and planned feed control for optimal performance.

3. KERNKENMERKE

HeavyDuty Crusher Ontwerp | Tegniese basis: Highchromium alloy cast iron liners & reinforced mainframe | Bedryfsvoordeel: Extended service life in highly abrasive conditions; withstands peak loading from large feed blocks | ROI impak: Reduces liner change frequency by 3050%, lowering parts inventory cost and maintenance labor hours.

Integrated Tramp Iron Protection | Tegniese basis: Hydraulic overload relief system with automatic reset | Bedryfsvoordeel: Prevents major damage by allowing the crusher to open its setting to pass uncrushable material, then automatically return to original setting | ROI impak: Eliminates costly unplanned downtime events and associated component damage, protecting millions in capital equipment.

Intelligent Feed Control System | Tegniese basis: Variablefrequency drive (VFD) on feeder coupled with crusher amp monitoring | Bedryfsvoordeel: Automatically regulates feed rate to maintain optimal cavity level and prevent choking or running empty | ROI impak: Maximizes throughput capacity by 515% while reducing specific energy consumption (kWh/ton).

Gevorderde stofonderdrukking-integrasie | Tegniese basis: Sealed transfer points with strategically placed fog cannons using minimal water | Bedryfsvoordeel: Contains dust at source, improving site visibility and air quality for operators | ROI impak: Ensures regulatory compliance, verminder skoonmaakkoste, and minimizes product loss as airborne fines.

Modular Walkway & Maintenance Design | Tegniese basis: Prefabricated access platforms, hydraulicassisted liner change systems | Bedryfsvoordeel: Bied veilige, efficient access for inspection and routine maintenance tasks | ROI impak: Besnoei beplande instandhoudingstyd met tot 40% and significantly improves worker safety metrics.

Gesentraliseerde smering & Toestandsmonitering | Tegniese basis: Automated lubrication system with PLC control and vibration/temperature sensor ports | Bedryfsvoordeel: Ensures critical bearings receive precise lubrication; enables predictive maintenance scheduling | ROI impak: Extends bearing life by over 20% and prevents unexpected failures through datadriven insights.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard basislyn | This Iron Ore Crushing Plant Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Liner Life (Skuurerts) | Gebaseer op standaard mangaanstaal | Proprietary alloy matrix & chamber design| +3550% |
| Operasionele Beskikbaarheid (Planned) | ~92% (insluitend voering veranderinge) |>96% (with fastchange systems)| +4+ persentasiepunte |
| Spesifieke energieverbruik| Varies by design; basislyn = 100%| Geoptimaliseerde kinematika & VFD control| Vermindering van 812% |
| Tramp Metal Incident Recovery Time| 2472 hours for inspection/repair|90% |
| Deurvloeikonsekwentheid (vs. Ontwerp)| ±15% fluctuation common|< ±5% fluctuation with smart feed control| Significantly more stable output |

5. TEGNIESE SPESIFIKASIES

Kapasiteitsreeks: Konfigureerbaar vanaf 2,000 oor 12,000 metrieke ton per uur (TPH), depending on model selection and ore characteristics.
Primary Crusher Types Available: Heavyduty gyratory crushers (54”75” feed opening) or large jaw crushers.
Kragvereistes: Hoofaandrywing motors van 300 kW tot 800 kW. Total installed plant power varies with ancillary equipment.
Materiaalspesifikasies: Mainframe construction from welded steel plate; liners in highchrome alloy iron; wear surfaces lined with replaceable AR400 steel plates.
Fisiese afmetings (Ongeveer., Gyratorybased plant): Footprint ~25m L x 15m W x 20m H (excluding feed hopper ramp).
Omgewingsbedryfsreeks: Designed for ambient temperatures from 30°C to +45°C; stofdigte elektriese omhulsels; IP65 rating on critical components.

6. TOEPASSINGSSCENARIO'S

Large OpenPit Magnetite Mine Expansion

Uitdaging: An existing operation needed to double primary crushing capacity but had limited space for expansion within the pit perimeter. Downtime during tiein was also a critical concern.
Oplossing: Implementation of a preassembled modular Chinese Iron Ore Crushing Plant on a new bench adjacent to the existing setup. The plant was factorytested before shipment.
Resultate: The modular approach reduced onsite construction time by 60%. The new plant achieved design throughput of 6,500 TPH within one week of commissioning, with zero impact on existing production during installation.

Hematite Processing Plant Modernization

Uitdaging:Aging primary jaw crushers suffered from excessive vibration, frequent bearing failures,and an inability to handle increasingly hard ore lenses,causing constant bottlenecks.
Solution Replacement with a modern gyratorybased Chinese Iron Ore Crushing Plant featuring advanced base frame designand automated lubrication.The installation included upgraded rock breaker stations at the feed tip
Results Unplanned breakdowns at primary stage were eliminated Throughput increased by22 due to superior reduction ratioand consistent feeding Annual maintenance costs decreased by an estimated35

7.KOMMERSIËLE OORWEGINGS

Equipment pricing is tiered based on capacityand selected core crusher technology:
Vlak 1(20004000TPH):Based on large jawcrusher technology
Vlak 2(40008000TPH):Based on midrangegyratorycrushers most commonfor major projects
Vlak 3(8000TPH+):Customengineeredgyratorysystems

Optional Features Include:
On skidmounted lubrication systems
Advanced predictive monitoring packages wireless sensor networks
Extendedwear packagesfor critical chutesand conveyors
Turnkey installation supervisionand commissioning services

Dienspakkette beskikbaar:
Standard warranty covering partsand laborfor12months
Extended performance agreementscovering total costper toncrushed
Annual inspectionand condition assessmentreports

Financing Options Project financing can be structured through partner institutions including leaseto own arrangementsor milestonebased payment plans alignedwith project development schedules

8.Gereelde vrae

Q What levelof preparationis requiredat my sitebefore installation?
A A level compacted platformwith engineered concrete foundationsis required Detailed civil drawingsare provided earlyin the project cyclefor site preparationto proceedin parallelwith equipment manufacturing

Q How does thisplant ensure compatibilitywith my existing secondarycrushingandscreening circuit?
A Our engineering teamwill reviewyour downstream equipment specificationsand product size requirementsThe discharge openingand conveyor interfaceof theprimary plantare designedto matchyour existing flow sheetensuringa smooth integration

Q Whatisthe expected timelinefrom orderto commissioning?
A For standard configurationslead timesrange from8to14months dependingon scaleand complexityThis includes manufacturing factory testing disassemblyfor shipping ocean freightand re assembly onsite Timelinesare defined clearlyin the project scheduleupon order confirmation

Q Are spare parts readily availablegiven the geographic locationof manufacture?
A Yes Critical wear parts are stockedin regional warehouseson multiple continents Furthermorea digital inventoryof your plant’s specific partswith detailed drawingsis providedto facilitate local machiningif ever requiredin an emergency

Q Can thisplant be automatedto tieintoa centralcontrol room?
A AbsolutelyThe crushingplantis controlledbyits ownPLCwhichis fullycapableof interfacingwith your broaderplant DCSor SCADA systemusing standard industrial protocols(eg Profibus Ethernet/IP)Remote monitoringand controlare standard features