1. فتحة مدفوعة بنقطة الألم

Are you managing a highvolume aggregate operation and facing persistent bottlenecks that erode profitability? لمديري المصانع والمقاولين الهندسيين, أ 250300 tph crushing plant is a critical capital asset, yet common operational challenges can significantly undermine its return on investment. These include inconsistent final product gradation leading to rejected loads, excessive wear part costs from poorly configured crushing chambers, unplanned downtime due to component failure, and high energy consumption per ton of processed material. التأثير المالي قابل للقياس: every hour of unscheduled downtime in this capacity range can cost over $1,200 in lost production, while suboptimal yield can waste 510% من العلف الخام. How do you ensure your primary crushing investment delivers stable, speccompliant output with predictable operating costs and maximum uptime? The solution lies not just in equipment, but in a fully engineered and certified system designed for relentless production.

2. نظرة عامة على المنتج

This offering is a complete, ثابتة ISO Certified 250300tph Stone Crushing Plant, engineered as a turnkey solution for highvolume production of aggregates for construction, قاعدة الطريق, وصابورة السكك الحديدية. The plant is designed as a multistage crushing and screening circuit to transform large quarryrun rock into precisely graded final products.

سير العمل التشغيلي:
1. التخفيض الأولي: Dump trucks feed >500mm quarryrun stone into a robust primary jaw crusher for initial size reduction.
2. سحق الثانوية & تشكيل: The crushed material is conveyed to a secondary cone crusher for further reduction and improved particle shape.
3. التحجيم & الانفصال: Material is then routed to a multideck vibrating screen where it is sorted into specified size fractions (على سبيل المثال, 05مم, 510مم, 1020مم).
4. سحق الثلاثي (if configured): Oversize material from the screens can be recirculated through a tertiary cone crusher for final shaping and reduction in a closedcircuit loop.
5. التخزين: Correctly sized aggregates are conveyed to designated stockpiles for loadout.

نطاق التطبيق & القيود:
نِطَاق: مثالية للجرانيت, البازلت, الحجر الجيري, وغيرها من الصخور متوسطة إلى عالية الكشط. Suited for largescale infrastructure projects, commercial quarrying, and dedicated aggregate supply yards requiring consistent, hightonnage output.
القيود: Not designed for very soft or sticky materials (على سبيل المثال, خام كلايريش) without significant prescreening/washing integration. Requires stable foundation preparation and adequate electrical grid connection.

3. الميزات الأساسية

Modular System Design | الأساس الفني: Preengineered, bolttogether structural modules with integrated walkways and maintenance platforms. | المنفعة التشغيلية: Reduces onsite civil work and installation time by up to 30%, allowing faster commissioning. Provides safer, easier access for routine maintenance and wear part replacement. | تأثير عائد الاستثمار: Lower capital installation costs and reduced risk of installation delays accelerate timetorevenue.
Intelligent Crushing Chamber Automation | الأساس الفني: PLCcontrolled hydraulic adjustment systems on cone crushers with continuous liner wear monitoring. | المنفعة التشغيلية: Maintains optimal crusher setting automatically to ensure consistent product gradation despite liner wear. Operators can adjust settings remotely from the control room based on realtime feedback.| تأثير عائد الاستثمار: Improves product yield within specification by an average of 8%, reducing waste of saleable material.
HeavyDuty Vibrating Screen with Polyurethane Decks | الأساس الفني: High Gforce screening action combined with abrasionresistant polyurethane screen panels.| المنفعة التشغيلية: Achieves higher screening efficiency (>95%) for cleaner product separation. Polyurethane decks last 35x longer than wire mesh in abrasive applications and reduce noise levels.| تأثير عائد الاستثمار: Lowers screen media replacement costs and frequency of changeouts, directly reducing operating expense per ton.
Centralized Dust Suppression System | الأساس الفني: Network of strategically placed spray nozzles at transfer points coupled with dust encapsulation skirts.| المنفعة التشغيلية: Actively controls airborne particulate at primary crusher discharge, screen feeds, and conveyor transfers to meet environmental compliance standards.| تأثير عائد الاستثمار: Mitigates risk of regulatory fines and work stoppages while promoting a healthier site environment.
Unified PLC Control & Monitoring System | الأساس الفني: A single automation panel providing VFD control of major motors, conveyor sequencing, and fullsystem telemetry.| المنفعة التشغيلية: Enables oneoperator control of the entire plant flow from feed to stockpile. Provides early fault diagnostics through amp draw monitoring and temperature sensors on critical bearings.| تأثير عائد الاستثمار: Optimizes labor efficiency and enables predictive maintenance scheduling to prevent catastrophic failures.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة (250300tph Plant) | ISO Certified 250300tph Solution | ميزة (% تحسين) |
| : | : | : | : |
| Overall Availability | ~85% 90% | >92% (هدف) | +3% ل +8% الجهوزية |
| استهلاك الطاقة (كيلوواط ساعة/طن) | يختلف على نطاق واسع; خط الأساس = X كيلوواط ساعة/طن| حتى 15% lower than baseline| 15% Energy Cost/Ton |
| ارتداء تكلفة الجزء (USD/ton processed)| Dependent on rock abrasiveness| Managed via optimized chamber design & alloy selection| Documented reductions of 1025% |
| Product Cubicity Index (for chipping)| ~65% 75% particles within spec| باستمرار >78% within spec| +5% Improved Aggregate Value |
| تثبيت & وقت التشغيل | 812 weeks postfoundation ready| Reduced by structured modular design| 30% Time Savings |

_Based on field data comparison against nonoptimized plants processing similar material._

5.المواصفات الفنية

القدرة المصممة: Configurable for nominal output of 250 ل 300 طن متري في الساعة (based on standard granite with bulk density ~1.6 t/m³).
كسارة أولية: Heavyduty jaw crusher with feed opening ≥750x1060mm.
كسارة ثانوية: Hydraulic cone crusher with chamber options for mediumfine crushing.
كسارة ثالثة (خياري): Finecone or vertical shaft impactor for shaping applications.
شاشة تهتز: Tripledeck inclined screen; total screening area ≥15m².
متطلبات الطاقة: إجمالي الطاقة المثبتة تقريبًا 350 450 كيلوواط. Requires stable industrial power supply (400V/50Hz or as specified).
مواصفات المواد الرئيسية: Main frame structure fabricated from S355JR steel; Highwear components utilize Mn18Cr2 or equivalent alloys; Conveyor belts rated for minimum EP400/3.
الأبعاد المادية (البصمة التقريبية): Length ~75m x Width ~25m x Max Height ~15m (يختلف مع التكوين).
نطاق التشغيل البيئي: مصمم لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +45 درجة مئوية; dust suppression system effective up to wind speeds of level 5.

6\. سيناريوهات التطبيق

Highway Construction Project Supply | تحدي: A contractor needed a guaranteed supply of over 500,000 tons of precisely graded base course and asphalt chips within an18month timeline from a local granite source. Existing mobile fleet could not meet consistent tonnage or gradation specs efficiently. Solution Implementation was our ISOcertified stationary stone crushing plant configured at280tph capacity. Results The plant achieved an average availabilityof93%. It produced specificationcompliant material at an average cost per ton12% below the project's budgeted rate enabling the contractorto complete the aggregate supply phase14 days aheadof schedule.

Commercial Quarry Expansion Challenge An established limestone quarry aimedto expand its marketby producing highvalue railway ballast which requires strict controlover particle shapeand size distribution Their existing twostage setup produced excessive flaky material Solution Integrationofa tertiary shaping crusher stageinto our standard250tph stone crushing plant design creatinga closedcircuit systemfor recrushing oversize Results The plant increasedthe yieldof premium ballastmaterialby22%. This allowedthe quarryto enter anew marketsegmentwitha highermargin product improving overall site profitability

7\. الاعتبارات التجارية

Our ISO certified plants are offered in clear pricing tiers based on core configuration:

1\. Base Plant Tier Includes primary jaw secondary cone screeningand basic conveying systems suitablefor producingtwothree aggregate products Pricedasacomplete package
2\. Enhanced Plant Tier Adds tertiary crushing stage automated chamber controlsand upgraded dust suppression Idealfor producers requiring superior product shapeand maximum flexibility
3\. Customized Plant Tier Incorporates specific client requirements suchas integrated washing systems specialized rockonrock impactorsor extended conveyingfor complex site layouts

Optional Features Prescreening grizzly feeder metal detection system automatic lubrication system remote monitoring telematics package extended warrantyon drivetrain components

Service Packages We offer tiered service agreementsfrom annual inspectionand parts discountingto full comprehensive coverageincluding scheduled maintenance wear part inventory managementand priority technical support

Financing Options Flexible commercial termsare available including leasing structures milestonebased project financingand tradein programsforexisting equipment facilitating capital expenditure planning

8\. التعليمات

Q What does ISO certification meanforthecrushing plant
A It verifies thatthe entire systemis designed manufacturedand assembled accordingto international standardsfor quality management(ISO9001)and safety This provides assuranceof documented procedures material traceabilityanda consistent benchmarkfor performance notjust individual component certifications

Q How do we ensure this plantis compatiblewith our existing quarry feed sizeand desired end products
A Our engineering teamconductsa presale reviewincluding analysisof your source rock samples required final product specificationsandsite layout This allows usto specifythe optimal crusher chamber profiles screen meshsizesand conveyor configurationsto matchyour exact requirements

Q Whatisthe typical operational manpower requirementtorunthisplant
A The centralized PLC automation enables efficient operationbya single control room operator supportedbya ground crewforthe feeding loadingand routine visual inspections Field data shows this staffing modelis standardin plants ofthis capacity range

Q Are spare parts readily available giventhe global supply chain
A Yes We maintaina strategic inventoryof critical wear partsand components Our modular designalso utilizesmany industrystandard bearings sealsand other consumables reducing proprietary part dependencyandsourcing risk

Q Whatisthe expected timelinefrom order placementto commissioning
A Forstandard configurations lead timeis typically2024 weeks exworks Site foundation preparation bythe client should proceedin parallel Commissioningand operator training requireapproximately23 weeks onsite dependingon complexity