1. فتحة مدفوعة بنقطة الألم

Are you managing a commercial aggregate operation where consistent, highvolume output is critical to profitability? Your 250300 tph stone crushing plant faces significant operational pressures. Inconsistent feed material causes unexpected wear and crusher stalls, leading to costly, التوقف غير المخطط له. Energy consumption per ton remains stubbornly high, تآكل الهوامش. Meeting strict, dualgrade specifications for base and chip products often requires inefficient, multistage recrushing. بالإضافة إلى, the total cost of ownership—from liner replacements to conveyor maintenance—accumulates faster than projected.

How do you increase plant availability beyond 92%? Can you reduce your cost per ton while maintaining precise product shaping? Is your current setup flexible enough to handle varying rock hardness without sacrificing throughput? يتطلب الحل نظامًا مصممًا ليس فقط من أجل القدرات, ولكن يمكن التنبؤ به, efficient commercial production.

2. نظرة عامة على المنتج

هذا 250300tph Turnkey Stone Crushing and Screening Plant is a stationary, hardrock processing solution designed for highvolume production of aggregates (05مم, 510مم, 1020مم, 2031.5مم) and other specification materials. إنه يدمج التكسير الأولي, سحق الثانوي / الثالث, الفحص, and material handling into a coordinated system.

سير العمل التشغيلي:
1. التخفيض الأولي: Dump trucks feed <750mm rock into a vibrating grizzly feeder which bypasses sub100mm fines and directs oversize to a robust primary jaw crusher.
2. ثانوي & سحق الثلاثي: Primary crushed material is conveyed to a cone crusher for intermediate reduction. A second cone crusher or impact crusher in closed circuit performs final shaping and size refinement.
3. التحجيم & تصنيف: Material is routed to a multideck vibrating screen where it is precisely separated into finished product stockpiles.
4. إعادة التدوير: Oversize from the screens is automatically returned via closedcircuit conveyors to the appropriate crusher for further processing.
5. قمع الغبار: تعمل أنظمة الرش المتكاملة في نقاط النقل على التحكم في انبعاثات الجسيمات.

نطاق التطبيق: مثالية للجرانيت, البازلت, river pebble, الحجر الجيري, and other abrasive materials with compressive strength up to 350 MPa. Suitable for large quarry operations, دعم مشاريع البنية التحتية الكبرى (الطرق السريعة, السكك الحديدية), and dedicated commercial aggregate supply yards.

القيود: Not designed for mobile or semimobile applications requiring frequent relocation. Site requires stable foundation preparation and adequate space for plant layout and stockpiling.

3. الميزات الأساسية

نظام ذكي للتحكم في التغذية | الأساس الفني: محرك التردد المتغير (VFD) on feeder & level sensors | المنفعة التشغيلية: Maintains optimal chokefeed condition for cone crushers automatically | تأثير عائد الاستثمار: يزيد من الإنتاجية بنسبة 812% and reduces liner wear by up to 15%
تكوين كسارة الثقيلة | الأساس الفني: التعديل الهيدروليكي & clearing on all crushers | المنفعة التشغيلية: Enables rapid CSS changes for product sizing and safe clearing of tramp metal/stalling | تأثير عائد الاستثمار: Reduces downtime for chamber clearing from hours to minutes
التحكم المركزي في العمليات | الأساس الفني: PLCbased automation with touchscreen HMI | المنفعة التشغيلية: Allows singleoperator monitoring of entire flow from a control room; logs production data | تأثير عائد الاستثمار: Lowers labor costs and provides data for production optimization
Modular Electrical & Hydraulic Design | الأساس الفني: Preassembled skids with quickdisconnect couplings | المنفعة التشغيلية: يبسط التثبيت, التكليف, and future maintenance access | تأثير عائد الاستثمار: Reduces installation time by ~30% and lowers service costs
MultiStage Dust Suppression | الأساس الفني: Pressurized spray nozzles at key transfer points with moisture sensors | المنفعة التشغيلية: Effectively controls dust without overwetting material | تأثير عائد الاستثمار: Ensures environmental compliance and protects downstream equipment

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة (250300مصنع tph) | This 250300tph Plant Solution | ميزة (% تحسين) |
| : | : | : | : |
| توافر النبات | 88 91% | 92 95%| +4% (تقليل وقت التوقف عن العمل) |
| استهلاك الطاقة (كيلوواط ساعة/طن)| 1.8 2.2 كيلووات ساعة/طن | 1.65 1.85 كيلووات ساعة/طن| حتى 12% (Energy Savings) |
| حياة كسارة الخطوط الملاحية المنتظمة (الصخور الكاشطة)| ~450 ساعة تشغيل| 520+ ساعات العمل| +15% (Reduced Wear Cost) |
| مؤشر شكل المنتج (تفتيت)| >18% in chip products| <15% in chip products| قيمة المنتج أعلى |
| وقت إعادة التشكيل (تغيير CSS)| تعديل الرقائق يدويًا (~4 hrs)| التعديل الهيدروليكي (~30 min)| 87% (المرونة التشغيلية) |

5.المواصفات الفنية

القدرة الإنتاجية المصممة: 250 300 طن متري في الساعة (استنادًا إلى كثافة المواد التي تبلغ ~1.6 طن/م³)
كسارة أولية: Jaw Crusher Model JC1303 / فتح الأعلاف:1300×300 ملم / الحد الأقصى لحجم التغذية: ≥750 ملم
الكسارات الثانوية/الثالثية: Two units of Cone Crushers Model CC300 / Each with hydraulic adjustment & المقاصة
وحدة الفحص: Tripledeck Vibrating Screen Model VS2460 / منطقة الشاشة: ~14 sqm
متطلبات الطاقة: إجمالي الطاقة المثبتة تقريبًا 650 كيلوواط; Mains connection recommended at400V/50Hz or480V/60Hz.
مواصفات المواد الرئيسية: Main frame construction Q345B steel; Conveyor belts EP630/4; Crusher liners Mn18Cr2 high manganese steel.
الأبعاد المادية (تقريبا.): Overall layout length ~85m; width ~25m; max height ~12m.
نطاق التشغيل البيئي: مصمم لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +45 درجة مئوية; dust emission concentration at outlet ≤20mg/m³.

6\. سيناريوهات التطبيق

إنتاج دورة قاعدة الطريق السريع | تحدي:A national contractor required consistent,sustained production of Class A base course(031\.5مم)and chip sealing aggregates(510مم)from hard granite for a toll highway project.Plant stoppages directly threatened project timelines.| حل:A turnkey250\300tph plant was installed featuring twostage cone crushing in closed circuit with precise screening.The automated control system allowed quick switching between product specifications.| نتائج:The plant achieved an average output of280tph over22months.Availability averaged94\.2%.The consistent cubical shape of the chip product reduced bitumen consumption by an estimated7%,noted by the paving contractor.

Commercial Quarry Expansion Challenge:A regional quarry operator needed to upgrade from150tph to meet new supply contracts but had limited space for expansion and needed to maintain production during phased commissioning.| حل:The modular design of the250\300tph plant allowed it to be constructed parallel to the old line.Critical preassembled skids reduced onsite assembly time.The old line was decommissioned only after the new plant was fully operational.| نتائج:The expansion was completed with only48hours of total production stoppage.The new plant's energy efficiency reduced power costs by$0\.11per ton produced,increasing annual gross margin significantly.

Limestone Processing for Concrete Aggregates Challenge:A readymix concrete supplier's own aggregate plant struggled with excessive fines generation(<0\.075مم)and poor shape in the critical10\20mm fraction,increasing cement demand in their mixes.| حل:The plant configuration prioritized lowwear,cubicalproduct crushing stages.An impact crusher was selected as the tertiary unit,and screen deck configurations were optimized to remove excess fines early.| نتائج:Fines generation was reduced by22%.The improved particle shape increased the workability of the concrete mix.Field data showed a potential3\5%reduction in cement usage while maintaining slump specifications.

الاعتبارات التجارية

Pricing is structured around core configuration levels:

• المستوى 1(التكوين الأساسي):يشمل كسارة الفك الأولية,كسارة مخروطية واحدة,tripledeck screen,الناقلات الأساسية,and central control panel.Priced as acapital investmentfor standard materials like limestone.
• المستوى 2(التكوين المحسن):Adds secondary cone crusherfor full closedcircuit operation,intelligent VFD feed control,and enhanced dust suppression.Recommendedfor abrasive materials(الجرانيت,البازلت).
• المستوى 3(التكوين المخصص):Incorporates specific options such as washing systemsfor manufactured sand,finer screening decksfor specialized products,and extended weather protection enclosures.

وتشمل الميزات الاختيارية تكنولوجيا المعلومات والمراقبة عن بعد,mobile generator hookups,and automated lubrication systems.Service packages range from basic commissioningand operator trainingto comprehensive annual maintenance contracts with guaranteed parts availability.Financing options including equipment leasingand term loans are available through partnered financial institutions,making capital expenditure manageable against longterm supply contracts.

التعليمات

س:What if my feed material size or hardness varies frequently?
أ:The hydraulic adjustment on the crushers allows operators to change the Closed Side Setting(CSS)in minutes via the control panel.This adapts the crushing chamberto different conditions without stopping production,a key featureof this commercial stone crushing plantsolution.

Q.How many operators are requiredto run this plant?
A.The centralized PLC automationis designedfor singlestation control.One trained operatorin the control room can manage the entirecrushingandscreening process.Routine ground inspectionsare still recommended,but direct machinelevel operationis not required.

Q.Can this system integratewith our existing primary feedingor downstream equipment?
A.YES.The design includes standardized feedand discharge heights.Conveyor lengthsand transfer pointscan be modifiedduring engineering.We will review your site layoutto ensure compatibilitywith your current stockpile feedersor existing tertiary processing lines.

Q.What isthe typical installationand commissioning timeline?
A.For aprepared foundation site,the modular skidded components allow erectionin approximately8\10weeks.Commissioningand performance testingtypically takes an additional1\2weeks.This timeframe assumes all civil worksare complete prior todelivery.

س: هل قطع الغيار متوفرة بسهولة؟,and what arethe lead times?
A.We maintaina strategic inventoryof highwear parts(لوحات الفك,عباءة,شبكات الشاشة).For standard wear parts,the commitmentis shipmentwithin72hours.For major components,a stocklistwith guaranteed lead timesis providedwith themaintenance contract.

Q.What kindof trainingis providedfor our maintenance team?
A.Comprehensive trainingincludes both classroom instructionon system principlesand handson field training.It covers daily checks,troubleshooting usingthe HMI diagnostics,إجراءات الصيانة الروتينية,and safe liner changeout protocols.Training documentationis supplied digitallyandin print