1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

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. Los puntos débiles comunes incluyen:
Tiempo de inactividad excesivo: Unplanned stoppages for liner changes and maintenance on underspecification crushers, Cuesta cientos de horas de producción al año..
Altos costos de desgaste: Rapid abrasion of crushing components in the face of hard, abrasive magnetite or hematite ores, leading to unsustainable consumables expenditure.
Rendimiento inconsistente: 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. DESCRIPCIÓN GENERAL DEL PRODUCTO

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 (memoria de sólo lectura) iron ore to a consistent product for downstream conveying and processing.

Flujo de trabajo operativo:
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.

Ámbito de aplicación: Ideal for greenfield installations or replacement of aging primary crushers in mediumtolarge scale iron ore operations processing magnetite, hematites, or goethite ores.

Limitaciones: 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. CARACTERÍSTICAS PRINCIPALES

Trituradora de mandíbulas de servicio pesado | Base técnica: Reinforced manganese steel jaws with optimized nip angle geometry | Beneficio operativo: Sustained high reduction ratios (típicamente 6:1 a 8:1) on abrasive ore with minimal wear flat development | Impacto del retorno de la inversión: Extended liner life reduces consumable costs by an estimated 1525% versus standard designs.

Alimentador Grizzly integrado | Base técnica: Plataforma de acero de alta resistencia con barras grizzly ajustables | Beneficio operativo: Prescreening increases effective crusher capacity by removing fines, reduces crusher cavity wear, and prevents plugging | Impacto del retorno de la inversión: Improves overall plant throughput efficiency and protects the crusher from unnecessary abrasion.

Seguridad certificada CE & Sistema de control | Base técnica: Full compliance with EU Machinery Directive 2006/42/EC, featuring guarded drive units, emergency stop circuits, and lockout/tagout points | Beneficio operativo: Provides a verifiable safety framework, protects personnel, and ensures market access in regulated regions | Impacto del retorno de la inversión: Mitigates project risk from noncompliance penalties and simplifies insurance procurement.

Diseño modular montado sobre patines | Base técnica: Preassembled structural steel skid with integrated walkways and maintenance platforms | Beneficio operativo: Significantly reduces civil works and onsite assembly time—plant can be operational within weeks of delivery | Impacto del retorno de la inversión: Lowers total installed cost by up to 30% compared to traditional fieldbuilt foundations and structures.

Lubricante centralizado & Sistema hidráulico | Base técnica: Singlepoint greasing lines for key bearings and integrated hydraulic system for adjustment & claro | Beneficio operativo: Simplifies routine maintenance schedules; enables quick setting adjustment and tramp iron release without downtime | Impacto del retorno de la inversión: Reduces planned maintenance time by approximately 20%, aumento de las horas de funcionamiento anuales disponibles.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Typical NonCE Plant) | Nuestra solución de planta trituradora de mineral de hierro con marca CE | Ventaja (% Mejora) |
| : | : | : | : |
| Vida del revestimiento (mineral abrasivo)| ~450,000 MT throughput per set| ~600,000 MT throughput per set| +33% |
| Tiempo medio entre fallos (MTBF)| ~800 horas| ~1200 horas| +50% |
| Instalación & Tiempo de puesta en servicio| 812 semanas| 35 semanas| ~60% más rápido |
| Consumo de energía por tonelada| Base (100%)| Aproximadamente 9295% de línea base| 58% reducción |
| Regulatory Market Access| Requires extensive retrofit & documentation| Full CE compliance from delivery| Eliminates retrofit cost & delay |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: 400 1,200 toneladas por hora (TPH), dependent on feed size distribution and ore characteristics.
Tipo de trituradora primaria: Trituradora de mandíbula de palanca única.
Apertura de alimentación: Up to 1,500mm x 1,200mm.
Tamaño máximo de alimentación: Up to 1,050mm edge length.
Rango de ajuste de descarga: 150 250mm CSS (Configuración del lado cerrado).
Requisitos de energía: Potencia total instalada aproximadamente 300 450 kilovatios (crusher motor + motor alimentador + tropas auxiliares).
Especificaciones de materiales: Crusher jaws in premiumgrade Manganese Steel (14%18%); grado de acero estructural S355JR; wear plates on feed hopper.
Dimensiones físicas (Skid): Aprox.. Longitud: 16m x ancho: 5m x altura: 6metro (varía según el modelo).
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C; dust suppression system connections standard.

6. ESCENARIOS DE APLICACIÓN

MidSized Magnetite Operation Expansion

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

Modernización de la planta de procesamiento de hematita

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

Consideraciones comerciales

Equipment Pricing Tiers are structured around throughput capacity core drive power
Nivel 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

Preguntas frecuentes

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