1. PYNPUNT GEDREWE OPENING

Managing an iron ore crushing circuit is a highstakes operation where efficiency directly defines profitability. Staan jy voor hierdie aanhoudende uitdagings?
Ongeskeduleerde stilstand: Unplanned stoppages due to tramp metal, onbreekbare materiaal, or component failure can cost over $10,000 per uur in verlore produksie en arbeid.
Inkonsekwente produkgradering: Fluktuasies in voergrootte of -hardheid lei tot afwykende produk, causing bottlenecks in downstream grinding and processing, reducing overall plant yield.
Hoë instandhoudingskoste & Dra: The abrasive nature of iron ore results in rapid wear of liners, blaasstawe, en ander verbruiksgoedere, driving up operational expenditure and requiring frequent, laborintensive changeouts.
Energie ondoeltreffendheid: Older or improperly configured crushing stages consume excessive power per ton of material processed, a significant and growing lineitem cost.
Onbuigsaamheid tot voervariasie: Fixedspeed crushers struggle to maintain optimal performance when ore characteristics change from one pit zone to another.

How can you achieve a more predictable tonnage cost, reduce operational risk, and ensure your primary crushing stage is an asset rather than a bottleneck?

2. PRODUK OORSIG: WHITE LABEL IRON ORE CRUSHING PLANT

Our solution is a configurable, white label primary and secondary crushing plant engineered specifically for hard, abrasive iron ores (Hematite, Magnetite). It is designed as a modular system for rapid deployment and integration into new or existing mineral processing circuits.

Operasionele werkvloei:
1. Primary Dump/Fee: ROM ore is fed via haul truck or loader into a rugged grizzly feeder, which scalps out fine material and directs oversize to the primary crusher.
2. Primêre verplettering: A heavyduty jaw crusher reduces the ore to a nominal 150200mm product.
3. Sekondêre verplettering & Sifting: The primary crushed material is conveyed to a secondary cone crusher for further reduction. A closedcircuit screen ensures precise final product sizing before transfer to the next processing stage.

Toepassingsomvang & Beperkings:
Omvang: Ideal for greenfield sites, plant expansion projects, or replacement of aging fixed infrastructure. Suitable for production capacities from 500 aan 2,500+ TPH.
Beperkings: Not designed as a tertiary or fine grinding solution. Maximum feed size is limited by primary crusher opening. Plant requires stable, prepared ground for installation.

3. KERNKENMERKE

Aanpasbare breekkamer | Tegniese basis: Hydroset CSS aanpassing & automated control system | Bedryfsvoordeel: Operators can remotely adjust the closedside setting (CSS) in minutes to compensate for feed changes or optimize product size without stopping the crusher. | ROI impak: Maintains target throughput and gradation, preventing downstream bottlenecks; geskat 58% opbrengsverbetering.

Tramp metaalbeskermingstelsel | Tegniese basis: Hydraulic overload relief cylinders with automatic reset | Bedryfsvoordeel: Instant pressure release protects crusher components from catastrophic damage caused by uncrushable steel or digger teeth. | ROI impak: Eliminates risk of major mechanical failure and associated repair costs (often exceeding $50k) and extended downtime.

AbrasionResistant Material Package | Tegniese basis: Premium manganese steel liners with optimized cavity profiles | Bedryfsvoordeel: Liners withstand extreme abrasion from silicarich iron ore, significantly extending service life between changeouts. | ROI impak: Verminder voering verbruik koste deur 1525% and lowers maintenance manhours per ton crushed.

Direct Drive Crusher Tegnologie | Tegniese basis: Eliminates Vbelts and sheaves; couples motor directly to crusher | Bedryfsvoordeel: Verbeter kragoordragdoeltreffendheid (tot 99%), verminder instandhoudingspunte, and allows for variable speed control for process optimization. | ROI impak: Verlaag energieverbruik met ongeveer 812% compared to traditional Vbelt driven systems.

Gesentraliseerde smering & Lube stelsel | Tegniese basis: Automated singlepoint lubrication with monitoring sensors | Bedryfsvoordeel: Verseker dat kritieke laers konsekwente smering ontvang sonder handmatige ingryping, voorkoming van droogloop mislukkings. | ROI impak: Verleng dralewe met tot 40%, reducing spare parts inventory costs and unplanned stops.

Modulêre wandelpaaie & Toegang tot platforms | Tegniese basis: Prefabricated bolttogether safety platforms around all service points | Bedryfsvoordeel: Bied veilige, compliant access for daily inspections and routine maintenance tasks such as liner changes. | ROI impak: Reduces safety incident risk and cuts planned maintenance time by up to 30%, verhoging van plant beskikbaarheid.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (Fixed Speed/Manual) | White Label Iron Ore Crushing Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Beskikbaarheid (Optyd) | 8590% (beplan & onbeplande stops) | 9396% (systemprotected operation) | +7% Verbetering |
| Kragverbruik (kWh/t)| Veranderlik; often inefficient at partial load| Geoptimaliseer via direkte aandrywing & variable speed control| Tot 12% Vermindering |
| Liner Life (Miljoen ton)| Hoogs veranderlik; frequent changeouts| Extended via material science & kamer ontwerp| +20% Average Increase|
| Produk Gradasie Konsekwentheid| Can fluctuate ±15% with feed variation| Maintained within ±5% via adaptive controls| +67% Meer konsekwent|
| Gemiddelde tyd tussen mislukking (MTBF)| Lower due to tramp metal damage risk| Significantly higher with integrated protection| Data shows +35% Verbetering|

5. TEGNIESE SPESIFIKASIES

Kapasiteitsreeks: Konfigureerbaar vanaf 500 TPH aan 2,500 TPH nominal throughput of iron ore (S.G. ~2.6 t/m³).
Primêre Breker: Heavyduty jaw crusher with feed openings up to 1,500mm x 1,200mm.
Sekondêre Breker: Highcapacity cone crusher with multiple cavity options.
Kragvereistes: Totale geïnstalleerde krag tipies tussen 500 kW 1,200 kW afhangende van konfigurasie; voltage customizable (bv., 6.6 kV).
Sleutel materiaal spesifikasies: Primêre raam gemaak van hoë-sterkte staalplaat; voerings van premium mangaanstaal (1822%); critical wear areas lined with AR400 steel plate.
Fisiese afmetings (Modulêr): Modules designed for standard shipping container dimensions; overall footprint optimized per customer layout.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 20°C tot +50°C; stofonderdrukkingstelsel ingesluit as standaard; electrical components rated for appropriate ingress protection.

6. TOEPASSINGSSCENARIO'S

Greenfield Magnetite Project

Uitdaging: A new mining operation required a scalable crushing solution with minimal onsite construction time due to remote location constraints. Consistent 32mm feed for downstream grinding was critical.
Oplossing: Implementation of a modular white label iron ore crushing plant with primary jaw and secondary cone crushers in closed circuit with a sizing screen.
Resultate: Aanleg in gebruik geneem in 60% less time vs traditional build. Achieved steadystate production of 800 TPH meeting target spec (>95% verbygaan), enabling onschedule rampup of the concentrator.

Aging Plant Retrofit

Uitdaging: An existing hematite processing facility suffered from low throughput (<600 TPH) and excessive downtime in its primary section due to constant liner wear failures on old equipment.
Oplossing: Replacement of the legacy primary gyratory with our white label jaw crushing module as a dropin solution within the existing structure footprint.
Resultate: Deurset het met meer as toegeneem 25%. Liner changeout intervals extended from every ~800k tons to over 1 million tons reducing annual maintenance costs by an estimated $120k USD while boosting overall plant availability.

7 KOMMERSIËLE OORWEGINGS

Our white label model provides significant commercial flexibility versus branded OEM solutions:

Prysvlakke:
Basiskonfigurasie: Sluit kernbreekmodules in (feeder/primary/secondary), walkways/platforms ladders , basiese stofonderdrukking ,and motor starters .
Geoptimaliseerde konfigurasie: Adds variable frequency drives , outomatiese smeerstelsel , advanced tramp metal protection ,and PLCbased control panel .
Turnkey-konfigurasie: Full EPC scope including structural supports conveyors electrical substation integration commissioning spares package .

Opsionele kenmerke: Onboard weighing instrumentation advanced rock level sensors remote monitoring connectivity packages custom paint schemes .

Dienspakkette beskikbaar:
1 Annual inspection parts discount program
3 /5year comprehensive service agreements including planned maintenance wear part supply technical support

Finansieringsopsies:
Equipment leasing capital loan facilitation through partner institutions project financing support available

8 Gereelde vrae

V Watter vlak van terreinvoorbereiding word vereis voor aflewering?
A The plant modules require prepared concrete foundations equivalent specifications will be provided during engineering Our team can supervise installation

Q How does this system integrate with my existing SAG/Ball mill feed conveyor?
A Our engineering team will design the discharge conveyor interface hopper ensure seamless integration into your current downstream process flow

Q Are spare parts readily available given it's a white label product?
A Yes All critical wearing parts bearings seals are standardized industrial components held global stock Major castings are sourced single certified foundry ensuring consistent supply lead times

Q What training provided our operations maintenance staff?
A We provide comprehensive onsite training covering normal operation troubleshooting routine maintenance procedures Detailed manuals schematic diagrams included

Q Can this plant handle lateritic ores sticky moisture content?
A While designed primarily hard abrasive ores we can configure specific options such as impact crushers secondary stage specialized feeder designs manage higher moisture mitigate clogging Discuss your specific feedstock during consultation

Q What typical delivery lead time after order confirmation?
A For standard configurations lead time ranges months depending final specification complexity Current project schedule will be confirmed upon quotation

Q Is performance guarantee offered?
A Yes We provide written performance guarantee covering rated throughput final product PSD specifications based agreed test protocol post commissioning