Import Crushing And Screening Equipment Manufacturers
1. فتحة مدفوعة بنقطة الألم
تؤدي تكاليف التشغيل المتصاعدة وفترات التوقف غير المتوقعة إلى تآكل هوامش مشروعك? في الإنتاج الكلي, معالجة المعادن, وإعادة التدوير, يعد التكسير والغربلة غير الفعالين بمثابة عنق الزجاجة الأساسي. وتشمل التحديات المشتركة:
التوقف المفرط للصيانة: تغييرات متكررة في الخطوط الملاحية المنتظمة, تحمل الفشل, and conveyor issues halt your entire production line.
تدرج المنتج غير متناسق: Poor screening efficiency and improper crushing chamber dynamics lead to offspec material, causing product rejection and revenue loss.
تكاليف تشغيلية عالية: ارتفاع استهلاك الطاقة للطن الواحد, coupled with high wear part replacement frequency, يؤثر بشكل مباشر على النتيجة النهائية الخاصة بك.
تكوين النبات الصلب: Fixed systems cannot adapt to changing feed material or final product requirements, الحد من المرونة التشغيلية.
هل تعالج أجهزتك الحالية هذه المشكلات؟, أم أنها مصدر لهم? The right primary crushing station is not just a purchase; it’s a strategic decision for longterm site profitability.
2. نظرة عامة على المنتج: PRIMARY CRUSHING AND SCREENING STATION
This primary crushing and screening station is a fullyintegrated, trackmounted or modular system designed for the initial size reduction of runofmine ore, صخرة المحجر, أو هدم الخرسانة. Its workflow is engineered for continuous heavyduty operation:
1. يٌطعم: Material is deposited via excavator or wheel loader into a robust vibrating grizzly feeder.
2. الفحص المسبق & سحق: The grizzly bypasses fines directly to a conveyor while oversize material is directed into the highcapacity jaw crusher.
3. سحق الابتدائي: The jaw crusher performs the first mechanical reduction using compressive force.
4. PostCrushing Screening: Crushed material is conveyed to an integrated screen for immediate separation into required product fractions.
5. Stockpiling or Secondary Conveyance: Sized fractions are stockpiled or conveyed to the next stage of processing.
نطاق التطبيق: مثالية لتعدين الصخور الصلبة, aggregate quarries, مشاريع البناء واسعة النطاق, و ج&D recycling operations requiring highvolume primary reduction.
القيود: غير مصممة لتشكيل المنتج النهائي (سحق الثالث) or processing highly abrasive materials without specific liner configurations. Feed size must adhere to crusher opening specifications.
3. الميزات الأساسية
Direct Drive Jaw Crusher | الأساس الفني: Eliminates Vbelts and associated components | المنفعة التشغيلية: Reduces power transmission losses and removes routine belt tensioning/maintenance | تأثير عائد الاستثمار: تظهر البيانات الميدانية ما يصل إلى 10% lower fuel consumption and 15% less scheduled maintenance time.
Independent PreScreen Module | الأساس الفني: Twodeck vibrating grid mounted ahead of the crusher | المنفعة التشغيلية: Removes fines and natural sand from the crusher feed, reducing chamber wear and increasing throughput of valuable midsize material | تأثير عائد الاستثمار: Can extend manganese liner life by up to 30% and increase total station output.
تعديل الإعداد الهيدروليكي (HSA) | الأساس الفني: Wedgebased chamber adjustment via hydraulic cylinders | المنفعة التشغيلية: Allows operators to change the crusher closedside setting (CSS) في تحت 2 minutes for precise product size control without stopping the plant | تأثير عائد الاستثمار: Minimizes nonproductive time during product changeovers by over 90%.
HeavyDuty Feeder with Step Grizzly | الأساس الفني: Reinforced feeder with stepped grizzly bars to prevent clogging | المنفعة التشغيلية: Ensures consistent feed flow even with sticky or claybound materials, preventing bridging and feeder stall | تأثير عائد الاستثمار: Maintains target throughput rates in challenging conditions, avoiding costly flow interruptions.
Integrated Plant Automation System (IPAS) | الأساس الفني: PLCbased control with touchscreen interface monitoring all critical functions | المنفعة التشغيلية: يوفر بيانات في الوقت الحقيقي عن معدلات الإنتاج, سحب الطاقة, and operational status; enables singlepanel control for setup and troubleshooting | تأثير عائد الاستثمار: يحسن فعالية المعدات بشكل عام (OEE) through better monitoring and reduces diagnostic time by an average of 50%.
نقاط تشحيم مركزية | الأساس الفني: Manifold system linking all major bearing points to a single station | المنفعة التشغيلية: تمكن آمنة, rapid daily lubrication checks without requiring access around moving components | تأثير عائد الاستثمار: Standardizes preventive maintenance routines, enhancing bearing life and reducing lubricationrelated failures.
4. المزايا التنافسية
| مقياس الأداء | الحل القياسي للصناعة | This Primary Crushing & Screening Station | ميزة (% تحسين) |
| : | : | : | : |
| طن في الساعة (الهيدروكربونات النفطية في الساعة) كفاءة| Reliant on optimal feed conditions only| يحافظ >90% of rated TPH with variable/ sticky feed due to step grizzly design| +1520% sustained output |
| ارتداء تكلفة الجزء لكل طن| Based on standard manganese composition| Utilizes sitespecific alloy analysis for jaw liners in highabrasion applications| حتى 25% تكلفة الطن سحقت |
| يثبت / Configuration Time| Multiple machine positioning & cable connections required| Singlelift modules with prerigged electrical connections between units| 70% relocation time |
| استهلاك الطاقة (كيلوواط ساعة/طن)| Direct mechanical drive with fixed speed motors| المكونات الهيدروليكية المستشعرة للحمل & direct electric crusher drive adjust power to demand| 8% متوسط استخدام الطاقة |
Based on comparative field trials in granite quarry applications.
5. المواصفات الفنية
نوع الكسارة الأولية: Nordberg C106 Jaw Crusher
فتح الأعلاف: 1,060 مم × 700 مم (42” x 28”)
الحد الأقصى لحجم التغذية: 600 مم (24")
إعداد الجانب المغلق (CSS) يتراوح: 70 200 مم
نطاق السعة: حتى 500 MTPH (تعتمد على كثافة المادة & CSS)
وحدة الطاقة: CAT C9 / C9.3 ACERT Tier 4 محرك الديزل النهائي
إجمالي الطاقة المثبتة: 224 كيلوواط
Feeder Type: Vibrating Grizzly Feeder VG43912V
Screen Module: Twodeck inclined screen TS303
Main Conveyor Width: 1,000 مم
أبعاد النقل (طول × عرض × ارتفاع): ~19m x ~3m x ~4m
الوزن التشغيلي: ~45 طن
نطاق درجة حرارة التشغيل: 25درجة مئوية إلى +40 درجة مئوية
6. سيناريوهات التطبيق
توسيع محجر الجرانيت الكلي | تحدي: Existing fixed primary plant could not service new pit face location without major infrastructure cost; mobile solutions lacked necessary throughput and prescreening. حل: Deployment of a trackmounted primary crushing and screening station fed directly by excavator at the new face. نتائج: Eliminated need for costly ramp construction and dump truck haulage to old plant. حققت إنتاجية متسقة من 380 Mtph of minus200mm base material with improved yield of valuable railway ballast fraction due to integrated screening.
مشروع البنية التحتية على نطاق واسع (Dam Construction) | تحدي: Processing riverrun gravel with high sand content led to rapid crusher wear choke points in traditional setups. Solution Implementation of a modular primary station featuring an independent prescreen module ahead of the jaw crusher Results Prescreen removed over 25% of sand/fines prior to crushing reducing abrasive wear Throughput increased by18% as crusher processed only oversize Wear part replacement intervals extended by approximately40%
7 الاعتبارات التجارية
Pricing for a primary crushing station varies significantly based on configuration:
- Base Configuration Includes core jaw crusher basic feeder engine chassis essential conveyors PLC start/stop controls Tier pricing typically begins in range appropriate for this capital equipment class
- Dust suppression system package including water tank spray bars
- Magnet installation over discharge conveyor ferrous metal removal
- Radio remote control unit for independent feeder/crusher operation from ground level
- Extended wear part kits stock
- Comprehensive Extended Warranty covering major components years unlimited hours
- Scheduled Maintenance Plan providing fixed cost annual inspections parts labor
- On Site Operator Training Program days hands instruction
Optional Features That Add Value:
حزم الخدمة المتاحة:
Financing Options Flexible capital solutions include equipment leasing long term rental purchase leaseback structures tailored support cash flow management project timelines
8 التعليمات
What type/size of excavator is recommended as a feeder?
A minimum operating weight class excavator equipped with suitable bucket capacity ensure consistent choke feeding maximize crusher efficiency productivity
How does this system handle reinforcing bar rebar in concrete demolition waste?
While jaw can process reinforced concrete integrated overband magnet discharge conveyor effectively removes liberated ferrous metals protecting downstream conveyors secondary crushers
What are typical delivery lead times after order confirmation?
Standard configurations have confirmed lead time weeks subject build slot availability engineering review Custom modular designs may require additional weeks detailed engineering fabrication
Is operator training provided with purchase?
Yes comprehensive onsite training program conducted commissioning covers daily operation routine maintenance safety procedures troubleshooting using actual plant systems
Can this station be integrated into existing fixed plant circuit as temporary primary unit?
Yes stations are designed standalone mobility can be positioned feed directly into existing secondary tertiary circuits via discharge conveyor ideal use during planned upgrades maintenance existing primary crushers