1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Está gestionando una operación de producción de agregados de mediana a gran escala y enfrenta obstáculos persistentes que erosionan la rentabilidad?? Para gerentes de planta y contratistas de ingeniería, una planta trituradora de piedra de 250300 tph es un activo crítico, Sin embargo, los desafíos operativos comunes impactan directamente sus resultados.. Considere estos problemas frecuentes:
Rendimiento inconsistente & Falta del tiempo: Unplanned stoppages due to feeder blockages, crusher overloads, or conveyor misalignment can cost thousands per hour in lost production and idle labor.
Alta operativa & Costos de mantenimiento: Reemplazo frecuente de piezas de desgaste, Alto consumo de energía por tonelada de producción., and the need for specialized maintenance crews steadily increase your cost per aggregate ton.
Mala forma del producto & Control de gradación: Inconsistent output leads to excess fines or outofspec material, reducing the market value of your end product and causing rejections.
Diseño de planta rígida & Límites de escalabilidad: Fixed designs struggle to adapt to changing feed material hardness or required product mixes, forcing costly retrofits or operating below optimal capacity.

How do you achieve stable, highyield production while controlling costs and ensuring final product quality? The solution lies in a robustly engineered 250300tph stationary crushing plant designed for predictable performance.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

This solution is a complete stationary stone crushing and screening plant engineered for a nominal output of 250 a 300 toneladas métricas por hora (tph) de agregado terminado. It is designed as a primarytotertiary processing system for mediumhard to hard stones like granite, basalto, y piedra caliza.

Flujo de trabajo operativo:
1. Trituración Primaria: Material de alimentación grande (≤750 mm) is reduced by a heavyduty jaw crusher or gyratory crusher.
2. Secundario & Trituración Terciaria: The primary crushed material is further processed by cone crushers for size reduction and improved particle shape.
3. Cribado & Clasificación: Vibrating screens separate material into precise size fractions, routing oversize back to crushers and directing onspec product to final stockpiles.

Ámbito de aplicación: Ideal para operaciones de canteras grandes, major infrastructure project support (autopistas, ferrocarriles), and commercial aggregate supply yards requiring highvolume, salida consistente.

Limitaciones clave: Feed material hardness must be within specified limits (p.ej., arriba a 300 Resistencia a la compresión MPa). Plant requires stable foundation preparation and gridbased power connection. Not designed for mobile or frequent relocation.

3. CARACTERÍSTICAS PRINCIPALES

Sistema de control de alimentación inteligente | Base técnica: Unidad de frecuencia variable (VFD) on primary feeder with level sensors | Beneficio operativo: Prevents crusher cavity overload and minimizes bridging, ensuring smooth material flow | Impacto del retorno de la inversión: Reduce el tiempo de inactividad no planificado hasta en 15% and improves crusher liner life

Laminated Crushing Chamber Design | Base técnica: Multilayer crushing cavity geometry in cone crushers | Beneficio operativo: Produces superior particle shape with lower flakiness index and controlled fines generation | Impacto del retorno de la inversión: Increases premium product yield by 812%, enhancing sales revenue

Engrase centralizado & Sistema hidráulico | Base técnica: Singlepoint lubrication stations with automated timers and pressure monitoring | Beneficio operativo: Ensures critical bearing points are serviced consistently, reducing failure risk | Impacto del retorno de la inversión: Lowers bearingrelated breakdowns by an estimated 25% and extends service intervals

HighStrength Modular Conveyor Framework | Base técnica: CADoptimized truss design using hightensile steel | Beneficio operativo: Proporciona una estabilidad excepcional bajo carga., reducing vibration and misalignment issues | Impacto del retorno de la inversión: Decreases conveyor maintenance time by approximately 20% over the plant lifecycle

PLCBased Automated Process Logic | Base técnica: Controlador lógico programable con interfaz hombre-máquina (HMI) for sequence control and interlocking | Beneficio operativo: Allows singleoperator oversight of startup/shutdown sequences and provides fault diagnostics | Impacto del retorno de la inversión: Optimizes power use during operation cycles and reduces labor requirements for plant control

HeavyDuty Vibrating Screen with QuickChange Decks | Base técnica: Rubber shear mounts and sidetensioned screen media attachment system | Beneficio operativo: Provides efficient sizing with reduced noise/vibration transmission; enables faster screen cloth replacement | Impacto del retorno de la inversión: Cuts screen maintenance downtime by up to 40% por evento de cambio

Sistema integrado de supresión de polvo | Base técnica: Nozzle arrays at transfer points connected to a highpressure pump system | Beneficio operativo: Effectively controls airborne particulate at primary dust generation sources | Impacto del retorno de la inversión: Garantiza el cumplimiento de la normativa medioambiental., avoiding potential fines and improving site working conditions

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (250300tph Planta) | This 250300tph Stone Crushing Plant Solution | Ventaja (% mejora) |
|||||
| Eficacia general del equipo (OEE) | ~76% | Target ≥84% | +10.5% |
| Consumo de energía (kWh/tonelada procesada) | Varía ampliamente; baseline = X | Optimized system design reduces baseline |7% a 12% |
| Desgaste de la vida útil de la trituradora (Revestimientos de manganeso)| Based on abrasive feed | Improved chamber design & alloy selection |15% Costo por tonelada |
| Tiempo medio entre fallas (MTBF) Key Conveyors ~1,200 hours ~1,650 hours +37.5% |
| Índice de forma del producto (Flakiness) Típicamente >20% Mantiene <15% 25% Improvement in Cubicity |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad nominal: 250 – 300 tph (varies based on feed material hardness & required product gradation).
Opciones de trituradora primaria: Cursor de mandíbula (PE900×1200) o trituradora giratoria; Feed Opening up to 750mm.
Trituradoras secundarias/terciarias: Multicylinder Hydraulic Cone Crushers.
Equipo de cribado: Tripledeck heavyduty circular motion vibrating screens; Total screening area ≥20m².
Potencia Total Instalada: Aproximadamente 550 – 650 kilovatios (dependiente de la configuración).
Especificaciones clave de materiales: Primary frame construction Q345B steel; Highwear components use Mn18Cr2 or equivalent alloys; Conveyor belts rated for minimum PIW 800.
Huella vegetal general (L x A): Approximately 85m x 65m (dependiente del diseño). Height restrictions apply (~25m max).
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C; Dust emission control achieves ≤20mg/m³ at key points.

6. ESCENARIOS DE APLICACIÓN

Proyecto de Ampliación de Cantera de Granito

Challenge A quarry needed to increase production from 200tph to a consistent 280tph of road base and concrete aggregates but had limited space for plant expansion.
Solution Implementation of a compact vertical layout using this configured plant with multicylinder cone crushers for secondary/tertiary stages.
Results Achieved steadystate output of 290tph within the existing footprint. Product cubicity met the highest local specification standards.

LargeScale Highway Construction Support

Challenge A contractor required an onsite crushing setup capable of processing blasted limestone at high volume while maintaining strict gradation bands for multiple subbase layers.
Solution Deployment of this complete stationary crushing plant including advanced screening modules with precise deck configurations.
Results The plant supplied over 1.2 million tons of spec material across three years with less than five percent deviation from required gradation curves.

7. CONSIDERACIONES COMERCIALES

Our solutions are offered in tiered configurations:
Nivel de configuración estándar: Incluye módulos de trituración de núcleos.,screening units,and basic PLC control.Priced as a turnkey package.
Nivel de alta eficiencia: Adds intelligent feed systems,crusher automation settings,and premium wear materials.Initial investment yields lower longterm operating costs.
Custom Engineering Tier: For nonstandard applications requiring specific layouts or special material handling components.Priced upon project engineering review.

Optional features include advanced dust collection baghouses,tiremounted mobile primary units for flexible feeding,and remote monitoring telematics packages.Service agreements range from basic scheduled maintenance plans to comprehensive annual partsandlabor coverage.Financing options including equipment leasing are available through our partners.

8. Preguntas frecuentes

What are the primary power requirements?
A stable threephase industrial power supply is required.Total connected load typically ranges from550to650kW.Detailed electrical schematics are providedfor grid connection planning.

Can this plant process river gravel or very abrasive materials?
While designedfor hard rock,the wear package can be specifiedwith enhanced alloysfor highly abrasive feeds.Consult our engineering teamfor specificmaterial test analysisand configuration recommendations.

What is the typical installationand commissioning timeline?
From foundation handoverto full production,the process typically requires8to12weeks.This includes mechanical erection,electrical connection,system calibration,and operator training conductedby our engineers.

Do you provide spare parts support globally?
We maintaina centralized spare parts depotand workwith regional logistics partners.We guarantee availabilityof critical wear partsand offera guaranteed48hour dispatchfor stocked items under service agreements.

How does thisplant handle variationsin feed sizeor hardness?
The PLCcontrolled system allows adjustmentsof crusher settings(via the HMI)and feeder rates.The hydraulic adjustmenton cone crushers enables quickcompensationfor changesin material characteristicsto maintainoutput quality