1. PYNPUNT GEDREWE OPENING

Stygende bedryfskoste en onvoorspelbare stilstand erodeer jou steengroef se winsgewendheid? Die bestuur van 'n klipgroef-breekaanleg bied duidelike uitdagings wat 'n direkte impak op jou wins het. Algemene pynpunte sluit in:
Oormatige stilstand vir instandhouding: Gereelde voering veranderinge, dra mislukkings, en onverwagte onderbrekings stop produksie. Bedryfsdata dui daarop dat onbeplande stilstand meer kan kos $10,000 per uur in verlore uitset en arbeid.
Inkonsekwente produkgradering: Fluktuasies in voermateriaal of breker prestasie lei tot offspec aggregaat, produkverwerping tot gevolg het, kostes te verminder, en ontevrede kliënte.
Hoë energieverbruik: Ondoeltreffende drukkamers en aandrywers verbruik oormatige krag, making energy one of the largest variable costs in your processing circuit.
Vinnige Slytasie Deel Degradasie: Abrasive stone varieties cause accelerated wear on liners, hamers, en kake, leading to high consumable costs and frequent production pauses.
Beperkte buigsaamheid & Skaalbaarheid: Inflexible plants struggle to adapt to changing market demands for different aggregate sizes or increased throughput.

Is your current solution equipped to minimize these operational risks? The right primary crushing station is not just a purchase; it's a strategic investment in plantwide stability and efficiency.

2. PRODUK OORSIG

The cornerstone of any efficient operation is a robust primary jaw crusher station. Engineered for the initial reduction of blasted quarry rock (typically from 600900mm down to 150250mm), this equipment forms the critical first stage in your size reduction circuit.

Operasionele werkvloei:
1. Voerinname: Dump trucks or wheel loaders deposit shot rock into a heavyduty vibrating grizzly feeder (VGFF VGF).
2. Voorafskerm & Bypass: The VGF removes natural fines and sub150mm material, directing it to a bypass conveyor to reduce unnecessary crusher load and wear.
3. Primêre verplettering: Oversize material is conveyed into the jaw crusher, waar 'n vaste kakebeen en 'n bewegende kakebeen geweldige drukkrag uitoefen om die klip te breek.
4. Ontslag & Transport: Gebreekte materiaal word op 'n hoofprodukvervoerband afgegooi vir vervoer na sekondêre vergruising of opberging.

Toepassingsomvang & Beperkings:
Omvang: Ideaal vir harde rotsgroewe (graniet, basalt, val rots) and abrasive applications. Suited for stationary primary crushing stations.
Beperkings: Nie ontwerp vir finale produk vorming of ultrafyn druk nie. Requires competent feed material; sticky or highclay content feed can cause chamber packing without proper prescreening.

3. KERNKENMERKE

Diep verpletterende kamer & Aggressiewe kneephoek | Tegniese basis: Geoptimaliseerde kinematiese ontwerp | Bedryfsvoordeel: Enables higher throughput capacity and effective breaking of larger feed blocks | ROI impak: Verhoog verwerkte ton per uur (TPH), batebenutting te verbeter

HeavyDuty vervaardigde staalraam | Tegniese basis: Eindige Element Analise (FEA)optimized construction | Bedryfsvoordeel: Bied uitsonderlike duursaamheid teen skokladings van onbreekbare materiaal | ROI impak: Verminder die risiko van katastrofiese raamversaking, die operasionele lewe verder verleng 20 jare

Hidrouliese verstelling & Skoonmaakstelsel | Tegniese basis: Geïntegreerde hidrouliese silinders vir wisselspanning en kamer skoonmaak | Bedryfsvoordeel: Allows quick CSS adjustment for product size changes and automatic release of tramp iron | ROI impak: Cuts adjustment time by 70% teenoor handstelsels, stilstand te verminder

Bolted Bearing Cartridge Design | Tegniese basis: Modulêr, preassembled bearing housings | Bedryfsvoordeel: Enables faster replacement of pitman bearings without machining onsite | ROI impak: Reduces critical bearing service time from days to hours, significantly boosting availability

QuarryGrade Sferiese Rollaers | Tegniese basis: Oversized bearings with L10 life calculations exceeding 50,000 ure | Bedryfsvoordeel: Handles high radial and axial loads with superior reliability | ROI impak: Lowers total cost of ownership by extending service intervals and preventing unplanned stoppages

Replaceable Liners with Multiple Profiles | Tegniese basis: High manganese steel alloys with optional chrome or ceramic additives | Bedryfsvoordeel: Offers profile choices (bv., geriffelde, kwasi) to match rock abrasiveness and desired output shape | ROI impak: Optimizes liner lifetocost ratio; velddata wys tot 30% longer life in abrasive granite

Geïntegreerde motorbasis & Ry wagte | Technical Basis Unified baseplate design with safetycompliant guarding| Operational Benefit Simplifies installation alignment and ensures operator safety during routine inspections| ROI Impact Reduces installation labor costs by approximately 15% and mitigates safety incident risk

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard | Ons Kaakbreker Oplossing | Voordeel (% verbetering) |
|||||
| Meganiese beskikbaarheid | 9092% | 9496% | +4% uptyd |
| Liner Life (Skuur graniet)| 120,000 150,000 ton | 180,000 200,000 ton | +30% lewensduur |
| Energieverbruik | Basislyn | Geoptimaliseerde kamermeetkunde & dryf |8% kWh per ton |
| Bearing Replacement Time | 2436 ure | 812 ure |67% service duration |
| Deursetkapasiteit | Baseline TPH Higher stroke & speed capability +15% TPH in comparable duty |

5. TEGNIESE SPESIFIKASIES

Modelreeks kapasiteit: 300 1,800 MT/H (varies by feed material density)
Voer openingsreeks: 900mm x 600mm up to 1,500mm x 1,200mm
Kragvereistes: Hoof breker motor van 75 kW tot 300 kW (400V/50Hz of aanpasbaar). Complete station includes feeder & vervoerband dryf.
Materiaalspesifikasies: Main frame – S355J2 steel; Liners – Mn18Cr2 / Mn22Cr2; Shaft – forged42CrMo4 steel.
Fisiese afmetings (Stasie): Typical footprint ranges from ~15m L x ~6m W x ~7m H.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 20°C tot +45°C. Stof verseëling standaard; opsionele verwarmingspakkette beskikbaar.

6. TOEPASSINGSSCENARIO'S

Granietsteengroef Uitbreidingsprojek

Challenge A granite quarry needed to increase primary circuit throughput by25%to feed anew secondary cone crusher line without expanding their blasting schedule
Solution Installation ofa highcapacity jaw crusher station with an aggressive nip angle anda deeper chamber tomaximize tonnage from existing feed size
Results Achieveda28%increasein primary throughput(measured intons per blast pile) andreduced the average product size P80by15%, verbeter sekondêre kegelbreker doeltreffendheid

Transitioningto More Abrasive Feed Material

Challenge A limestone quarry facing depletion needed tousea new pitwith significantly more chertand quartz inclusions leading tounacceptable wear rates ontheir existing primary crusher
Solution Retrofitteda new jaw crusher featuring bolted bearing cartridges foreasier maintenanceand installed optional hybrid ceramic/manganese liners inthe most critical wear zones
Results Extended liner change intervals from6weeks backto the original8week cycle despite more abrasive feed reducing annual liner costby22%and maintaining availability

7.KOMMERSIËLE OORWEGINGS

Equipment pricing is tiered based on size capacity:
Vlak 1(300600TPH): Foundational modelsfor smallto midsize quarries
Vlak 2(6001200TPH): Highperformance modelswith advanced hydraulicsand telemetry standard
Vlak 3(12001800TPH): Heavyduty stationsfor largescale mining operations including integrated automation interfaces

Opsionele kenmerke:
Advanced wear monitoring systems Remote vibration sensing packages Automated grease lubrication systems Walkin modules forenclosed maintenance

Dienspakkette:
Level1– Parts& Ondersteuning(standard warranty)
Level2– Scheduled Inspections& Toestandsmonitering(includes annual health check)
Level3– Full Maintenance Agreement(covers planned parts laborand24/7 emergency support)

Financing Options Available through partner institutions including operating lease capital leaseor projectbased financing typically structured over37years

8.Gereelde vrae

Q Can this jaw crusher station integrate with our existing PLC control system?
A Yes most models feature standardized communication protocols(Modbus Profibus) allowing integration into existing plant SCADA systems formonitoring key parameters like power drawand CSS

Q What isthe expected impact onour overall plant energy consumption?
A Field data shows that due toefficient drive designand optimized kinematics our solution typically reduces energy useper tonof crushed material by510% depending onthe rock hardness This directly lowers operating costs

V Is slytasieonderdele wêreldwyd geredelik beskikbaar?
A We maintain regional inventory hubs onthree continents ensuring critical wear parts like linersare available within48hours formost locations minimizing potential downtime

Q What arethe commercial terms formajor spare parts?
A We offer guaranteed pricing contracts forwear part kits which lock inprices fora defined period(usually1224months) providing predictable budgetingforyour maintenance planning

Q How long doesinstallation typically takeand what site preparation isrequired?
A Fora complete station installation requires approximately1014days with our supervised erection team Site preparation requires level compacted ground anda concrete foundation accordingtosupplied engineering drawings delivered prior tomobilization