1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Managing a stone quarry crushing plant involves constant pressure to balance output, costo, y confiabilidad. ¿Estás enfrentando estos desafíos persistentes??
Tiempo de inactividad no programado: Bearing failures or component wear in primary crushers can halt your entire production line for days, costing tens of thousands in lost revenue per hour of stoppage.
Gradación de producto inconsistente: Fluctuations in feed size or worn crushing chambers lead to offspec aggregate, resulting in product rejection, recrushing costs, and dissatisfied customers.
Altos costos operativos: Rising energy consumption from inefficient crushing processes and the frequent need for manual adjustment and maintenance directly erode profit margins.
Seguridad & Intensidad Laboral: Routine inspections and clearing of jammed material in critical zones expose personnel to risk and divert skilled labor from proactive maintenance tasks.

What if your primary crushing stage could deliver more predictable throughput, reduzca su costo por tonelada, and improve site safety? The solution lies in selecting a robust, intelligently engineered primary jaw crusher station.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

This product description details our Planta trituradora de mandíbula primaria estacionaria, a complete, preengineered module designed for the first stage of rock reduction in a quarry crushing circuit. It forms the critical foundation for your entire mineral processing operation.

Flujo de trabajo operativo:
1. Consumo de alimento: RunofQuarry (ROQ) material is dumped by haul trucks directly into a rugged vibrating grizzly feeder (VGF VGF).
2. Pre-selección & Derivación: The VGF removes natural fines and bypasses subsize material to a conveyor, reducing unnecessary wear on the crusher.
3. Reducción Primaria: Oversize material is directed into the deep crushing chamber of a heavyduty jaw crusher, where it is compressed between a fixed and a moving jaw plate.
4. Descargar & Transporte: Crushed product is discharged at the specified CSS (Configuración del lado cerrado) onto a main product conveyor for transport to secondary crushing or stockpiling.

Ámbito de aplicación: Ideal for processing hard rock types like granite, basalto, y piedra caliza. Diseñado para continuo, operaciones de alto tonelaje.
Limitaciones: No está diseñado como una planta independiente de productos terminados.; requires secondary and tertiary stages for most aggregate specifications. Feed size is limited by the physical dimensions of the crusher opening.

3. CARACTERÍSTICAS PRINCIPALES

Diseño modular BoltTogether | Base técnica: Prefabricated structural steel sections with machined connection interfaces | Beneficio operativo: Reduce el tiempo de instalación en campo hasta en 40% versus traditional weldedonsite plants, enabling faster commissioning. | Impacto del retorno de la inversión: Lower labor costs and earlier production start translate to quicker capital payback.

Alimentador Grizzly Vibrante de Servicio Pesado (VGF VGF) | Base técnica: Highstrength steel deck with replaceable grizzly bars; adjustable eccentric shaft drives | Beneficio operativo: Effectively scalps fines and evenly distributes feed across the full crusher inlet, preventing chokefeeding on one side. | Impacto del retorno de la inversión: Protects crusher from abrasive wear caused by fines, extends liner life by an estimated 1520%, and improves overall energy efficiency.

Hydrostatic Jaw Crusher Drive | Base técnica: Directdrive system with variablespeed hydraulic motors instead of traditional Vbelts and sheaves | Beneficio operativo: Provides reversible operation to clear blockages and allows precise control of crusher speed to match feed conditions dynamically. | Impacto del retorno de la inversión: Eliminates belt maintenance costs and downtime; Los datos de campo muestran una 30% reduction in time spent clearing jams.

Integrated PLCBased Control System | Base técnica: Centralized programmable logic controller with touchscreen HMI monitoring motor amps, temperaturas de los rodamientos, and hydraulic pressure | Beneficio operativo: Gives operators realtime visibility into plant health and allows remote start/stop sequencing from a safe location. | Impacto del retorno de la inversión: Enables predictive maintenance scheduling based on trend data, preventing catastrophic failures.

WalkAround Maintenance Platforms & Access Ladders | Base técnica: OSHAcompliant platforms with nonslip grating provide safe 360degree access to all service points. | Beneficio operativo: Su equipo de mantenimiento puede realizar controles de rutina., lubricación, and liner changes safely and efficiently. | Impacto del retorno de la inversión: Reduces risk of workplace incidents and lowers insurance premiums while improving mean time to repair (MTTR).

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria | Our Primary Jaw Crusher Plant Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad (tiempo de actividad)| ~9294% (programado & paradas no programadas) |>96% (based on 24month field data) |>24% aumentar |
| Tiempo de cambio de revestimiento| 1824 hours for similar capacity units| <12 hours with hydraulic assist tools| ~3350% faster |
| Consumo de energía por tonelada| Baseline set at 100% for comparable plants| Average reduction to ~92% via efficient drive & optimal kinematics| ~8% lower kWh/ton |
| Instalación & Commissioning Duration| 810 weeks from delivery start| 56 weeks due to modular design| ~30% faster |

5. ESPECIFICACIONES TÉCNICAS

Crusher Model: JC5460 HeavyDuty Jaw Crusher
Apertura de alimentación: 54" incógnita 60" (1372 mm x 1524 milímetros)
Tamaño máximo de alimentación: 48" (1220 milímetros) lump
Configuración del lado cerrado (CSS) Rango: 6" 14" (150 milímetros 355 milímetros)
Rango de capacidad: 550 1,500 STPH (500 1,360 MTPH), dependiente del material de alimentación y CSS.
Total Installed Power: Aprox.. 600 caballos de fuerza (450 kilovatios) combined for crusher drive,VGF VGF,y transportadores.
Main Structure Material: ASTM A36 Steel with abrasionresistant wear liners at impact points.
Overall Module Dimensions (LxAnxAl): Aprox.. 65' x 25' x 22' (19.8m x 7.6m x 6.7m).
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +50°C (4°F to +122°F). Dust suppression system connections are standard.

6. ESCENARIOS DE APLICACIÓN

Ampliación de cantera de granito | Desafío: An existing operation needed to increase primary throughput by 35% without expanding their truck dump footprint or primary conveyor infrastructure.| Solución: Replacement of an older jaw plant with our highcapacity modular JC5460 plant featuring an optimized feeder geometry.| Resultados: Achieved the required 35% throughput increase within the same footprint.Product gradation consistency improved,customer rejections fell by 12%.

HighAbrasion Basalt Processing | Desafío:Liner wear costs in the primary stage were excessive,causing liner changes every 6 weeks at significant cost in parts,mano de obra,and lost production.| Solución: Implementation of our jaw plant with proprietary manganese steel jaw plates paired with the efficient material flow from the heavyduty VGF.| Resultados:Liner life extended to an average of 9 semanas,a 50% improvement in changeout frequency,yielding an annual savings of over $85k in direct wear part costs.

7.CONSIDERACIONES COMERCIALES

Our stationary primary jaw crusher plants are offered in three core configurations:
Nivel básico: Incluye trituradora,VGF VGF,motor drives,basic walkways,and control panel.Focused on essential functionality.
Nivel de rendimiento (Más común): Adds integrated dust suppression spray systems,hydraulic setting adjustment for the crusher,and enhanced guarding packages.
Nivel Premium: Incorporates advanced condition monitoring sensors(online lubrication,temperatura,vibración),extended service platforms,and premium wear liners with guaranteed MTBF(Tiempo medio entre fallos).

Optional features include magnet systems,sistemas de alivio de restos de hierro,and custom conveyor lengths.Service packages range from basic commissioning support to comprehensive multiyear maintenance agreements with guaranteed parts availability.Financing options include capital lease agreements tailored to match projected cash flow from increased production.

8.Preguntas frecuentes

q:What if my haul trucks deliver slightly larger rock than your maximum specified feed size?
A:The heavyduty design includes reinforced components,but consistently exceeding max feed size risks damage.We offer optional oversized feed protection solutions such as hydraulic rock breakers mounted on the feeder deck frame.

Q.How does this plant integrate with my existing secondary cone crushers?
A.The discharge conveyor is sized based on your required peak capacity.The control system can be configured via standard protocols(Modbus,Ethernet/IP)to communicate with your existing PLCs.All electrical interfaces are clearly documented for your engineering team.

Q.What is the expected operational impact on my power consumption?
A.Field data typically shows stable or reduced specific energy consumption(kWh/tonelada)due to efficient drive systems.Optional softstart controls further mitigate peak demand charges during startup.

Q.Are spare parts readily available?
A.We maintain regional inventory hubs globally.Critical wear parts like jaw plates are stocked based on predictive models derived from thousands of operating hours.Customers under service agreements receive priority allocation.

Q.What commercial terms are available?
A.We offer ExWorks,FOB Port,and Delivered Duty Paid(DDP) incoterms.Payment structures typically involve progress payments tied to manufacturing milestones.Please inquire about current lead times which vary based on configuration complexity