1. PYNPUNT GEDREWE OPENING

Are you managing a midtolarge scale aggregate operation and facing the constant pressure to balance highvolume output with operational stability? Die uitdagings van 'n 250300tph-klipbreekaanleg is beduidend. Unplanned downtime from equipment failure can cost thousands per hour in lost production and idle labor. Inconsistent feed material leads to fluctuating final product gradation, causing rejections and compromising contract compliance. Stygende energiekoste erodeer direk winsmarges op elke ton wat geproduseer word. Verder, meeting stringent environmental regulations on dust and noise adds complexity and capital expense. Is hierdie kwessies 'n impak op jou winspunt? Hoe bereik jy betroubare, hightonnage production while controlling operational costs and ensuring plant longevity? The solution lies in a fundamentally robust and intelligently engineered crushing plant design.

2. PRODUK OORSIG

This datasheet details a complete stationary 250300tph klip breek plant engineered for granite, basalt, kalksteen, and other hard rock applications. It is a multistage processing system designed for continuous, highvolume production of highquality aggregates (05mm, 510mm, 1020mm, 2031.5mm).

Operasionele werkvloei:
1. Primêre verplettering: Dump trucks feed material into a largecapacity vibrating grizzly feeder which removes fines before directing oversize to a heavyduty jaw crusher for initial size reduction.
2. Sekondêr & Tersiêre verplettering: The primary crushed material is conveyed to a cone crusher for secondary reduction. A subsequent cone crusher or impact crusher (depending on material abrasiveness and product shape requirements) performs tertiary crushing.
3. Sifting & Klassifikasie: Material is routed through multipledeck vibrating screens to precisely separate it into specified product sizes.
4. Materiaalhantering & Voorraad opgaar: Onspec aggregates are conveyed to designated stockpiles via radial stackers or fixed conveyors, while oversize material is recirculated back to the appropriate crusher.

Toepassingsomvang: Ideaal vir groot steengroefbedrywighede, groot infrastruktuur projek ondersteuning (hoofweë, spoorweë), and commercial concrete/asphalt plant feed. Beperkings: Not suitable for portable or skidmounted applications; requires stable foundation and substantial upfront civil works.

3. KERNKENMERKE

Intelligente voerbeheerstelsel | Tegniese basis: Veranderlike frekwensie-aandrywing (VFD) on feeder with level sensors | Bedryfsvoordeel: Maintains optimal chokefeed condition for crushers, preventing empty running and cavity flooding | ROI impak: Tot 15% reduction in energy consumption per ton and ~10% increase in liner life.

Centralized Dust Suppression Envelope | Tegniese basis: Ingekapsuleerde oordragpunte met strategies geplaasde miskanonne & bag filters | Bedryfsvoordeel: Contains dust at source across entire flow path, ensuring compliance and improving site visibility/worker health | ROI impak: Mitigates regulatory fines and reduces cleanup labor by an estimated 30%.

Hoë-doeltreffendheid breekkamer ontwerp | Tegniese basis: Laminated crushing principle with optimized kinematics in jaw and cone crushers | Bedryfsvoordeel: Generates more interparticle crushing for improved product shape (higher cubicity) and increased yield of premium fractions | ROI impak: Higher market value for crushed products and reduced waste.

PLCB-gebaseerde outomatiese proseslogika | Tegniese basis: Programmable Logic Controller with HMI touchscreen monitoring crusher load, vervoerband spoed, and screen efficiency | Bedryfsvoordeel: Allows singleoperator oversight of entire plant flow; automatic adjustments prevent overloads and blockages | ROI impak: Reduces operational staffing requirements by up to 2 FTE per shift while increasing system availability.

Modulêre Onderhoud Toegang Ontwerp | Tegniese basis: Hidrouliese verstelling & setting release systems on crushers; walkin platforms around all major components | Bedryfsvoordeel: Enables faster liner changes, routine inspections, and component replacement with standard tools | ROI impak: Besnoei beplande instandhoudingstyd met tot 40%, directly increasing annual production hours.

HeavyDuty Conveyor Specification | Tegniese basis: CEMA Class IV idlers with impact beds at loading zones; gevulkaniseerde bandverbindings | Bedryfsvoordeel: Eliminates premature belt wear at transfer points, drastically reducing belt failure risk—a leading cause of unplanned stoppage | ROI impak: Verleng gemiddelde tyd tussen mislukkings (MTBF) for conveying system by over 50%.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (250300tph Plant) | This Sustainable Stone Crushing Plant Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Overall System Availability | ~85% 88% (Seasonal) |> 92% (Jaarlikse teiken) |> +5% aan +8% |
| Energieverbruik per ton gebreekte| ~1.8 2.1 kWh/t |> 1.6 1.7 kWh/t |> ~10% Reduction |
| Totale koste van eienaarskap (5Jaarprojeksie)| Basislyn |> 1520% Laer |> Direct Cost Savings |
| Produk Vorm (% Cubical Content)| Wissel wyd (~6575%) |> Konsekwent > 78% |> Higher Premium Product Yield |
| Noise Emission at Property Line| Dikwels >75 dB(A) |> Beheer < 70 dB(A) |> Easier Permitting & Gemeenskapsverhoudinge |

_Based on field data from comparable installations using similar granite feed material._

5. TEGNIESE SPESIFIKASIES

Ontwerp deursetkapasiteit: 250 300 metrieke ton per uur (tph), afhangende van voermateriaal hardheid (<180 MPa aanbeveel), grootte verspreiding (<750mm), en vereiste produkgradasie.
Totale gekoppelde krag: Ongeveer 550 650 kW.
Sleutel materiaal spesifikasies:
Primary Crusher Feed Size Max.: ≤750 mm
Finale produkgroottes: Configurable from 05mm sand up to 31.5mm aggregate.
Conveyor Belt Width/Speed: Main conveyors typically B1000mm width @1.6m/s.
Fisiese Voetspoor (Ongeveer.): Length ~120m x Width ~65m (excluding stockpile areas). Requires detailed civil foundation engineering.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 20°C tot +45°C met toepaslike smeerstelsels; standard dust suppression rated for conditions up to 85% relatiewe humiditeit.

6. TOEPASSINGSSCENARIO'S

Large Quarry Expansion Project

Uitdaging: A regional quarry needed to increase output from 200tph to over 280tph reliably to fulfill a new highway contract but faced space constraints and strict new county noise ordinances.
Oplossing: Implementation of this compactly designed multistage stone crushing plant featuring soundinsulated enclosures around key equipment like the secondary/tertiary crushers.
Resultate: Achieved consistent throughput of ≥290tph while passing compliance noise audits (<70dB at site boundary). The automated control system allowed management of the increased throughput without adding shift personnel.

Integrated Concrete Producer

Uitdaging: A vertically integrated concrete company operating its own limestone quarry experienced high maintenance costs from abrasive wear on tertiary stage equipment and inconsistent sand yield affecting mix designs.
Oplossing: Installation of this plant configuration featuring a tertiary cone crusher specifically selected for abrasive rock with a specialized chamber profile.
Resultate: Tertiary crusher manganese liner life increased by approximately two weeks per set under identical conditions due to optimized feed from preceding stages combined with chamber design.The consistent gradation curve improved sand yield stability by ±3%, leading directly to more predictable concrete batch quality.

7.KOMMERSIËLE OORWEGINGS

A sustainable stone crushing plant represents a significant capital investment designed for longterm returns.

Toerustingprysvlakke:
Base Configuration includes primary jaw crusher feeder station secondary cone tertiary impactor basic screening structure conveyors electrical control panel
Enhanced Configuration adds automated grease systems centralized lubrication advanced PLC automation package upgraded dust suppression bag filter units
Turnkey Premium Configuration includes full civil works design support erection commissioning supervision training extended commissioning period

Optional Features include metal detection tramp iron relief systems automatic sampler units remote monitoring telematics packages water recycling systems

Service Packages are offered as annual preventative maintenance contracts including scheduled inspections parts discounts priority technical support

Financing Options available through partner institutions include traditional equipment leasing longterm loans or powerbythehour style performancebased agreements where service costs are bundled

Gereelde vrae

What type of electrical supply is required?
The complete plant typically requires a mediumvoltage connection (~10kV) feeding into a dedicated transformer substation due to the total connected load (~550650kW). Detailed power requirements are provided during the project engineering phase.

How does this setup handle wet or sticky feed material?
The vibrating grizzly feeder deck can be equipped with heating elements or special liners We also recommend screen deck heating systems as an option These features prevent material buildup ensuring consistent flow during cold or damp conditions

What is the expected timeframe from order placement to commissioning?
For a standard configuration lead time is typically months following detailed engineering For turnkey projects including civil works total project duration generally ranges from months subject to sitespecific conditions

Is onderdele geredelik beskikbaar?
Yes Critical wear parts like mantles concaves jaw plates are standardized items held in regional inventory Standard mechanical electrical components use globally available bearings seals motors drives minimizing procurement delays

Can this plant be reconfigured later if my product requirements change?
Yes The modular design allows for future modifications such as adding an extra screen deck integrating a different tertiary crusher type or rerouting conveyors Engineering support is provided for such upgrade projects