Fda Approved Iron Ore Crushing Plant Catalog
1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR
¿Sus operaciones de procesamiento de mineral de hierro están limitadas por un tamaño de alimentación inconsistente?, mantenimiento no planificado, and rising energy costs? Inefficient primary crushing creates bottlenecks that ripple through your entire beneficiation circuit, impactando directamente el rendimiento y la rentabilidad. Considere estos desafíos comunes:
Tiempo de inactividad excesivo: Unplanned stoppages for liner changes or mechanical repairs in your primary crusher can cost thousands per hour in lost production.
Altos costos operativos: Inefficient crushing cycles and excessive power draw from poorly matched equipment inflate your costperton metric.
Variabilidad de la calidad del producto: Inconsistent output size distribution from the primary stage overloads downstream screening and secondary crushing, reduciendo la eficiencia general de la planta.
Costos de desgaste abrasivo: The highly abrasive nature of iron ore leads to rapid wear on crusher components, resulting in high spare parts consumption and labor for replacements.
Is your current primary crushing solution delivering the reliability and costefficiency required in today's market? The foundation of a profitable iron ore plant is a robust, highcapacity primary crushing circuit.
2. DESCRIPCIÓN GENERAL DEL PRODUCTO: FDA Approved Iron Ore Crushing Plant
This product description details our engineered primary crushing station, specifically configured for hightonnage iron ore processing. This turnkey module is designed for the initial size reduction of runofmine (memoria de sólo lectura) mineral de hierro, typically reducing material from up to 1.5meter feed down to a conveyable product for further processing.
Flujo de trabajo operativo:
1. ROM iron ore is dumped into a heavyduty vibrating grizzly feeder (VGF VGF).
2. The VGF removes sub100mm fines via a scalping section and evenly feeds oversize material into the jaw crusher or gyratory crusher.
3. The primary crusher performs the initial compressive breakage of the ore.
4. Crushed product is discharged onto a main plant conveyor for transport to the next processing stage.
Ámbito de aplicación & Limitaciones:
Alcance: Ideal for greenfield installations or expansion projects requiring capacities from 1,500 a más 10,000 toneladas por hora (tph). Suited for magnetite, hematites, y otros minerales que contienen hierro.
Limitaciones: Esta es una solución de trituración primaria.; secondary and tertiary crushing require additional circuit design. El tamaño de la alimentación debe controlarse dentro de las dimensiones máximas de entrada diseñadas para la trituradora..
3. CARACTERÍSTICAS PRINCIPALES
Alimentador Grizzly Vibrante de Servicio Pesado (VGF VGF) | Base técnica: Construcción de acero de alta resistencia con barras grizzly ajustables | Beneficio operativo: Scalps fines to bypass the crusher, reduces wear, and ensures even feed distribution for optimal cavity utilization | Impacto del retorno de la inversión: Increases effective crusher capacity by up to 15% and extends wear life of primary liners
Sistema de accionamiento de trituradora hidrostática | Base técnica: Direct hydraulic drive for the main shaft | Beneficio operativo: Proporciona un arranque suave bajo carga, operación reversible para eliminar obstrucciones, y control de velocidad variable infinito para un rendimiento óptimo | Impacto del retorno de la inversión: Eliminates costly shearing of mechanical drive components; Los datos de campo muestran una 30% reducción del tiempo de inactividad relacionado con bloqueos
Diseño de revestimiento modular | Base técnica: Segmented manganese steel liners secured with boltin systems | Beneficio operativo: Enables partial liner replacement and significantly reduces changeout time compared to monolithic liners | Impacto del retorno de la inversión: Reduces liner maintenance downtime by approximately 40%, Reducir los costos laborales y aumentar la disponibilidad.
Geometría de cámara avanzada | Base técnica: Computermodeled nip angle and crushing chamber profile | Beneficio operativo: Optimizes compressive force application for iron ore’s fracture characteristics, improving reduction ratio and particle shape | Impacto del retorno de la inversión: Delivers a more consistent product size, reducing recirculation load and energy consumption in downstream stages
Lubricación automatizada centralizada | Base técnica: Sistema programable que entrega volúmenes precisos de grasa a todos los rodamientos críticos | Beneficio operativo: Ensures optimal bearing health regardless of operator intervention, protecting against contaminant ingress in dusty environments | Impacto del retorno de la inversión: Las pruebas de la industria demuestran una correlación directa con un 60% increase in major bearing service life
RockBreaker Integration Platform | Base técnica: Reinforced chassis with preengineered mounting points | Beneficio operativo: Allows for safe installation of stationary rock breaker to address hangups at the crusher inlet without manual intervention | Impacto del retorno de la inversión: Mitigates a major safety risk and prevents prolonged stoppages due to bridging
4. VENTAJAS COMPETITIVAS
| Métrica de rendimiento | Estándar de la industria (Average Jaw/Gyratory) | Nuestra solución de planta de trituración de mineral de hierro | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad (Tiempo de ejecución programado) | 9294% | 96%+| +34% |
| Tiempo de cambio de revestimiento (Horas) | 2436 horas (full set) | 1418 horas| ~45% más rápido |
| Tonelaje por kWh (Eficiencia Energética) Línea de base = 100 Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score=|IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard)=105110| +510% |
| Tiempo medio entre fallos (MTBF) Componentes principales| ~4,000 hours| 5,500+ horas| +37% |
5. ESPECIFICACIONES TÉCNICAS
Rango de capacidad: Configurable desde 1,500 tph a 10,000+ tph.
Opciones de tipo de trituradora: Heavyduty jaw crusher or primary gyratory crusher.
Tamaño de alimentación máximo: Up to 1,500mm (59").
Rango de ajuste de descarga: 150mm 300 mm (6" 12"), adjustable based on model.
Requisitos de energía: La potencia total instalada oscila entre 450 kW a más 1.2 MW depending on capacity selection; diseñado para suministro de alto voltaje (6.6kV típico).
Especificaciones de materiales: Estructura principal fabricada en acero de alta resistencia; wear liners manufactured from ASTM A128 manganese steel; shafting from forged alloy steel.
Dimensiones físicas (Módulo): Approximate footprint range: Length 2540m x Width 812m x Height 810m.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 30°C a +50°C; dustsealed bearings and components standard.
6. ESCENARIOS DE APLICACIÓN
Proyecto concentrador de magnetita Greenfield
Challenge A new mine required a primary crushing plant capable of processing very hard magnetite ore at >6，000 tph with extreme reliability， as any downtime would delay concentrator rampup． Initial designs using standard crushers projected high liner wear costs．
Solution Implementation of our gyratorybased FDA approved iron ore crushing plant with modular liners， hydrostatic drive，and an oversized heavyduty VGF．
Resultados Se logró un rendimiento sostenido de 6，200 tph during commissioning． Liner life exceeded projections by 18%，and plant availability averaged 96．5％in the first year．
Existing Hematite Processing Plant Expansion
Challenge An aging jaw crusher station was the bottleneck， limiting plant expansion goals． Frequent blockages caused erratic feed to downstream processes，and maintenance was laborintensive．
Solution Replacement with our turnkey FDA approved iron ore crushing plant module，designed as a direct retrofit into the existing flow sheet，including an integrated rockbreaker．
Results Primary throughput increased by 35％immediately． Blockages were reduced by over 90％，and automated lubrication cut scheduled maintenance hours by 25％per month．
7． CONSIDERACIONES COMERCIALES
Equipment pricing is tiered based on capacity（tph）and selected core crusher type（jaw vs．gyratory）．
Niveles de precios：
Tier I（7，000 tph）：Configured with large gyratory crushers．
Características opcionales：
Advanced condition monitoring sensors（vibration，temperature）
Integración del sistema de supresión de polvo.
Wear liner monitoring system
Paquetes de garantía extendida
Paquetes de servicios：
A comprehensive selection is available including：
Inspección anual &optimization plans
Onsite parts inventory holding agreements
Remote diagnostics &technical support packages
Opciones de financiación：
Flexible commercial leasing structures are available through partners，
allowing CAPEX preservation． Project financing may be considered
for largescale developments．
8． Preguntas frecuentes
Q What if my ROM feed size varies significantly？
A The heavyduty VGF和hydrostatic drive are specifically designed to handle variance．The reversible hydraulic drive can clear minor blockages automatically，
and chamber geometry accommodates reasonable fluctuation without significant efficiency loss．
Q How does this solution integrate with my existing control system？
A The FDA approved iron ore crushing plant module comes with its own PLCbased control panel which communicates via standard industrial protocols（Modbus TCP/IP，
Profibus）．It can operate as a standalone unit or be fully integrated into your central SCADA system．
Q What is the expected operational impact on my workforce？
A The design prioritizes safety和reduces manual labor．Features like centralized lubrication，
modular liners和remote diagnostics reduce time spent on hazardous tasks和routine checks，
allowing your team to focus on oversight和optimization．
Q Are there long lead times for critical wear parts？
A We maintain regional inventory hubs for fastmoving wear items like liner sets．
Using proprietary alloy specifications ensures consistent performance和availability．
Q Can you provide assistance with foundation design和civil works？
A Yes．With purchase we provide detailed foundation drawings，
load data和anchor bolt specifications required by your civil engineering contractor
for proper installation．
Q What are the commercial terms典型for such equipment？
A Terms are typically FCA our manufacturing facility．
Envío、insurance和installation are quoted separately based on project location．
Payment milestones are tied to engineering approval、manufacturing completion、
and shipment．
Q Is operator training included？
A Comprehensive training on operation、mantenimiento de rutina、
and safety procedures is included with installation commissioning，
conducted both at our facility during FAT和onsite during startup