1. PYNPUNT GEDREWE OPENING

Stygende bedryfskoste en onvoorspelbare stilstand erodeer jou totale produksiemarges? Vir aanlegbestuurders en ingenieurskontrakteurs, die kernuitdagings in primêre vergruising spruit dikwels uit toerusting wat nie by die volle omvang van materiaal- en uitsetvereistes pas nie. Algemene pynpunte sluit in:

Ongeskeduleerde stilstand & Hoë slytasiekoste: Abrasive feed material rapidly degrades crusher components not engineered for specific abrasion indices, leading to frequent liner changes and associated labor costs, jou hele verwerkingslyn stop.
Inkonsekwente deurset & Knelpunte: Underpowered or incorrectly configured primary crushers create a bottleneck, failing to feed downstream screens and conveyors at an optimal rate, capping your plant’s total potential output.
Oormatige boetes Generasie & Product Mismanagement: Improper crushing chamber geometry and stroke can produce a higher percentage of undersized material than required, reducing saleable product yield and increasing waste.
Hoë operasionele kompleksiteit & Veiligheidsrisiko's: Manual adjustment systems for setting changes or clearing blockages increase exposure time in highrisk areas and require skilled personnel, impacting both safety protocols and operational agility.

Is your primary crushing station a source of reliability, or a recurring cost center? The solution lies in selecting a primary stone crusher plant engineered not just to break rock, but to optimize your entire production chain’s efficiency and profitability.

2. PRODUK OORSIG

A stationary primary stone crusher plant is a permanently installed system designed for the first reduction of runofmine (ROM) material from large quarried rock (tipies tot 1,5 m groot) down to a conveyable product, usually between 150mm to 300mm. It forms the critical foundation of any aggregate or mining operation.

Operasionele werkvloei:
1. Voerinname: ROM material is dumped by haul trucks into a heavyduty vibrating grizzly feeder (VGFF VGF).
2. Voorafskerm & Bypass: The VGF separates fines (bv., grond, small rocks) from the main feed, directing them to a bypass conveyor while scalping oversize material directly into the crusher.
3. Primêre verplettering: The core jaw crusher or gyratory crusher applies compressive force via a fixed and moving surface to fracture the rock.
4. Ontslag & Transport: Crushed material is discharged onto a main product conveyor for transport to secondary crushing or stockpiling stages.

Toepassingsomvang: Ideal for hightonnage quarrying of granite, basalt, kalksteen, en ander skuur aggregate; grootskaalse mynbedrywighede; and major infrastructure project support plants.

Sleutelbeperkings: Requires significant civil works for foundation; not suitable for portable or skidmounted applications; initial capital investment is higher than mobile solutions but offers superior longterm throughput and wear life in fixed locations.

3. KERNKENMERKE

Diep verpletterende kamer & Geoptimaliseerde kinematika | Tegniese basis: Increased nip angle and longer vertical stroke | Bedryfsvoordeel: Enables higher capacity per stroke and reduces bridging incidents | ROI impak: Sustained design throughput with fewer operational interruptions for clearing

HeavyDuty vervaardigde staalraam | Tegniese basis: Eindige Element Analise (FEA) geoptimaliseerde stresverspreiding | Bedryfsvoordeel: Bied uitsonderlike duursaamheid teen skokladings van onbreekbare materiaal | ROI impak: Minimaliseer die risiko van katastrofiese raamversaking, protecting longterm asset integrity

Hidrouliese verstelling & Skoonmaakstelsel | Tegniese basis: Geïntegreerde hidrouliese ramme vir CSS-verstelling en kamer skoonmaak | Bedryfsvoordeel: Laat vinnig toe, safe setting changes and reversal to clear blockages without manual intervention | ROI impak: Verminder stilstand vir roetine-aanpassings met tot 80% in vergelyking met handafsteekstelsels

HighPerformance Bearing Cartridge | Tegniese basis: Spherical roller bearings mounted in a removable cartridge housing | Bedryfsvoordeel: Simplifies bearing replacement and ensures precise alignment for extended service life | ROI impak: Lowers maintenance time from days to hours during major service intervals

QuarryGrade Kaak sterf & Voeringe | Tegniese basis: Manganese steel alloy composition tailored for specific material abrasiveness | Bedryfsvoordeel: Maximizes wear life between changeouts under severe crushing conditions | ROI impak: Directly reduces costperton for wear parts through extended service cycles

Geïntegreerde motorbasis & Ry wagte | Tegniese basis: Unified baseplate design with full mechanical guarding | Bedryfsvoordeel: Simplifies installation alignment and ensures operator safety around drive components | ROI impak: Reduces installation labor costs and mitigates compliance risks

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard Norm | Our Primary Stone Crusher Plant Solution | Gedokumenteerde voordeel |
| : | : | : | : |
| Beskikbaarheid / Optyd | 9294% (geskeduleer + ongeskeduleerd) | >96% sustained availability in field data reports| +3% verbetering |
| Dra Life (Jaw Liners Abrasive Rock) | ~120,000 metric tons per set (MTPT)| Tot 150,000 MTPT with optimized alloy/design| +25% verbetering |
| Kragverbruik per ton gebreekte| Varies with settings; basislyn = 100%| Gemiddelde vermindering van 58% via efficient kinematics & dryf ontwerp| 7% verbetering |
| Aanpassing / Clearing Time (CSS Verandering)| 24 ure met manuele shims / tralies| <30 minutes via remote hydraulic system| ~85% reduction |

5. TEGNIESE SPESIFIKASIES

Model Aanwysing: PJC1200x900
Breker tipe: HeavyDuty Single Toggle Jaw Crusher
Voer opening: 1200mm x 900 mm (47" x 35")
Maksimum voergrootte: ~850mm edge length
Geslote kant-instelling (CSS) Reeks: 150mm 300 mm
Kapasiteitsreeks (@ gegee CSS): 450 750 metrieke ton per uur (MTPH)
Dryfkragvereiste: 160 kW / 200 HP elektriese motor
Total Installed Plant Power: ~250 kW (inkl. VGFF VGF & vervoerbande)
Hoofraamkonstruksie: Gelaste staalplaat, stresverlig
Approximate Total Plant Weight: ~85 metric tons (breker + voerder + struktuur)
Grondslagvereistes: Reinforced concrete as per supplied load drawings
Omgewingsbedryfsreeks: 20°C tot +45 °C omgewing; dust suppression system compatible.

6. TOEPASSINGSSCENARIO'S

Granietsteengroef Uitbreidingsprojek

Uitdaging: An existing quarry needed to double its annual production but was constrained by an aging primary crusher causing excessive downtime (>15%) due to wear part failures and blockages.
Oplossing: Installation of our PJC1200x900 stationary stone crusher plant with hydraulic adjustment and quarrygrade jaw dies specifically selected for highsilica granite.
Resultate: Plant beskikbaarheid het toegeneem tot >96%. Wear part life extended by approximately 28%, contributing directly to a calculated reduction in costperton of crushed material by an estimated $0.15/ton at sustained higher throughput.

LargeScale Limestone Processing for Cement Production

Uitdaging: A cement plant’s raw material feed required consistent sizing below 250mm but their existing primary impactor was generating excessive fines (40mm), wasting energy on overcrushing.
Oplossing: Replacement with our configured jawtype primary stone crusher plant featuring deepchamber geometry optimized for limestone compression crushing.
Resultate: Achieved more controlled fragmentation with the percentage of target product (+40mm/250mm) increasing by over 20%. This reduced load on secondary grinding circuits, leading to an estimated annual energy saving of several hundred thousand kilowatthours.

7. KOMMERSIËLE OORWEGINGS

Our primary stone crusher plants are offered in structured tiers based on capacity:

1. Standaarddiensreeks (1000 MTPH): For megaquarry applications.

Opsionele kenmerke sluit in:
Automated Setting Regulation based on load feedback
Advanced Condition Monitoring sensors package
Verlengde drag komponent pakkette

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including scheduled inspections and priority parts supply.

Flexible financing options are available through partners including equipment leasing structures tailored for capital expenditure planning or projectbased financing linked directly to project milestones.

8\. Gereelde vrae

Q1\. Is this type of stationary plant compatible with my existing downstream screening/conveying setup?
A1\. Yes provided your downstream equipment can handle the designed output capacity range Our engineering team can review your current layout specifications during presales consultation We provide detailed interface drawings including discharge heights conveyor positions etc ensuring compatibility

Q2\. Wat is die tipiese deurlooptyd vanaf bestellingplasing tot ingebruikneming?
A2\. For standard models lead times typically range between six months depending on final configuration This includes manufacturing factory testing disassembly shipping reassembly onsite installation supervision commissioning support Site preparation civil works should be completed prior arrival

Q3\. How does this solution impact my overall site manpower requirements?
A3\. The design emphasizes operational simplicity automation where beneficial Features like remote hydraulic adjustment reduce need personnel perform risky manual tasks However overall staffing levels typically dictated entire processing facility operation not single machine unit Training provided ensure efficient operation maintenance procedures established

Q4\. What are key factors determining total cost ownership beyond initial purchase price?
A4\. Primary factors include wear part consumption rates expressed costperton energy consumption measured kWh/ton scheduled preventive maintenance labor costs potential production losses due unscheduled downtime Our solutions engineered optimize each these variables providing detailed lifecycle cost analysis during selection process

Q5\. Can you supply complete turnkey installation including civil works foundations?
A5\. We specialize supply erection commissioning core crushing equipment itself We work closely network certified local civil engineering contractors who can execute foundation work based our detailed specifications We manage interface coordination ensure seamless project execution