1. PAINPOINT DRIVEN OPENING

Are your bulk limestone mining operations constrained by escalating costs and unpredictable throughput? Key operational challenges directly impact your bottom line:
High Cost per Ton: Inefficient extraction and primary crushing cycles lead to excessive fuel, labor, and bit wear costs.
Unscheduled Downtime: Equipment not engineered for abrasive limestone applications suffers premature failure, causing costly production halts.
Inconsistent Feed Size: Poorly fragmented shot rock creates bridging and chokefeeding at the primary crusher, reducing overall plant capacity by 1530%.
Rising Overburden Removal Costs: Inefficient stripping methods add nonproductive time before profitable limestone seams are exposed.

How do you increase yield per blast, ensure reliable feeding of your processing plant, and reduce your total cost of ownership on the hardestworking equipment in your flow? The solution begins at the primary extraction and reduction stage.

2. PRODUCT OVERVIEW

This content details highcapacity, heavyduty bulk limestone mining equipment, specifically focused on primary mobile crushing and screening solutions (MC&S) for quarry face applications. These systems are engineered to replace or augment traditional truckandshovel cycles directly at the pit.

Operational Workflow:
1. An excavator or wheel loader feeds shot limestone directly into the mobile primary crusher’s hopper at the quarry face.
2. The heavyduty jaw or impact crusher reduces the rock to a conveyable size, typically below 250mm.
3. An integrated or separate mobile conveyor system transports the crushed material directly to a longdistance overland conveyor or a fixed secondary plant, eliminating dozens of truck cycles.

Application Scope: Ideal for largescale quarry operations with annual production exceeding 1 million tons. Suited for medium to hard limestone formations.

Limitations: Not designed for selective mining of thin, multiple seams without significant operational adjustment. Initial capital investment requires analysis against longterm haulage savings.

3. CORE FEATURES

Direct Face Feeding | Technical Basis: Pitside material integration | Operational Benefit: Eliminates primary haul trucks between the face and stationary crusher | ROI Impact: Reduces fuel, tire, and labor costs associated with truck fleets by up to 40% on this cycle

AbrasionResistant Crushing Chamber | Technical Basis: Highchrome martensitic steel liners & jaw plates | Operational Benefit: Withstands continuous abrasion from silica content in limestone | ROI Impact: Extends wear part life by 3050%, lowering costperton for consumables

Hydraulic Setting Adjustment | Technical Basis: Centralized hydraulic cylinders for crusher gap control | Operational Benefit: Allows operators to adjust product size in under 2 minutes for different product stockpiles | ROI Impact: Increases plant flexibility and reduces downtime for size changes

Intelligent Feeder Control | Technical Basis: Frequencycontrolled vibratory or apron feeder with loadsensing | Operational Benefit: Prevents crusher overload and optimizes feed rate for maximum throughput | ROI Impact: Protects drive components from shock loads and ensures rated capacity is consistently achieved

Integrated Dust Suppression System | Technical Basis: Nozzle arrays at transfer points with programmable logic controller (PLC) timing | Operational Benefit: Actively manages particulate emissions during crushing and conveying | ROI Impact: Maintains regulatory compliance and improves site working conditions without manual intervention

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Truck & Shovel to Fixed Crusher) | Bulk Limestone Mining Solution (Mobile Primary Crushing) | Advantage (% Improvement) |
| : | : | : | : |
| Fuel Cost per Ton | High (Multiple truck cycles) | Low (Direct conveying from face) | Up to 60% reduction |
| Primary Reduction Downtime| Scheduled maintenance + unplanned haul delays <5% availability loss| Centralized maintenance on single system <10% availability gain |
| Labor Intensity| Requires multiple equipment operators (drills, shovels, trucks)| Reduced fleet simplifies logistics ~25% reduction in operators |
| Feed Size Consistency| Variable due to shot rock segregation| Controlled via active feeder & grizzly ~40% reduction in crusher stalls |

5. TECHNICAL SPECIFICATIONS

Capacity/Rating: 400 1,500 tonnes per hour (TPH), depending on model and feed size distribution.
Power Requirements: Primary unit typically requires a 300500 kVA external power pack or onboard dieselelectric generator set.
Material Specifications: Crusher wear parts manufactured from TENSAMANG® or equivalent highgrade steel; chassis constructed from welded Q345B steel plate.
Physical Dimensions (Example): Operating length approx. 22m; width approx. 3.5m; height approx. 4.2m. Transport configurations available.
Environmental Operating Range: Designed for 20°C to +45°C ambient temperature. Dust protection to IP65 standards on electrical components.

6. APPLICATION SCENARIOS

Large Aggregate Producer Challenge Specific problem needed consistent feed to new secondary plant located 2km from expanding pit face Solution Implementation of a trackmounted primary jaw crusher with a mobile field conveyor Results Direct diesel fuel savings of approximately $180 per operating hour; achieved required plant feed rate of $800 TPH within three months of commissioning

Cement Plant Raw Material Extraction Challenge High maintenance costs on aging haul truck fleet moving limestone to primary crusher Solution Deployment of a semimobile gyratory crusher station at a strategic pit location Results Reduced operating cost per ton by $22%; haul truck fleet requirements cut from twelve units to four

7 COMMERCIAL CONSIDERATIONS

Equipment pricing is tiered based on capacity robustness and level of automation:
Standard Tier: Highcapacity jaw plant with basic controls Capable of $800$1000 TPH
Premium Tier: Integrated gyratory crusher with advanced automation telemetry remote monitoring Capable of $1200+ TPH
Optional features include hybrid dieselelectric drive systems secondary screening modules onboard weighing systems extended warranties Service packages range from scheduled maintenance only to full comprehensive coverage including wear parts Financing options include capital lease operating lease leasetoown structures tailored to cash flow requirements

8 FAQ

What is the typical setup time required when relocating this equipment within the quarry?
With selfpropelled track systems relocation between prepared platforms can be completed in under one hour by a single operator

How does this solution integrate with our existing secondary crushing circuit?
The system is designed as a direct feed source Conveyor discharge heights are adjustable ensuring compatibility with most existing surge piles or secondary crusher feeders

What are the expected maintenance intervals compared to stationary primary plant?
Maintenance schedules are similar but centralized Field data shows that accessibility can reduce service time by up to % due to improved component layout

Can you provide a detailed analysis of projected ROI specific parameters?
Yes commercial proposals include a proprietary costmodeling tool that inputs your current fuel labor maintenance consumable costs generates sitespecific payback period projection

What training provided our operations maintenance staff?
We offer comprehensive onsite training programs covering safe operation routine maintenance troubleshooting procedures ensure minimal disruption during implementation