1. فتحة مدفوعة بنقطة الألم

Are you managing a stone quarry operation where inconsistent feed, التوقف غير المخطط له, and rising operational costs are eroding your margins? Key challenges in primary crushing include:

التوقف المفرط للصيانة: Frequent liner changes and unexpected component failures in the primary crusher can halt your entire processing line for hours, costing thousands in lost production per event.
ارتفاع تكاليف قطع الغيار: Abrasive feed material leads to rapid wear of crusher jaws, عباءة, ومقعرة, creating a significant and recurring expense for your parts inventory.
إنتاجية غير متناسقة & تدرج المنتج: Fluctuations in feed size or hardness can cause chokefeeding or poor cavity utilization, resulting in suboptimal tonnage and offspec product that requires recrushing.
عدم كفاءة الطاقة: Older or poorly configured crushing plants consume excessive power per ton of processed material, التأثير بشكل مباشر على النتيجة النهائية مع ارتفاع تكاليف الطاقة.
مخاوف تتعلق بالنزاهة الهيكلية: The immense forces generated in a primary crushing station demand a fabricated structure of exceptional durability. Inadequate design can lead to costly frame fatigue, cracks, and alignment issues over time.

How do you select a crushing plant fabricator that not only provides robust equipment but also delivers the operational reliability and total cost of ownership metrics that your business requires?

2. نظرة عامة على المنتج: ISOCertified Stationary Primary Crushing Plant

We engineer and fabricate heavyduty, stationary primary crushing plants designed as the cornerstone of hard rock quarry operations. These turnkey solutions are built to receive blasted feed from haul trucks and reduce it to a consistent, منتج قابل للنقل للمعالجة الثانوية.

سير العمل التشغيلي:
1. يٌطعم & الفحص المسبق: Runofquarry (ROQ) material is dumped into a rugged vibrating grizzly feeder (فجفف فجفف), which scalps out fine undersize material to bypass the crusher, improving efficiency.
2. تخفيض الحجم الأساسي: Oversize material is directed into a highcapacity jaw crusher (أو كسارة دوارة, depending on application) where it is compressed and fractured against fixed and moving surfaces.
3. نقل المنتج: Crushed material is discharged onto a heavyduty main product conveyor, transporting it to the next stage of the processing circuit.

نطاق التطبيق: مثالية لمعالجة الحمولة العالية للجرانيت, البازلت, الحجر الجيري, وغيرها من المجاميع الكاشطة. Suited for permanent installation in largescale quarry operations.

القيود: غير مصممة للتطبيقات المحمولة أو المحمولة. Maximum feed size is determined by crusher model selection; extremely sticky or claybound materials may require additional preprocessing.

3. الميزات الأساسية

Modular Fabricated Base Frame | الأساس الفني: تم تحسينه بواسطة CA, highstrength steel weldment with internal reinforcing diaphragms | المنفعة التشغيلية: Provides an unwavering foundation that maintains precise crusher and motor alignment under cyclical loading | تأثير عائد الاستثمار: Eliminates costly realignment downtime and extends bearing & drive component life by up to 30%.
Integrated Maintenance Platforms & وصول | الأساس الفني: Ergonomic design per ISO safety standards with nonslip grating, guardrails, and strategic service points | المنفعة التشغيلية: Your crew can perform routine inspections, liner checks, and maintenance tasks safely and efficiently | تأثير عائد الاستثمار: Reduces service time by an average of 25%, خفض تكاليف العمالة وزيادة توافر المصنع.
وحدة تغذية أشيب اهتزازية شديدة التحمل (فجفف فجفف) قسم | الأساس الفني: Robust deck construction with replaceable grizzly bars and highinertia vibrator motors | المنفعة التشغيلية: Effectively removes fines while absorbing direct impact from haul truck dumping | تأثير عائد الاستثمار: Increases primary crusher capacity by preventing chokefeeding with fines; يحمي الكسارة من أحمال الصدمات.
التشحيم المركزي & النظام الهيدروليكي | الأساس الفني: Manifolded system with failsafe indicators and easyaccess service ports | المنفعة التشغيلية: تمكن آمنة, ينظف, and consistent lubrication of all critical crusher bearings from a single location | تأثير عائد الاستثمار: Standardizes maintenance procedures prevents lubrication failures which are a leading cause of major component damage.
Cable Management & Utility Routing | الأساس الفني: Prefabricated steel conduits and trays integrated into the plant structure | المنفعة التشغيلية: Protects power and control cables from damage dust contamination ensuring reliable electrical supply | تأثير عائد الاستثمار: Minimizes electrical faults reduces installation time onsite by providing a plugandplay wiring infrastructure.

4. المزايا التنافسية

| مقياس الأداء | الممارسة القياسية للصناعة | حل محطة التكسير الحاصل على شهادة ISO | ميزة (% تحسين) |
| : | : | : | : |
| Structural Durability (Fatigue Life) | Fieldwelded fabrication with variable quality control; potential for stress points. | Plantwide FEA analysis; precision shopwelding under controlled conditions per ISO 38342. +40% estimated service life before major refurbishment. |
| التثبيت في الموقع & وقت التشغيل| 46 weeks for foundation work assembly alignment testing. Modular design with preassembled sections; laseraligned at factory. 50% onsite labor time reduced project risk. |
| التوفر التشغيلي (الجهوزية) ~92% based on typical maintenance schedules unplanned stops.| >95% documented via telemetry from installed units optimized access predictive maintenance design.| +3 percentage points translating to significant annual tonnage gains. |
| استهلاك الطاقة لكل طن معالج| Varies widely older drives directonline starting.| Engineered drive train efficiency softstart systems optimized kinematics.| تظهر البيانات الميدانية 815% تخفيض في استهلاك الطاقة المحددة |

5. المواصفات الفنية

نطاق السعة: Configurable for throughputs from 400 ل 2 000+ طن متري في الساعة (الهيدروكربونات النفطية في الساعة)
خيارات الكسارة الأولية: لعن الفك (900 × 1200 مم 1500 × 2000 مم) أو الكسارة الدورانية الأولية
Grizzly Feeder: العرض من 1 200مم ل 2 400مم; lengths from 4 500مم ل 7 500مم
متطلبات الطاقة: إجمالي الطاقة المثبتة عادة بين 250 كيلوواط 600 كيلوواط يعتمد على التكوين
مواصفات المواد: Main frame fabricated from S355JR structural steel; wear surfaces utilize AR400 abrasionresistant steel liners
الأبعاد المادية (عادي): Approximate footprint of 18m (ل) × 8 م (دبليو) x 9m (ح). Custom designs available
Environmental Operating Range Designed for ambient temperatures from 20°C to +45°C dust moisture conditions typical of outdoor quarry operation

6. سيناريوهات التطبيق

Granite Quarry Expansion Southeast Asia Challenge A major quarry needed to double primary circuit capacity but had limited space for new foundations faced stringent noise/vibration regulations Solution A compact highcapacity jaw crusher plant was designed with an integrated acoustic enclosure vibrationisolation pads mounted on a single deeppile foundation Results Achieved target throughput of 1 200 TPH within existing site footprint community noise complaints reduced by 60%

Basalt Processing Plant Upgrade North America Challenge Chronic downtime due to frame fatigue cracks poor accessibility for mantle changes on an aging primary station Solution Complete replacement with a customfabricated primary plant featuring reinforced modular base walkin maintenance platforms around the crusher Results Mantle changeout time reduced from 36 ساعات ل 14 hours no structural integrity issues reported after 3 years of continuous operation

7 الاعتبارات التجارية

Our ISOcertified fabrication process ensures transparent costing predictable delivery schedules

طبقات التسعير
1 Base Plant Includes fabricated structure VGF crusher mounting main discharge conveyor walkways ladders
2 Premium Package Adds centralized automated lube system integrated dust suppression spray system premium motor starters
3 Turnkey Pro Includes full electrical control package PLC instrumentation advanced condition monitoring sensors

Optional Features Acoustic cladding special coatings for corrosive environments custom feed hopper designs belt scales metal detection

Service Packages Extended warranty plans scheduled inspection services remote performance monitoring subscriptions wear part supply agreements

Financing Options Available through partner institutions including equipment leasing longterm rental plans tradein options for existing assets

8 التعليمات

What level of site preparation is required prior to delivery?
We provide detailed foundation drawings load data anchor bolt templates Your contractor prepares the civil works according to our specifications ensuring our team can commence efficient mechanical erection

How does your fabrication quality control impact longterm reliability?
Our ISO 9001 38342 certifications mandate documented procedures for material traceability welding qualifications dimensional checks This systematic approach eliminates defects that cause premature failure ensuring predictable lifecycle costs

Can this plant be integrated with my existing secondary circuit conveyor?
Yes Our design team will engineer the discharge height conveyor speed transfer point to match your existing system specifications We ensure seamless material flow integration

ما هي المهلة الزمنية النموذجية من تقديم الطلب إلى التشغيل؟?
Lead times vary based on project scope complexity A standard configured plant typically has a 68 month timeline including engineering procurement fabrication testing disassembly shipping Site commissioning requires approximately 34 weeks with our supervision

Do you provide operational training for our crew?
Yes Comprehensive training covering safe operation routine maintenance procedures basic troubleshooting is provided during commissioning Documentation includes detailed operation maintenance manuals