1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Are you managing a midtolarge scale aggregate operation and facing consistent pressure to meet project deadlines while controlling capital and operational expenditure? The challenges of a 250300tph stone crushing plant are significant. Inconsistent feed material causes unexpected wear and downtime on critical components. Bottlenecks in one crushing stage throttle the entire line’s output, leaving capacity unrealized. Rising energy costs directly erode profit margins on every ton produced. Además, frequent maintenance interrupts production schedules, and configuring a plant for multiple product specifications often requires manual adjustments and costly delays.

How do you achieve reliable 300tonperhour output without excessive maintenance overhead? Can your plant adapt to varying feed hardness and size without sacrificing final product gradation? Is your current solution delivering the expected return on investment through sustained availability and low costperton?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

Este producto es un completo, stationary 250300tph turnkey stone crushing and screening plant designed for highvolume production of aggregates for road base, concreto, y asfalto. It is engineered for primary contractors and quarry operators requiring consistent, specificationgrade output.

Flujo de trabajo operativo:
1. Trituración Primaria: pienso grande (≤750 mm) se reduce mediante una robusta trituradora de mandíbulas o un impactador primario.
2. Secundario & Trituración Terciaria: Material is conveyed to cone crushers or secondary impactors for further size reduction and shaping.
3. Cribado: Multipledeck vibrating screens precisely separate crushed material into required product sizes (p.ej., 05milímetros, 510milímetros, 1020milímetros).
4. Manejo de materiales: A network of conveyors with centralized control transfers material between stages and to final stockpiles.
5. Supresión de polvo: Los sistemas de pulverización integrados en los puntos de transferencia controlan las emisiones de partículas, ensuring environmental compliance.

Ámbito de aplicación & Limitaciones:
Alcance: Ideal para roca dura (granito, basalto), caliza, and river gravel applications. Suited for permanent installation in large quarry sites or major infrastructure project batching plants.
Limitaciones: No diseñado como equipo móvil o semimóvil.. Feed size and material abrasiveness must align with configured crusher chamber selections for optimal performance.

3. CARACTERÍSTICAS PRINCIPALES

Diseño de patín modular | Base técnica: Premontado, steelframed substructures | Beneficio operativo: Reduce el tiempo de instalación en sitio hasta en 40%, ensures precise factory alignment of motors and drives | Impacto del retorno de la inversión: Una puesta en servicio más rápida acelera la generación de ingresos; standardized modules simplify future maintenance.

Sistema inteligente de control de procesos | Base técnica: Automatización basada en PLC con algoritmos de carga compartida | Beneficio operativo: Optimizes crusher feed rates in realtime to prevent choking or running empty; monitors power draw for peak efficiency | Impacto del retorno de la inversión: Reduces energy consumption per ton by an estimated 815% y minimiza el error del operador.

HeavyDuty Wear Component Package | Base técnica: Barras de golpe de alto cromo, manganese steel jaws/concaves, reinforced screen meshes | Beneficio operativo: Extiende los intervalos de servicio en 3050% in abrasive applications, maintains consistent product gradation longer | Impacto del retorno de la inversión: Lowers costperton for wear parts and reduces downtime frequency for component changeouts.

MultiStage Dust Control Integration | Base técnica: Strategically placed spray nozzles with solenoid valves tied to conveyor operation | Beneficio operativo: Effectively suppresses dust at each transfer point, improving site visibility and operator health | Impacto del retorno de la inversión: Mitigates risk of environmental noncompliance fines and reduces cleanup labor.

Engrase centralizado & Sistema de lubricación | Base técnica: Automated pump system with distribution lines to key bearing points | Beneficio operativo: Ensures critical bearings receive correct lubrication on schedule without manual intervention | Impacto del retorno de la inversión: Prevents premature bearing failure, a leading cause of unplanned downtime.

HighCapacity Vibrating Screens with Deck Access System | Base técnica: Large screening area with adjustable throw; pasarelas integradas & plataformas | Beneficio operativo: Maximizes screening efficiency; provides safe, easy access for mesh inspection and replacement | Impacto del retorno de la inversión: Improves final product quality control and enhances worker safety during routine checks.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (250300tph Planta) | This 250300tph Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad de planta | 8588% (incluido el mantenimiento planificado) | 92%+ (engineered design) | +47% tiempo de actividad |
| Consumo de energía (kWh/tonelada)| Varía ampliamente; often not optimized per stage| Managed via intelligent load control| Arriba a 15% reduction demonstrable |
| Wear Life on Abrasive Rock| Standard manganese/chrome components| Premium alloy selection & optimización de la cámara| +30% aumento promedio |
| Instalación & Tiempo de puesta en servicio| 812 weeks onsite assembly| ~57 weeks (modular skid design)| ~40% de reducción |
| Consistencia de la gradación del producto| Manual feed adjustment leads to variance| Automated setting regulation (ASRitype systems)| Variance improved by up to 25% |

5. ESPECIFICACIONES TÉCNICAS

Capacidad de rendimiento diseñada: 250 300 toneladas métricas por hora (varies based on feed material hardness & distribución de tamaño).
Opciones de trituradora primaria: Cursor de mandíbula (900x1200mm) o trituradora de impacto primaria (Φ1600x2000mm).
Trituradora secundaria/terciaria: Two units of Hydraulic Cone Crushers (p.ej., HPC315).
Screening Stations: Two units of TripleDeck HeavyDuty Vibrating Screens (2400x6000mm).
Potencia Total Instalada: Aproximadamente 800 950 kilovatios.
Especificaciones clave de materiales: Main frame structure fabricated from Q345B steel; wear liners use Mn18Cr2 or equivalent highgrade alloys.
Huella vegetal general (Largo x ancho): ~120m x 85m (layout can be customized).
Rango de operación ambiental: Diseñado para una temperatura ambiente de 20 °C a +45 °C; dust emission control meets standard regulatory limits (<20mg/m³ at property boundary).

6. ESCENARIOS DE APLICACIÓN

Highway Construction Base Course Production | Desafío: A national infrastructure project required consistent supply of three graded aggregates for road base layers from highly abrasive granite. The existing plant struggled with rapid wear and inconsistent sizing, threatening project timelines.| Solución: Implementation of this heavyduty configured plant featuring cone crushers with automated settings control and premium wear packages.| Resultados: Achieved sustained output of 280tph. Wear part life increased by over 35%, reducing changeout downtime. Product gradation consistency met strict highway authority specifications throughout the contract.

Commercial Limestone Quarry Expansion | Desafío: A quarry expanding its market needed to increase finished product range without adding separate processing lines or excessive manual sorting.| Solución: Installation of this multistage plant with precise secondary/tertiary crushing circuits and highefficiency multideck screens.| Resultados:The plant reliably produces five distinct products simultaneously—from coarse aggregate to manufactured sand—at a combined rate exceeding 270tph, enabling entry into new concrete and asphalt mix markets.

7. CONSIDERACIONES COMERCIALES

Our approach provides clarity in investment planning:

Niveles de precios: We offer three standard configurations:
Básico: Core crushing & screening modules for reliable singleproduct output.
Advanced: Includes automation systems, enhanced dust control, wider conveyor specification.
De primera calidad: Full turnkey package with premium wear materials package extended warranty coverage

Características opcionales & Actualizaciones: Specific options include automated metal detection/rejection systems advanced rockonrock shaping chambers additional sound attenuation enclosures remote monitoring telematics packages

Paquetes de servicios: Choose from annual maintenance contracts providing scheduled inspections guaranteed spare parts delivery priority technical support Extended warranty plans are available covering major structural components

Opciones de financiación: We work with established financial partners offer flexible leasing arrangements milestonebased project financing solutions tailored capital expenditure plans

8.Preguntas frecuentes

1.q:What if our feed rock hardness exceeds the standard design parameters?
A:The plant's core structural design accommodates high loads but we conduct a detailed feed material analysis during quotation For extremely hard or abrasive materials we specify upgraded wear component alloys chamber geometries ensure designed throughput longevity

2.Q How does this plant manage fluctuations in incoming feed size?
A The intelligent process control system regulates feeder speeds based realtime crusher motor load preventing choking This combined surge pile capacity before primary crusher smooths out typical frontend loader variation

3.Q What typical timeframe expected from order placement commissioning?
A For standard configuration lead time manufacturing shipping approximately months Onsite installation commissioning modular skid design typically requires weeks depending local civil works readiness

4.Q Are spare parts readily available longterm?
A Yes We maintain global inventory strategic wear parts provide guaranteed stockholding agreements as part service packages All major mechanical electrical components internationally standardized brands ensuring supply chain redundancy

5.Q Can existing equipment integrated into new plant?
A Potentially yes An initial audit your current conveyors screens can determine compatibility integration feasibility often possible especially material handling equipment reducing overall project cost

6.Q What ongoing operational staffing requirements?
A The automated central control system allows efficient operation primary operators monitoring stations Additional personnel required routine mechanical checks stockpile management but labor intensity significantly lower versus manually controlled plants

7.Q What key factors influence final price quotation?
A Final pricing determined specific equipment selection required options degree site preparation needed local regulatory compliance costs shipping logistics destination Comprehensive site survey forms basis fixedprice turnkey proposal