1. فتحة مدفوعة بنقطة الألم

Are you managing a stone quarry operation where profit margins are consistently pressured by equipment performance? The challenges of primary crushing are often the bottleneck. خذ بعين الاعتبار هذه العقبات التشغيلية الشائعة:
التوقف المفرط للصيانة: تغييرات متكررة في الخطوط الملاحية المنتظمة, فشل تحمل غير متوقع, and wear part replacement halt your entire production line, تكلف الآلاف في الساعة من الإيرادات المفقودة.
حجم التغذية غير متناسق & الإنتاجية: التجسير, الفصل, and irregular feed from the quarry face lead to poor crusher cavity fill, تقليل القدرة وزيادة التآكل بشكل غير متساو.
تكاليف تشغيلية عالية: ارتفاع استهلاك الطاقة لكل طن من المواد المعالجة, coupled with the high and frequent cost of wear parts like mantles, مقعر, وألواح الفك, directly erode profitability.
عدم اتساق جودة المنتج: Inability to reliably control topsize output or an excessive proportion of flaky material can impact downstream processes and final product marketability.
أمان & Accessibility Concerns: Routine inspections and maintenance tasks that are timeconsuming or require personnel to work in hazardous proximity to the equipment.

Is your primary crushing station a source of reliability or a recurring cost center? The right contract manufacturer for your stone quarry crushing plant addresses these issues at the design phase, focusing on total cost of ownership rather than just initial purchase price.

2. نظرة عامة على المنتج

This content outlines the critical considerations for a stationary primary jaw crusher station within a complete stone quarry crushing plant. Designed as the first mechanical reduction stage, this system is engineered for high availability and low costperton in hard rock applications like granite, البازلت, والحجر الجيري.

سير العمل التشغيلي:
1. تناول الأعلاف: Dump trucks or wheel loaders discharge runofquarry (ROQ) material into a rugged vibrating grizzly feeder (فجفف فجفف).
2. الفحص المسبق & إزالة الغرامات: The VGF scalps out natural fines and subcrushsize material via its grizzly bars, bypassing the crusher to increase efficiency and reduce wear.
3. التخفيض الأولي: Oversize material is conveyed into the jaw crusher cavity, where compressive force between a fixed and a moving jaw plate fractures the rock.
4. تسريح & نقل: يتم تفريغ المواد المكسرة على ناقل المنتج الرئيسي لنقلها إلى عملية التكسير أو التخزين الثانوية.

نطاق التطبيق & القيود:
نِطَاق: مثالية للحمولة العالية, abrasive hard rock quarries requiring a robust primary breaker. Optimal for material with compressive strength up to 400 MPa.
القيود: غير مناسب للالتصاق, مواد الطين دون المعالجة المسبقة. A gyratory crusher may offer superior throughput for capacities exceeding 1,500 tph in certain configurations.

3. الميزات الأساسية

وحدة تغذية أشيب اهتزازية شديدة التحمل (فجفف فجفف) | الأساس الفني: Highstrength steel plate construction with boltin AR liners | المنفعة التشغيلية: Regulates feed rate to the crusher, يزيل التجسير, removes fines to prevent crusher packing | تأثير عائد الاستثمار: Increases effective crusher capacity by up to 15% and reduces unnecessary wear on crusher components

WedgeBased Jaw Plate Adjustment System | الأساس الفني: Mechanically locked wedges replace traditional shim plates | المنفعة التشغيلية: تمكن آمنة, fast CSS adjustment and jaw plate changes from the crusher’s nondrive side in under two hours | تأثير عائد الاستثمار: يقلل وقت التوقف عن إجراء التعديلات الروتينية تقريبًا 60%, maximizing productive operating hours

تحسين هندسة غرفة التكسير | الأساس الفني: الحركية الحاسوبية وتصميم زاوية الارتشف | المنفعة التشغيلية: Promotes deepbed crushing throughout the chamber for consistent particleonparticle breakage | تأثير عائد الاستثمار: Produces a more cubical product shape (improving secondary crush efficiency) and extends jaw plate service life by distributing wear more evenly

قاعدة محرك متكاملة & حارس الحزام | الأساس الفني: Unified steel fabrication housing crusher motor(ق) وحراس القيادة | المنفعة التشغيلية: Eliminates complex field alignment during installation; يوفر آمنة, integral guarding compliant with site safety standards | تأثير عائد الاستثمار: يقلل من وقت التثبيت والتكلفة بنسبة تصل إلى 30%, ensuring faster commissioning

نقاط تشحيم مركزية & منافذ مراقبة الحالة | الأساس الفني: Lube lines routed to accessible groundlevel stations with ports for vibration/temperature sensors | المنفعة التشغيلية: Enables daily lubrication and health checks without operators needing to access elevated platforms near moving parts | تأثير عائد الاستثمار: Enhances preventative maintenance adherence, improving bearing life and preventing catastrophic failures

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة | لدينا حلول محطة تكسير الحجارة | ميزة (% تحسين) |
| : | : | : | : |
| وقت تغيير الخطوط الملاحية المنتظمة | 68 ساعات (لوحات الفك) | < 2 ساعات (لوحات الفك) | ~70% أسرع |
| كفاءة الطاقة| 0.85 1.1 كيلووات ساعة/طن معالج| هدف: 10% تحسين |
| توافر كسارة| ~9294% (المقرر & غير مجدولة)| Design Target: >96%| ~34% زيادة |
| استخدام جزء ارتداء| ~6070% of theoretical weight used before changeout| Design enables use of >85% of liner mass| ~25% better utilization |

5. المواصفات الفنية

مرجع النموذج: STQPrimary1442HD
نوع كسارة: كسارة الفك ذات التبديل المفرد الثقيلة
فتح الأعلاف: 1400مم × 1100 مم (55" س 42")
الحد الأقصى لحجم التغذية: 1000مم (40") طول الحافة
إعداد الجانب المغلق (CSS) يتراوح: 150مم 300 مم (6" 12")
نطاق السعة: 450 850 متري الهيدروكربونات النفطية (dependent on feed gradation & CSS)
متطلبات طاقة المحرك: 200 كيلوواط (275 HP), electric motor with softstart compatibility
Total Plant Power Demand (Feeder/Crusher/Conveyors): تقريبا. 350 كيلوواط
مواصفات المواد الرئيسية: الإطار الرئيسي لوحة الصلب ملفقة; Jaw plates Manganese steel alloy; رمح سبائك الصلب مزورة; محامل نوع الأسطوانة الكروية.
البصمة التقريبية (الطول × العرض): 18m x 8m
نطاق التشغيل البيئي: مصمم لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +45 درجة مئوية; محامل الغبار; weather protection covers standard.

6. سيناريوهات التطبيق

مشروع توسعة محجر الجرانيت

تحدي: An existing granite quarry needed to expand production but was constrained by an aging primary plant causing over 40 hours of unplanned downtime monthly due to reliability issues.
حل: Contract design and supply of a complete new primary stone quarry crushing plant station built around a heavyduty jaw crusher with enhanced accessibility features.
نتائج: Postinstallation data showed plant availability increased from 88% ل 96%. Unplanned downtime was reduced by over 90%, enabling the site to meet its expanded production target within six months.

Basalt Aggregate Producer Seeking Cost Control

تحدي: A producer faced volatile profitability due to uncontrollably high energy costs per ton and rapid wear part consumption in their primary stage.
حل: Implementation of an optimized plant design featuring chamber geometry focused on energyefficient breakage and a feeder system that removed more fines prior to crushing.
نتائج: Field data tracked over one year showed a reduction in specific energy consumption from 0.98 kWh/ton to 0.82 kWh/ton—a direct utility cost saving—and extended average jaw plate life by approximately 22%.

7. الاعتبارات التجارية

Our approach as your contract manufacturer is based on transparent value engineering:

طبقات التسعير
1. Standard Plant Package includes core equipment as specified above with basic walkways/platforms.
2.Optimized Plant Package includes additional features such as dust suppression system integration advanced condition monitoring sensor packages automated grease systems (+1015%)
3.Turnkey Project Package includes full civil design support installation supervision commissioning services (+يختلف)

Optional Features include metal detection systems tramp iron relief automation hydraulic setting adjustment vs manual modular skid designs for faster relocation

حزم الخدمة:
• Commissioning Support Onsite training operational readiness review
• Planned Maintenance Contracts Guaranteed parts supply scheduled inspections fixed annual cost models
• Performance Audits Annual review of throughput wear rates efficiency recommendations

Financing Options available through our partners include capital lease operating lease longterm rentaltoown structures tailored typically over 3 7 10شروط السنة

8.التعليمات

Q What if my current secondary crushers are not from your company? Is compatibility an issue?
A No Our stone quarry crushing plant is designed as an independent modular station Output specifications including product size distribution are engineered based on your input requirements ensuring seamless interface with any downstream equipment via proper transfer conveyors

Q How does this solution address my high energy costs?
A Energy efficiency is engineered into multiple components including optimized feedercrusher interaction efficient drive motor selection correctly sized gearboxes The overall system design aims minimize bottlenecks that cause motors run underloaded which inefficient Field data shows our optimized plants typically achieve measurable reductions specific energy consumption kWh per ton processed

Q What guarantees do you provide on performance metrics like throughput?
A We provide process performance guarantees based agreedupon feed material characteristics These are detailed commercial terms within contract specifying test methods duration We guarantee mechanical performance structural integrity workmanship standard industryleading warranties major components

Q Can you accommodate limited space on my existing site?
A Yes As contract manufacturer we specialize designing plants fit constrained layouts offering modular configurations vertical arrangements reduce footprint compared traditional horizontal flow designs Detailed layout studies conducted during proposal phase ensure feasibility before commitment made

Q What typical lead time expected from contract signing delivery?
A For standard configured stone quarry crushing plant lead times typically range 6 9 months depending complexity current manufacturing schedule Expedited options may available additional cost Longlead items like castings forgings identified early process