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?? In aggregate production, procesamiento de minerales, y reciclaje, La trituración y cribado ineficientes son el principal cuello de botella. Los desafíos comunes incluyen:
Tiempo de inactividad excesivo para mantenimiento: Cambios frecuentes de revestimiento, fallas en los rodamientos, and conveyor issues halt your entire production line.
Gradación de producto inconsistente: Poor screening efficiency and improper crushing chamber dynamics lead to offspec material, causing product rejection and revenue loss.
Altos costos operativos: Aumento del consumo de energía por tonelada, junto con una alta frecuencia de reemplazo de piezas de desgaste, impacta directamente su resultado final.
Configuración de planta rígida: Los sistemas fijos no pueden adaptarse a los cambios en el material de alimentación o los requisitos del producto final., limitar la flexibilidad operativa.

¿Su equipo actual soluciona estos problemas?, or is it the source of them? La estación de trituración primaria adecuada no es sólo una compra; it’s a strategic decision for longterm site profitability.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO: PRIMARY CRUSHING AND SCREENING STATION

This primary crushing and screening station is a fullyintegrated, trackmounted or modular system designed for the initial size reduction of runofmine ore, roca de cantera, or demolition concrete. Its workflow is engineered for continuous heavyduty operation:
1. Alimentar: Material is deposited via excavator or wheel loader into a robust vibrating grizzly feeder.
2. Pre-selección & Aplastante: The grizzly bypasses fines directly to a conveyor while oversize material is directed into the highcapacity jaw crusher.
3. Trituración Primaria: The jaw crusher performs the first mechanical reduction using compressive force.
4. PostCrushing Screening: Crushed material is conveyed to an integrated screen for immediate separation into required product fractions.
5. Stockpiling or Secondary Conveyance: Sized fractions are stockpiled or conveyed to the next stage of processing.

Ámbito de aplicación: Ideal para minería de roca dura, aggregate quarries, proyectos de construcción a gran escala, y C&D recycling operations requiring highvolume primary reduction.
Limitaciones: No diseñado para dar forma al producto final. (trituración terciaria) or processing highly abrasive materials without specific liner configurations. Feed size must adhere to crusher opening specifications.

3. CARACTERÍSTICAS PRINCIPALES

Trituradora de mandíbula de accionamiento directo | Base técnica: Eliminates Vbelts and associated components | Beneficio operativo: Reduces power transmission losses and removes routine belt tensioning/maintenance | Impacto del retorno de la inversión: Los datos de campo muestran hasta 10% lower fuel consumption and 15% less scheduled maintenance time.

Independent PreScreen Module | Base técnica: Twodeck vibrating grid mounted ahead of the crusher | Beneficio operativo: Removes fines and natural sand from the crusher feed, reducing chamber wear and increasing throughput of valuable midsize material | Impacto del retorno de la inversión: Can extend manganese liner life by up to 30% and increase total station output.

Ajuste de configuración hidráulica (HSA) | Base técnica: Wedgebased chamber adjustment via hydraulic cylinders | Beneficio operativo: Allows operators to change the crusher closedside setting (CSS) en menos 2 minutes for precise product size control without stopping the plant | Impacto del retorno de la inversión: Minimizes nonproductive time during product changeovers by over 90%.

HeavyDuty Feeder with Step Grizzly | Base técnica: Reinforced feeder with stepped grizzly bars to prevent clogging | Beneficio operativo: Ensures consistent feed flow even with sticky or claybound materials, preventing bridging and feeder stall | Impacto del retorno de la inversión: Maintains target throughput rates in challenging conditions, avoiding costly flow interruptions.

Integrated Plant Automation System (IPAS) | Base técnica: PLCbased control with touchscreen interface monitoring all critical functions | Beneficio operativo: Proporciona datos en tiempo real sobre las tasas de producción., consumo de energía, and operational status; enables singlepanel control for setup and troubleshooting | Impacto del retorno de la inversión: Mejora la eficacia general del equipo. (OEE) through better monitoring and reduces diagnostic time by an average of 50%.

Puntos de engrase centralizados | Base técnica: Manifold system linking all major bearing points to a single station | Beneficio operativo: Permite seguridad, rapid daily lubrication checks without requiring access around moving components | Impacto del retorno de la inversión: Standardizes preventive maintenance routines, enhancing bearing life and reducing lubricationrelated failures.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Solución estándar de la industria | This Primary Crushing & Screening Station | Ventaja (% Mejora) |
| : | : | : | : |
| Toneladas por Hora (TPH) Eficiencia| Reliant on optimal feed conditions only| Mantiene >90% of rated TPH with variable/ sticky feed due to step grizzly design| +1520% sustained output |
| Costo de piezas de desgaste por tonelada| Based on standard manganese composition| Utilizes sitespecific alloy analysis for jaw liners in highabrasion applications| Arriba a 25% cost per ton crushed |
| Configuración / Configuration Time| Multiple machine positioning & cable connections required| Singlelift modules with prerigged electrical connections between units| 70% relocation time |
| Consumo de energía (kWh/tonelada)| Direct mechanical drive with fixed speed motors| Loadsensing hydraulics & direct electric crusher drive adjust power to demand| 8% average energy use |

Based on comparative field trials in granite quarry applications.

5. ESPECIFICACIONES TÉCNICAS

Tipo de trituradora primaria: Nordberg C106 Jaw Crusher
Apertura de alimentación: 1,060 mm x 700 milímetros (42” x 28”)
Tamaño máximo de alimentación: 600 milímetros (24")
Configuración del lado cerrado (CSS) Rango: 70 200 milímetros
Rango de capacidad: Arriba a 500 MTPH (dependiente de la densidad del material & CSS)
Unidad de potencia: CAT C9 / C9.3 ACERT Tier 4 último motor diésel
Potencia Total Instalada: 224 kilovatios
Feeder Type: Vibrating Grizzly Feeder VG43912V
Módulo de pantalla: Twodeck inclined screen TS303
Main Conveyor Width: 1,000 milímetros
Dimensiones de transporte (LxAnxAl): ~19m x ~3m x ~4m
Peso operativo: ~45 toneladas
Rango de temperatura de funcionamiento: 25°C a +40°C

6. ESCENARIOS DE APLICACIÓN

Ampliación de la cantera de agregados de granito | Desafío: Existing fixed primary plant could not service new pit face location without major infrastructure cost; mobile solutions lacked necessary throughput and prescreening. Solución: Deployment of a trackmounted primary crushing and screening station fed directly by excavator at the new face. Resultados: Eliminated need for costly ramp construction and dump truck haulage to old plant. Se logró un rendimiento constante de 380 Mtph of minus200mm base material with improved yield of valuable railway ballast fraction due to integrated screening.

Proyecto de infraestructura a gran escala (Dam Construction) | Desafío: Processing riverrun gravel with high sand content led to rapid crusher wear choke points in traditional setups. Solution Implementation of a modular primary station featuring an independent prescreen module ahead of the jaw crusher Results Prescreen removed over 25% of sand/fines prior to crushing reducing abrasive wear Throughput increased by18% as crusher processed only oversize Wear part replacement intervals extended by approximately40%

7 CONSIDERACIONES COMERCIALES

Pricing for a primary crushing station varies significantly based on configuration:

• Base Configuration Includes core jaw crusher basic feeder engine chassis essential conveyors PLC start/stop controls Tier pricing typically begins in range appropriate for this capital equipment class

Optional Features That Add Value:

• Dust suppression system package including water tank spray bars
• Magnet installation over discharge conveyor ferrous metal removal
• Radio remote control unit for independent feeder/crusher operation from ground level
• Extended wear part kits stock

Paquetes de servicios disponibles:

• Comprehensive Extended Warranty covering major components years unlimited hours
• Scheduled Maintenance Plan providing fixed cost annual inspections parts labor
• On Site Operator Training Program days hands instruction

Financing Options Flexible capital solutions include equipment leasing long term rental purchase leaseback structures tailored support cash flow management project timelines

8 Preguntas frecuentes

What type/size of excavator is recommended as a feeder?
A minimum operating weight class excavator equipped with suitable bucket capacity ensure consistent choke feeding maximize crusher efficiency productivity

How does this system handle reinforcing bar rebar in concrete demolition waste?
While jaw can process reinforced concrete integrated overband magnet discharge conveyor effectively removes liberated ferrous metals protecting downstream conveyors secondary crushers

What are typical delivery lead times after order confirmation?
Standard configurations have confirmed lead time weeks subject build slot availability engineering review Custom modular designs may require additional weeks detailed engineering fabrication

Is operator training provided with purchase?
Yes comprehensive onsite training program conducted commissioning covers daily operation routine maintenance safety procedures troubleshooting using actual plant systems

Can this station be integrated into existing fixed plant circuit as temporary primary unit?
Yes stations are designed standalone mobility can be positioned feed directly into existing secondary tertiary circuits via discharge conveyor ideal use during planned upgrades maintenance existing primary crushers