1. فتحة مدفوعة بنقطة الألم

تؤدي تكاليف التشغيل المتصاعدة وفترات التوقف غير المتوقعة إلى تآكل هوامش مشروعك? For plant managers and contractors overseeing bulk material processing, inefficient crushing and screening is a primary bottleneck. وتشمل التحديات المشتركة:
High PerTon Cost: Inefficient flow, excessive recirculation, and frequent component wear directly increase your cost per ton of processed material.
التوقف غير المقرر: Unplanned stops for maintenance, انسداد, or mechanical failures disrupt entire production schedules, causing significant revenue loss.
تدرج المنتج غير متناسق: Offspec material results in product rejection, تكاليف إعادة المعالجة, and dissatisfied clients.
Rising Labor & كثافة الطاقة: Equipment requiring constant monitoring, التعديل اليدوي, or excessive power consumption drives up operational expenditures.
قيود قابلية التوسع: Fixed systems struggle to adapt to changing feed material or required product specifications, limiting contract flexibility.

Is your current setup equipped to maximize throughput while controlling these variables? A strategic investment in modern exportgrade crushing and screening equipment is not merely a capital purchase; it is a direct intervention on your bottom line.

2. نظرة عامة على المنتج

يشمل خط الإنتاج هذا الخدمة الشاقة, containerized crushing and screening plants engineered for highvolume primary, ثانوي, and tertiary processing of aggregates, خام, والمعادن الصناعية. Designed for export and demanding site conditions, these systems transform raw feed into precisely graded end products.

سير العمل التشغيلي:
1. التخفيض الأولي: Raw feed is introduced to a robust jaw or gyratory crusher for initial size reduction.
2. الفحص الأولي & نقل: Crushed material is conveyed to a primary screen deck where subsize product is separated; oversize is routed for further crushing.
3. Secondary/Tertiary Processing: Oversize material is directed to cone or impact crushers for additional reduction in closedcircuit with screening units.
4. Final Product Sorting: Multiple deck screens separate the processed material into 35 specified final product fractions.
5. التخزين: Finished products are conveyed to designated stockpiles or loading areas.

نطاق التطبيق: Ideal for largescale quarrying, mining preconcentration, major infrastructure projects (قاعدة الطريق, صابورة السكك الحديدية), and commercial aggregate production.
القيود الرئيسية: Not suitable for ultrafine grinding (sub5mm) without specialized circuits; maximum feed size and hardness are defined by modelspecific engineering limits.

3. الميزات الأساسية

هندسة الغرفة المتقدمة | الأساس الفني: زاوية ارتشف محسنة وشكل تجويف التكسير | المنفعة التشغيلية: Increases firstpass reduction ratio, minimizing recirculating load and wear on downstream components | تأثير عائد الاستثمار: Reduces energy consumption per ton by up to 15% and extends liner life

Centralized Grease Automation | الأساس الفني: Programmable, highpressure centralized lubrication system | المنفعة التشغيلية: Ensures consistent bearing lubrication under all load conditions without manual intervention | تأثير عائد الاستثمار: Lowers bearing failure risk by an estimated 70%, directly preventing costly unscheduled downtime

Hybrid Power Flexibility | الأساس الفني: Configurable power train accepting grid connection or onboard dieselgenerator sets | المنفعة التشغيلية: Enables rapid deployment to remote sites and provides operational resilience during grid instability | تأثير عائد الاستثمار: Eliminates infrastructure delays; تظهر البيانات الميدانية أ 40% reduction in site commissioning time

تصميم المكونات المعيارية | الأساس الفني: Bolttogether substructures with standardized interfaces | المنفعة التشغيلية: Simplifies transport in standard containers and allows for strategic component replacement or future circuit reconfiguration | تأثير عائد الاستثمار: Cuts international shipping costs by approximately 25% versus monolithic units

التحكم الذكي في العمليات (IPC) نظام | الأساس الفني: PLCbased system with load management and CSS adjustment capabilities | المنفعة التشغيلية: Automatically regulates feed rates and crusher settings to maintain optimal throughput and product gradation | تأثير عائد الاستثمار: Maintains consistent spec yield (>98%), reducing waste and reprocessing

HeavyDuty Vibrating Screen with Deck Access System | الأساس الفني: High Gforce exciters mounted on reinforced decks with walkways | المنفعة التشغيلية: Provides efficient material stratification and sizing even with sticky or damp feed; allows safe, quick media changes | تأثير عائد الاستثمار: Improves screening efficiency by 20%, boosting overall plant capacity

قمع الغبار المتكامل & الحد من الضوضاء | الأساس الفني: Spray bar systems at transfer points with acoustic encapsulation panels | المنفعة التشغيلية: Meets stringent international environmental compliance standards for particulate matter and noise pollution | تأثير عائد الاستثمار: Mitigates project delay risks from regulatory noncompliance and community complaints

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة | سحق لدينا & حل الفرز | ميزة (% تحسين) |
|||||
| طن في الساعة (الهيدروكربونات النفطية في الساعة) / كيلوواط | Varies by application | Optimized flow design & كفاءة القيادة | +1015% كفاءة الطاقة |
| وقت تغيير الخطوط الملاحية المنتظمة | 812 ساعات (الفك / المخروط) | التعديل الهيدروليكي & assisted tooling |35% التوقف |
| Screening Efficiency ~8590% Patented throw & deck design +1012% Yield |
| متوسط ​​الوقت بين حالات الفشل (المحامل الحرجة) ~1218 months Premium seals & grease automation +50% خدمة الحياة |
| OnSite Assembly Duration ~1014 days Preassembled modular skids 40% وقت التشغيل |

5. المواصفات الفنية

نطاق السعة: قابلة للتكوين من 300 ل 1,200 طن متري في الساعة (الهيدروكربونات النفطية في الساعة), depending on feed material (الكثافة الظاهرية ~ 1.6 طن/م3) and product gradation.
متطلبات الطاقة: Primary plant power range from 250 كيلو فولت أمبير إلى 800 كيلو فولت أمبير. Available as 50Hz or 60Hz compliant. Hybrid option includes integrated Stage V/Tier 4 Final diesel generators.
مواصفات المواد: Highabrasion steel wear plates (HB400+); Crusher mantles/concaves in premium manganese steel (18%22%); Screen decks in rubberpolyurethane composite or woven wire mesh.
الأبعاد المادية (Typical Primary Unit): Transportable within standard highcube containers. Assembled dimensions approx.: Length 25m x Width 7m x Height 5m.
نطاق التشغيل البيئي: مصممة لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +50 درجة مئوية. Dust suppression system rated for control below 10 mg/m³ at emission points.

6. سيناريوهات التطبيق

Granite Quarry Expansion – Southeast Asia

Challenge A quarry operation needed to increase output by 60% to fulfill a new highway contract but was constrained by space limitations and a dated twostage plant with high fines production.
Solution Implementation of a compact threestage trackmounted crushing circuit featuring an advanced cone crusher in closed circuit with a tripledeck screen.
Results The new setup achieved a 65% throughput increase within the same footprint while improving yield of valuable chip products by 22%. تم تحقيق الاسترداد في أقل من 14 months through the contract fulfillment.

Iron Ore Scalping & PreConcentration – West Africa

Challenge A mining operation faced high processing costs due to transporting lowgrade waste rock through the entire primary circuit.
Solution Integration of an ultraheavyduty grizzly scalper ahead of the primary crusher station to remove barren waste rock (>250مم).
Results Field data shows over 30% of total volume was rejected at the scalp level, significantly reducing energy consumption and wear in the downstream crushing stages. This increased effective plant capacity without adding new primary crushers.

7. الاعتبارات التجارية

طبقات التسعير: Solutions are offered across three tiers:
معيار: Highefficiency base plant for common aggregate applications.
HighAbrasion: Upgraded wear packages for abrasive feeds like granite/basalt.
MiningSpec: Reinforced structures & components for heavyfeed ore applications.

الميزات الاختيارية: أنظمة الوزن على متن الطائرة, automated metal detection/tramp relief systems,
remote telematics for performance monitoring,
extra dust encapsulation packages.

حزم الخدمة: Choose from annual inspection plans,
wearsandspares contracts with guaranteed supply,
or fullsite service agreements including labor.

خيارات التمويل: We work with export credit agencies
to provide project financing,
and offer leasetoown structures
to align payment schedules with your cash flow from project milestones.

8. التعليمات

Q1 Are these plants compatible with our existing conveyors stackers?
A1 Yes within defined engineering parameters The control system can be integrated Standard discharge heights conveyor widths belt speeds are documented Our engineering team can perform a compatibility review based on your existing layout drawings

Q2 What is the expected operational impact during the transition from our old plant?
A2 With modular design the objective is minimal disruption Preassembly testing minimizes onsite commissioning A phased implementation over weeks can be planned typically allowing partial operation of your legacy system during cutover

Q3 How do you guarantee performance metrics like throughput gradation
A3 Performance guarantees are based on certified test reports using customersupplied sample materials These form part of the commercial contract Guarantees cover capacity power consumption key wear part life under defined operating conditions

Q4 What are typical lead times from order placement delivery
A4 For standard configured plants lead time ranges between months depending on model complexity Custom configurations may require additional engineering time All timelines are confirmed upon project specification

Q5 What training is provided for our operations maintenance teams
A5 Comprehensive training is included covering daily operation routine maintenance troubleshooting safety procedures Training occurs during commissioning both classroom instruction handson equipment familiarization Manuals schematics provided digitally permanently accessible