1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y el tiempo de inactividad impredecible están erosionando los márgenes de su proyecto?? Para gerentes de planta y contratistas de ingeniería, El circuito de trituración y cribado es a menudo la fuente de cuellos de botella críticos.. Los desafíos comunes incluyen:
Altos costos de mantenimiento: Frequent bearing failures, screen cloth changes, and conveyor belt wear from improper material flow can consume 1520% of your annual operating budget.
Tiempo de inactividad no programado: A primary crusher failure or screen box structural issue can halt an entire site, costing tens of thousands per hour in lost production and labor.
Flujo de materiales ineficiente: Poorly matched equipment leading to recirculating loads, chokefeeding, or underutilization reduces overall system capacity by up to 30%.
Gradación de producto inconsistente: Offspec aggregate or mineral product results in costly recrushing, stockpile segregation issues, and rejected loads.
Aumento del consumo de energía: Más viejo, mechanically inefficient drives and components directly increase your kWhperton cost, a key metric under constant pressure.

Is your operation equipped to minimize these risks while maximizing throughput and product quality? The foundation lies in selecting robust, intelligently engineered crushing and screening equipment.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

This content outlines the critical considerations for stationary and trackmounted crushing and screening equipment, the core machinery for reducing raw feed material (p.ej., quarry rock, hormigón reciclado, mineral ore) en tamaños agregados específicos. El flujo de trabajo operativo es un proceso continuo.:
1. Reducción de tamaño primario: Large feed material is reduced by jaw or gyratory crushers.
2. Material Transport & especulación: Conveyors move material to vibrating screens that remove undersize material prior to secondary crushing.
3. Trituración Secundaria/Terciaria: Cone or impact crushers further reduce material to required dimensions.
4. Proyección final & Clasificación: Multideck screens accurately separate crushed material into precise product fractions (p.ej., ¾” chip, arena manufacturada).
5. Almacenamiento & ReCirculation: Onspec product is conveyed to stockpiles; oversize material is recirculated back into the circuit.

El ámbito de aplicación incluye la extracción, minería, construcción & reciclaje de demolición, y producción agregada. Key limitations involve feed material abrasiveness (impacting wear life) y especificaciones requeridas del producto final (dictating circuit design).

3. CARACTERÍSTICAS PRINCIPALES

Geometría de cámara patentada | Base técnica: Computermodeled kinematics and cavity profiles | Beneficio operativo: Optimized nip angle and crushing stroke for higher reduction ratios with less wear on manganese surfaces | Impacto del retorno de la inversión: Arriba a 12% lower costperton in abrasive applications due to extended liner life.

Modular Screen Media System | Base técnica: Quicktensioning wedgelock design with polyurethane damping | Beneficio operativo: Screen deck changes completed in under 2 hours versus a typical 68 hour shift, with consistent tension for longer cloth life | Impacto del retorno de la inversión: Reduces labor hours for maintenance by ~70% per changeout, aumento de la disponibilidad de la planta.

Engrase centralizado & Monitoreo de condición | Base técnica: Automated lube points with flow sensors feeding a central PLC | Beneficio operativo: Ensures critical crusher and screen bearings receive precise lubrication without manual intervention; alerts operators to blockages | Impacto del retorno de la inversión: Prevents an estimated 85% of bearingrelated failures, avoiding associated downtime costs.

Hybrid Power Drive System | Base técnica: Dieselelectric configuration with onboard genset or external grid connection capability | Beneficio operativo: Operators can select the most costeffective power source; electric mode reduces fuel consumption by 100% when grid power is available | Impacto del retorno de la inversión: Field data shows average energy cost savings of 2540% in hybrid mode versus dieselonly operation.

HeavyDuty Feeder with PreScreening Section | Base técnica: Grizzly feeder with integrated stepped grizzly bars or punch plate section | Beneficio operativo: Removes natural fines and subproduct size material before the primary crusher, reducing chamber volume usage and wear | Impacto del retorno de la inversión: Increases effective primary crusher throughput by up to 15% by eliminating precrushed material.

Reinforced Structural Frame Design | Base técnica: Análisis de elementos finitos (FEA) optimized steel fabrication with highstress zone reinforcements | Beneficio operativo: Withstands continuous highcycle loading without frame fatigue or cracking common in highproduction environments | Impacto del retorno de la inversión: Eliminates unplanned structural repairs, protecting asset lifespan over a 15+ year service period.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Punto de referencia estándar de la industria | Nuestro aplastamiento & Screening Solution Documented Performance | Ventaja (% Mejora) |
| : | : | : | : |
| Crusher Liner Wear Life (Roca abrasiva) | ~450,000 tons per set (Cone Crusher Mn18) | ~520,000 tons per set (Proprietary Mn22 Alloy) | +15% Vida más larga |
| Screen Box Sideplate Vibration Fatigue Failure Mean Time Between Failure (MTBF) | ~8,000 operating hours before weld repair required| >14,000 operating hours before inspection advised| +75% Improved Durability |
| Consumo de energía (kWh per Ton Processed) Baseline for a 300tph Circuit| ~0.85 kWh/Ton Average| ~0.72 kWh/Ton Documented Average| 15% Menor costo de energía |
| Costo total de propiedad (costo total de propiedad) encima 5 Years (Mantenimiento + Regiones + Falta del tiempo)| Indexed at 100% for comparison| Estimado en 7882% of benchmark TCO| 18% a 22% Lower TCO |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Plantas estacionarias de 150 a más 1,200 toneladas por hora (TPH). Trackmounted mobile units from 200 a 500 TPH.
Requisitos de energía: Primary crushing units typically require 150400 kW drives. Full electric stationary plants may require a total connected load of 8002,500 kVA según escala.
Especificaciones de materiales: Fabricado con acero estructural S355JR; highwear components utilize HB500 abrasionresistant steel liners; crusher jaws/cones in premium manganese steel (Mn18Cr2/Mn22Cr2).
Dimensiones físicas (Example Mobile Unit): Transport length approx.16m; Operating length approx.19m; Max height approx.4m; Operating weight approx.45 tonnes.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 25°C a +45°C; rodamientos protegidos contra el polvo (IP65+); capable of operating at altitudes up to 3,000 meters with engine deration.

6. ESCENARIOS DE APLICACIÓN

Proyecto de Ampliación de Cantera de Granito

Challenge A major quarry needed to increase production by 40% without expanding their permitted footprint or adding a second processing shift.
Solution Implementation of a new tertiary crushing stage featuring a highspeed cone crusher paired with a tripledeck fine screen in closed circuit.
Results Achieved target throughput increase within existing footprint. The closedcircuit design reduced recirculating load by over half compared to the old layout while improving cubicity of the chip products.

Urbano C&D Recycling Operation

Challenge Processing highly variable construction demolition waste led to frequent jamming in the primary impact crusher from uncrushable rebar matts and excessive fines clogging screens.
Solution Deployment of a heavyduty jaw crusher as primary stage for better tramp metal tolerance and an aggressive linear stroke screen ahead of secondary processing for fines removal.
Results Unplanned stoppages due to feeding issues decreased by approximately90%. The removal of fines early in the circuit significantly improved efficiency of downstream sorting equipment.

7 CONSIDERACIONES COMERCIALES

Equipment pricing tiers are structured around capacity capability:
Nivel I (600 TPH): Customengineered stationary crushing and screening plants.

Optional features include advanced dust suppression systems automated metal detection/ ejection magnetic head pulleys extended conveyor systems

Service packages range from basic warranty support through comprehensive multiyear maintenance agreements including scheduled parts kits

Financing options are available including capital lease operating lease commercial loans tailored

8 Preguntas frecuentes

What level of ground preparation is required for installing this equipment?
Stationary plants require engineered concrete foundations Mobile track mounted units require stable compacted ground but minimal civil work enabling rapid redeployment

How does your equipment interface with our existing conveyors stackers?
Our engineering team provides detailed interface specifications for chute heights discharge trajectories belt widths ensuring compatibility

What is the typical lead time from order commissioning?
For standard mobile units lead time is typically weeks For large custom stationary plants detailed engineering procurement fabrication requires months

¿Ofrecen garantías de rendimiento??
Yes we offer guaranteed minimum capacity based on agreed feed material specifications Guarantees are backed by pre purchase material testing circuit simulation

What operator training technical support do you provide?
We include comprehensive onsite training for operations maintenance crews along with digital manuals Access remote diagnostic support via data link standard