1. PAINPOINT DRIVEN OPENING

Are your iron ore processing margins being eroded by persistent operational bottlenecks? Plant managers and procurement specialists face significant challenges in primary crushing stages that directly impact the entire downstream circuit. Common pain points include:
Excessive Downtime: Unplanned stoppages for liner changes and maintenance on underspecification crushers, costing hundreds of production hours annually.
High Wear Costs: Rapid abrasion of crushing components in the face of hard, abrasive magnetite or hematite ores, leading to unsustainable consumables expenditure.
Inconsistent Throughput: Feed size fluctuations and material bridging causing chokefed or starved crushers, preventing consistent tonnage targets.
Regulatory Compliance Risk: Operating nonCE marked equipment exposes your project to legal liability, insurance complications, and potential site shutdowns in regulated markets.

How do you secure a robust primary crushing solution that ensures reliable throughput, controls operational costs, and meets stringent EU safety directives—all within a constrained capital budget?

2. PRODUCT OVERVIEW

Our solution is a CE Marked Stationary Primary Crushing Plant engineered specifically for hard rock iron ore applications. This turnkey module is designed for the initial size reduction of runofmine (ROM) iron ore to a consistent product for downstream conveying and processing.

Operational Workflow:
1. ROM ore is fed via dump truck or loader into a rugged vibrating grizzly feeder.
2. The feeder removes sub100mm fines via a grizzly section and evenly introduces oversize material to the primary jaw crusher.
3. The crusher reduces the ore to a nominal 150200mm product, which is discharged onto a main plant conveyor.

Application Scope: Ideal for greenfield installations or replacement of aging primary crushers in mediumtolarge scale iron ore operations processing magnetite, hematite, or goethite ores.

Limitations: This plant configuration is designed for primary crushing duty only. For full circuit needs, secondary/tertiary crushing and screening modules are required. Maximum feed size and capacity are bound by model specifications.

3. CORE FEATURES

HeavyDuty Jaw Crusher | Technical Basis: Reinforced manganese steel jaws with optimized nip angle geometry | Operational Benefit: Sustained high reduction ratios (typically 6:1 to 8:1) on abrasive ore with minimal wear flat development | ROI Impact: Extended liner life reduces consumable costs by an estimated 1525% versus standard designs.

Integrated Grizzly Feeder | Technical Basis: Highstrength steel deck with adjustable grizzly bars | Operational Benefit: Prescreening increases effective crusher capacity by removing fines, reduces crusher cavity wear, and prevents plugging | ROI Impact: Improves overall plant throughput efficiency and protects the crusher from unnecessary abrasion.

CE Certified Safety & Control System | Technical Basis: Full compliance with EU Machinery Directive 2006/42/EC, featuring guarded drive units, emergency stop circuits, and lockout/tagout points | Operational Benefit: Provides a verifiable safety framework, protects personnel, and ensures market access in regulated regions | ROI Impact: Mitigates project risk from noncompliance penalties and simplifies insurance procurement.

Modular SkidMounted Design | Technical Basis: Preassembled structural steel skid with integrated walkways and maintenance platforms | Operational Benefit: Significantly reduces civil works and onsite assembly time—plant can be operational within weeks of delivery | ROI Impact: Lowers total installed cost by up to 30% compared to traditional fieldbuilt foundations and structures.

Centralized Lube & Hydraulic System | Technical Basis: Singlepoint greasing lines for key bearings and integrated hydraulic system for adjustment & clearing | Operational Benefit: Simplifies routine maintenance schedules; enables quick setting adjustment and tramp iron release without downtime | ROI Impact: Reduces planned maintenance time by approximately 20%, increasing annual available operating hours.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Typical NonCE Plant) | Our CE Marked Iron Ore Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life (Abrasive Ore)| ~450,000 MT throughput per set| ~600,000 MT throughput per set| +33% |
| Mean Time Between Failure (MTBF)| ~800 hours| ~1,200 hours| +50% |
| Installation & Commissioning Time| 812 weeks| 35 weeks| ~60% faster |
| Energy Consumption per Tonne| Baseline (100%)| Approximately 9295% of baseline| 58% reduction |
| Regulatory Market Access| Requires extensive retrofit & documentation| Full CE compliance from delivery| Eliminates retrofit cost & delay |

5. TECHNICAL SPECIFICATIONS

Capacity Range: 400 1,200 tonnes per hour (TPH), dependent on feed size distribution and ore characteristics.
Primary Crusher Type: Single Toggle Jaw Crusher.
Feed Opening: Up to 1,500mm x 1,200mm.
Max Feed Size: Up to 1,050mm edge length.
Discharge Setting Range: 150 250mm CSS (Closed Side Setting).
Power Requirements: Total installed power approximately 300 450 kW (crusher motor + feeder motor + auxiliaries).
Material Specifications: Crusher jaws in premiumgrade Manganese Steel (14%18%); structural steel grade S355JR; wear plates on feed hopper.
Physical Dimensions (Skid): Approx. Length: 16m x Width: 5m x Height: 6m (varies by model).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system connections standard.

6. APPLICATION SCENARIOS

MidSized Magnetite Operation Expansion

Challenge: A Nordic mine needed to expand primary capacity but faced high local labor costs for extended onsite construction. Regulatory requirements mandated full CE compliance.
Solution: Installation of a preassembled skidmounted CE marked iron ore crushing plant with integrated dust suppression.
Results: The plant was commissioned in under four weeks postdelivery. It achieved permitted throughput immediately while reducing projected installation costs by approximately €150k.

Hematite Processing Plant Modernization

Challenge An aging processing facility suffered from constant unplanned downtime in its primary section due to crusher failures and excessive liner wear on hard hematite ore.
Solution Replacement of the legacy primary setup with our heavyduty jaw crusher plant featuring centralized lube systems and reinforced liners.
Results Field data shows liner life improved from an average of ~380k tonnes to over 550k tonnes. Annual planned maintenance events were reduced from five to three directly increasing annual available operating time

Commercial Considerations

Equipment Pricing Tiers are structured around throughput capacity core drive power
Tier I (900 TPH): Highcapacity configuration with premium components

Optional Features include advanced condition monitoring sensors onboard weighing systems automated grease systems specific wear package upgrades for highly abrasive ores

Service Packages range from basic commissioning support up through comprehensive multiyear scheduled maintenance plans including liner changeout services performed by factorytrained technicians

Financing Options are available including leasing structures that preserve capital expenditure lines or progressbased payment plans aligned with project milestones

FAQ

Q Is this plant compatible with my existing secondary circuit conveyors
A Yes The discharge height conveyor interface points can be adapted during engineering Standard discharge heights are provided but modifications are possible prior to build

Q What is the expected impact on my overall plant availability
A Based on historical performance data this design improves primary section availability typically achieving >94 due primarily to increased component life reduced unscheduled stops

Q Does CE marking cover the entire electrical system
A Yes Full CE certification encompasses all mechanical electrical control aspects ensuring conformity with relevant EU directives essential for projects requiring European certification

Q Are wear parts readily available globally
A We maintain strategic parts inventories in key mining regions Lead times for critical wear parts like jaw liners average less than days supported by our global logistics network

Q What commercial terms are standard
A Standard terms involve progress payments against engineering milestones factory acceptance testing FAT shipment Final payment is due upon completion of successful site commissioning