1. PYNPUNT GEDREWE OPENING

Stygende bedryfskoste en onvoorspelbare stilstand erodeer jou projekmarges? In totale produksie, mineraal verwerking, en herwinning, ondoeltreffende vergruising en sifting is 'n primêre bottelnek. Algemene uitdagings sluit in:
Oormatige stilstand vir instandhouding: Gereelde voering veranderinge, dra mislukkings, and conveyor issues halt your entire production line.
Inkonsekwente produkgradering: Poor screening efficiency and improper crushing chamber dynamics lead to offspec material, causing product rejection and revenue loss.
Hoë bedryfskoste: Stygende energieverbruik per ton, coupled with high wear part replacement frequency, 'n direkte impak op jou winspunt.
Rigiede plantkonfigurasie: Vaste stelsels kan nie aanpas by veranderende voermateriaal of finale produkvereistes nie, operasionele buigsaamheid beperk.

Is jou huidige toerusting besig om hierdie probleme aan te spreek, of is dit die bron daarvan? Die regte primêre breekstasie is nie net 'n aankoop nie; it’s a strategic decision for longterm site profitability.

2. PRODUK OORSIG: PRIMARY CRUSHING AND SCREENING STATION

This primary crushing and screening station is a fullyintegrated, trackmounted or modular system designed for the initial size reduction of runofmine ore, steengroef, of sloopbeton. Its workflow is engineered for continuous heavyduty operation:
1. Voer: Material is deposited via excavator or wheel loader into a robust vibrating grizzly feeder.
2. Voorafskerm & Verpletterend: The grizzly bypasses fines directly to a conveyor while oversize material is directed into the highcapacity jaw crusher.
3. Primêre verplettering: The jaw crusher performs the first mechanical reduction using compressive force.
4. PostCrushing Screening: Crushed material is conveyed to an integrated screen for immediate separation into required product fractions.
5. Stockpiling or Secondary Conveyance: Sized fractions are stockpiled or conveyed to the next stage of processing.

Toepassingsomvang: Ideaal vir harde rots mynbou, aggregate quarries, grootskaalse konstruksieprojekte, en C&D recycling operations requiring highvolume primary reduction.
Beperkings: Nie ontwerp vir finale produk vorming nie (tersiêre verplettering) or processing highly abrasive materials without specific liner configurations. Feed size must adhere to crusher opening specifications.

3. KERNKENMERKE

Direct Drive Jaw Crusher | Tegniese basis: Eliminates Vbelts and associated components | Bedryfsvoordeel: Reduces power transmission losses and removes routine belt tensioning/maintenance | ROI impak: Velddata wys tot 10% laer brandstofverbruik en 15% less scheduled maintenance time.

Independent PreScreen Module | Tegniese basis: Twodeck vibrating grid mounted ahead of the crusher | Bedryfsvoordeel: Removes fines and natural sand from the crusher feed, reducing chamber wear and increasing throughput of valuable midsize material | ROI impak: Can extend manganese liner life by up to 30% and increase total station output.

Hidrouliese instelling verstelling (HSA) | Tegniese basis: Wedgebased chamber adjustment via hydraulic cylinders | Bedryfsvoordeel: Allows operators to change the crusher closedside setting (CSS) in onder 2 minutes for precise product size control without stopping the plant | ROI impak: Minimizes nonproductive time during product changeovers by over 90%.

HeavyDuty Feeder with Step Grizzly | Tegniese basis: Reinforced feeder with stepped grizzly bars to prevent clogging | Bedryfsvoordeel: Ensures consistent feed flow even with sticky or claybound materials, preventing bridging and feeder stall | ROI impak: Maintains target throughput rates in challenging conditions, avoiding costly flow interruptions.

Integrated Plant Automation System (IPAS) | Tegniese basis: PLCbased control with touchscreen interface monitoring all critical functions | Bedryfsvoordeel: Verskaf intydse data oor produksiekoerse, krag trek, and operational status; enables singlepanel control for setup and troubleshooting | ROI impak: Verbeter algehele doeltreffendheid van toerusting (OEE) through better monitoring and reduces diagnostic time by an average of 50%.

Gesentraliseerde smeerpunte | Tegniese basis: Manifold system linking all major bearing points to a single station | Bedryfsvoordeel: Aktiveer veilige, rapid daily lubrication checks without requiring access around moving components | ROI impak: Standardizes preventive maintenance routines, enhancing bearing life and reducing lubricationrelated failures.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Nywerheid Standaard Oplossing | This Primary Crushing & Screening Station | Voordeel (% Verbetering) |
| : | : | : | : |
| Ton per uur (TPH) Doeltreffendheid| Reliant on optimal feed conditions only| Onderhou >90% of rated TPH with variable/ sticky feed due to step grizzly design| +1520% sustained output |
| Dra Deel Koste per ton| Based on standard manganese composition| Utilizes sitespecific alloy analysis for jaw liners in highabrasion applications| Tot 25% koste per ton gebreekte |
| Opstelling / Configuration Time| Multiple machine positioning & cable connections required| Singlelift modules with prerigged electrical connections between units| 70% relocation time |
| Energieverbruik (kWh/ton)| Direct mechanical drive with fixed speed motors| Loadsensing hydraulics & direct electric crusher drive adjust power to demand| 8% gemiddelde energieverbruik |

Based on comparative field trials in granite quarry applications.

5. TEGNIESE SPESIFIKASIES

Primêre Breker Tipe: Nordberg C106 Jaw Crusher
Voer opening: 1,060 mm x 700 mm (42” x 28”)
Maksimum voergrootte: 600 mm (24”)
Geslote kant-instelling (CSS) Reeks: 70 200 mm
Kapasiteitsreeks: Tot 500 MTPH (afhanklik van materiaaldigtheid & CSS)
Krag Eenheid: CAT C9 / C9.3 ACERT Tier 4 Finale dieselenjin
Totale geïnstalleerde krag: 224 kW
Feeder Type: Vibrating Grizzly Feeder VG43912V
Skermmodule: Twodeck inclined screen TS303
Main Conveyor Width: 1,000 mm
Vervoer Afmetings (LxBxH): ~19m x ~3m x ~4m
Bedryfsgewig: ~45 ton
Bedryfstemperatuurreeks: 25°C tot +40°C

6. TOEPASSINGSSCENARIO'S

Graniet Aggregate Quarry Uitbreiding | Uitdaging: Existing fixed primary plant could not service new pit face location without major infrastructure cost; mobile solutions lacked necessary throughput and prescreening. Oplossing: Deployment of a trackmounted primary crushing and screening station fed directly by excavator at the new face. Resultate: Eliminated need for costly ramp construction and dump truck haulage to old plant. Behaal konsekwente deurset van 380 Mtph of minus200mm base material with improved yield of valuable railway ballast fraction due to integrated screening.

Grootskaalse infrastruktuurprojek (Dam Construction) | Uitdaging: Processing riverrun gravel with high sand content led to rapid crusher wear choke points in traditional setups. Solution Implementation of a modular primary station featuring an independent prescreen module ahead of the jaw crusher Results Prescreen removed over 25% of sand/fines prior to crushing reducing abrasive wear Throughput increased by18% as crusher processed only oversize Wear part replacement intervals extended by approximately40%

7 KOMMERSIËLE OORWEGINGS

Pricing for a primary crushing station varies significantly based on configuration:

• Base Configuration Includes core jaw crusher basic feeder engine chassis essential conveyors PLC start/stop controls Tier pricing typically begins in range appropriate for this capital equipment class

Optional Features That Add Value:

• Dust suppression system package including water tank spray bars
• Magnet installation over discharge conveyor ferrous metal removal
• Radio remote control unit for independent feeder/crusher operation from ground level
• Extended wear part kits stock

Dienspakkette beskikbaar:

• Comprehensive Extended Warranty covering major components years unlimited hours
• Scheduled Maintenance Plan providing fixed cost annual inspections parts labor
• On Site Operator Training Program days hands instruction

Financing Options Flexible capital solutions include equipment leasing long term rental purchase leaseback structures tailored support cash flow management project timelines

8 Gereelde vrae

What type/size of excavator is recommended as a feeder?
A minimum operating weight class excavator equipped with suitable bucket capacity ensure consistent choke feeding maximize crusher efficiency productivity

How does this system handle reinforcing bar rebar in concrete demolition waste?
While jaw can process reinforced concrete integrated overband magnet discharge conveyor effectively removes liberated ferrous metals protecting downstream conveyors secondary crushers

What are typical delivery lead times after order confirmation?
Standard configurations have confirmed lead time weeks subject build slot availability engineering review Custom modular designs may require additional weeks detailed engineering fabrication

Is operator training provided with purchase?
Yes comprehensive onsite training program conducted commissioning covers daily operation routine maintenance safety procedures troubleshooting using actual plant systems

Can this station be integrated into existing fixed plant circuit as temporary primary unit?
Yes stations are designed standalone mobility can be positioned feed directly into existing secondary tertiary circuits via discharge conveyor ideal use during planned upgrades maintenance existing primary crushers