1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Está usted administrando una operación agregada comercial donde sea consistente?, La producción de alto volumen es fundamental para la rentabilidad.? Su 250300 tph stone crushing plant faces significant operational pressures. Inconsistent feed material causes unexpected wear and crusher stalls, leading to costly, tiempo de inactividad no planificado. Energy consumption per ton remains stubbornly high, erosionando márgenes. Meeting strict, dualgrade specifications for base and chip products often requires inefficient, multistage recrushing. Además, the total cost of ownership—from liner replacements to conveyor maintenance—accumulates faster than projected.

How do you increase plant availability beyond 92%? Can you reduce your cost per ton while maintaining precise product shaping? Is your current setup flexible enough to handle varying rock hardness without sacrificing throughput? The solution requires a system engineered not just for capacity, but for predictable, efficient commercial production.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

Este 250300tph Turnkey Stone Crushing and Screening Plant is a stationary, hardrock processing solution designed for highvolume production of aggregates (05milímetros, 510milímetros, 1020milímetros, 2031.5milímetros) and other specification materials. Integra trituración primaria, trituración secundaria/terciaria, cribado, and material handling into a coordinated system.

Flujo de trabajo operativo:
1. Reducción Primaria: Alimentación de camiones volquete <750mm rock into a vibrating grizzly feeder which bypasses sub100mm fines and directs oversize to a robust primary jaw crusher.
2. Secundario & Trituración Terciaria: Primary crushed material is conveyed to a cone crusher for intermediate reduction. A second cone crusher or impact crusher in closed circuit performs final shaping and size refinement.
3. Apresto & Clasificación: Material is routed to a multideck vibrating screen where it is precisely separated into finished product stockpiles.
4. Recirculación: Oversize from the screens is automatically returned via closedcircuit conveyors to the appropriate crusher for further processing.
5. Supresión de polvo: Los sistemas de pulverización integrados en los puntos de transferencia controlan las emisiones de partículas.

Ámbito de aplicación: Ideal para granito, basalto, river pebble, caliza, and other abrasive materials with compressive strength up to 350 MPa. Suitable for large quarry operations, apoyo a grandes proyectos de infraestructura (autopistas, ferrocarriles), and dedicated commercial aggregate supply yards.

Limitaciones: Not designed for mobile or semimobile applications requiring frequent relocation. Site requires stable foundation preparation and adequate space for plant layout and stockpiling.

3. CARACTERÍSTICAS PRINCIPALES

Sistema de control de alimentación inteligente | Base técnica: Unidad de frecuencia variable (VFD) on feeder & level sensors | Beneficio operativo: Maintains optimal chokefeed condition for cone crushers automatically | Impacto del retorno de la inversión: Aumenta el rendimiento mediante 812% and reduces liner wear by up to 15%
Configuración de trituradora de servicio pesado | Base técnica: Ajuste hidráulico & clearing on all crushers | Beneficio operativo: Enables rapid CSS changes for product sizing and safe clearing of tramp metal/stalling | Impacto del retorno de la inversión: Reduces downtime for chamber clearing from hours to minutes
Control de procesos centralizado | Base técnica: Automatización basada en PLC con HMI con pantalla táctil | Beneficio operativo: Allows singleoperator monitoring of entire flow from a control room; logs production data | Impacto del retorno de la inversión: Lowers labor costs and provides data for production optimization
Modular Electrical & Hydraulic Design | Base técnica: Preassembled skids with quickdisconnect couplings | Beneficio operativo: Simplifica la instalación, puesta en marcha, and future maintenance access | Impacto del retorno de la inversión: Reduces installation time by ~30% and lowers service costs
MultiStage Dust Suppression | Base técnica: Pressurized spray nozzles at key transfer points with moisture sensors | Beneficio operativo: Effectively controls dust without overwetting material | Impacto del retorno de la inversión: Ensures environmental compliance and protects downstream equipment

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (250300tph Planta) | This 250300tph Plant Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad de planta | 88 91% | 92 95%| +4% (Tiempo de inactividad reducido) |
| Consumo de energía (kWh/tonelada)| 1.8 2.2 kWh/t | 1.65 1.85 kWh/t| Arriba a 12% (Ahorro de energía) |
| Vida útil del revestimiento de la trituradora (Roca abrasiva)| ~450 horas de funcionamiento| 520+ horas de funcionamiento| +15% (Reduced Wear Cost) |
| Índice de forma del producto (Escamadura)| >18% in chip products| <15% in chip products| Mayor valor del producto |
| Tiempo de reconfiguración (Cambio de CSS)| Ajuste manual de cuñas (~4 hrs)| Ajuste hidráulico (~30 min)| 87% (Flexibilidad operativa) |

5.ESPECIFICACIONES TÉCNICAS

Capacidad de rendimiento diseñada: 250 300 toneladas métricas por hora (basado en una densidad del material de ~1,6 t/m³)
trituradora primaria: Jaw Crusher Model JC1303 / Apertura de alimentación:1300x300mm / Tamaño máximo de alimentación: ≤750 mm
Trituradoras secundarias/terciarias: Two units of Cone Crushers Model CC300 / Each with hydraulic adjustment & claro
Unidad de detección: Tripledeck Vibrating Screen Model VS2460 / Screen Area: ~14 sqm
Requisito de energía: Potencia total instalada aproximadamente 650 kilovatios; Mains connection recommended at400V/50Hz or480V/60Hz.
Especificaciones clave de materiales: Main frame construction Q345B steel; Conveyor belts EP630/4; Crusher liners Mn18Cr2 high manganese steel.
Dimensiones físicas (Aprox.): Overall layout length ~85m; width ~25m; max height ~12m.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C; dust emission concentration at outlet ≤20mg/m³.

6\. ESCENARIOS DE APLICACIÓN

Producción de cursos base de carreteras | Desafío:A national contractor required consistent,sustained production of Class A base course(031\.5milímetros)and chip sealing aggregates(510milímetros)from hard granite for a toll highway project.Plant stoppages directly threatened project timelines.| Solución:A turnkey250\300tph plant was installed featuring twostage cone crushing in closed circuit with precise screening.The automated control system allowed quick switching between product specifications.| Resultados:The plant achieved an average output of280tph over22months.Availability averaged94\.2%.The consistent cubical shape of the chip product reduced bitumen consumption by an estimated7%,noted by the paving contractor.

Commercial Quarry Expansion Challenge:A regional quarry operator needed to upgrade from150tph to meet new supply contracts but had limited space for expansion and needed to maintain production during phased commissioning.| Solución:The modular design of the250\300tph plant allowed it to be constructed parallel to the old line.Critical preassembled skids reduced onsite assembly time.The old line was decommissioned only after the new plant was fully operational.| Resultados:The expansion was completed with only48hours of total production stoppage.The new plant's energy efficiency reduced power costs by$0\.11per ton produced,increasing annual gross margin significantly.

Limestone Processing for Concrete Aggregates Challenge:A readymix concrete supplier's own aggregate plant struggled with excessive fines generation(<0\.075milímetros)and poor shape in the critical10\20mm fraction,increasing cement demand in their mixes.| Solución:The plant configuration prioritized lowwear,cubicalproduct crushing stages.An impact crusher was selected as the tertiary unit,and screen deck configurations were optimized to remove excess fines early.| Resultados:Fines generation was reduced by22%.The improved particle shape increased the workability of the concrete mix.Field data showed a potential3\5%reduction in cement usage while maintaining slump specifications.

CONSIDERACIONES COMERCIALES

Pricing is structured around core configuration levels:

• Tier1(Configuración básica):Incluye trituradora de mandíbula primaria.,trituradora de cono simple,tripledeck screen,transportadores basicos,and central control panel.Priced as acapital investmentfor standard materials like limestone.
• Tier2(Configuración mejorada):Adds secondary cone crusherfor full closedcircuit operation,intelligent VFD feed control,and enhanced dust suppression.Recommendedfor abrasive materials(granito,basalto).
• Tier3(Configuración personalizada):Incorporates specific options such as washing systemsfor manufactured sand,finer screening decksfor specialized products,and extended weather protection enclosures.

Las características opcionales incluyen telemática de monitoreo remoto,mobile generator hookups,and automated lubrication systems.Service packages range from basic commissioningand operator trainingto comprehensive annual maintenance contracts with guaranteed parts availability.Financing options including equipment leasingand term loans are available through partnered financial institutions,making capital expenditure manageable against longterm supply contracts.

Preguntas frecuentes

q:What if my feed material size or hardness varies frequently?
A:The hydraulic adjustment on the crushers allows operators to change the Closed Side Setting(CSS)in minutes via the control panel.This adapts the crushing chamberto different conditions without stopping production,a key featureof this commercial stone crushing plantsolution.

Q.How many operators are requiredto run this plant?
A.The centralized PLC automationis designedfor singlestation control.One trained operatorin the control room can manage the entirecrushingandscreening process.Routine ground inspectionsare still recommended,but direct machinelevel operationis not required.

Q.Can this system integratewith our existing primary feedingor downstream equipment?
A.YES.The design includes standardized feedand discharge heights.Conveyor lengthsand transfer pointscan be modifiedduring engineering.We will review your site layoutto ensure compatibilitywith your current stockpile feedersor existing tertiary processing lines.

Q.What isthe typical installationand commissioning timeline?
A.For aprepared foundation site,the modular skidded components allow erectionin approximately8\10weeks.Commissioningand performance testingtypically takes an additional1\2weeks.This timeframe assumes all civil worksare complete prior todelivery.

P. ¿Hay repuestos disponibles?,and what arethe lead times?
A.We maintaina strategic inventoryof highwear parts(placas de mandíbula,mantos,mallas de pantalla).For standard wear parts,the commitmentis shipmentwithin72hours.For major components,a stocklistwith guaranteed lead timesis providedwith themaintenance contract.

Q.What kindof trainingis providedfor our maintenance team?
A.Comprehensive trainingincludes both classroom instructionon system principlesand handson field training.It covers daily checks,troubleshooting usingthe HMI diagnostics,procedimientos de mantenimiento de rutina,and safe liner changeout protocols.Training documentationis supplied digitallyandin print