1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Are your iron ore processing margins being eroded by persistent, tiempo de inactividad no planificado? Commercial operators and plant managers face significant financial pressure from equipment that cannot withstand the abrasive reality of highvolume iron ore. Los desafíos comunes incluyen:
Desgaste excesivo & Fallo de componente: Standard crushing chambers and liners degrade rapidly under continuous Taconite or Hematite load, leading to frequent shutdowns for maintenance and high parts replacement costs.
Rendimiento inconsistente & Gradación del producto: Fluctuations in feed size or hardness result in poor control over final product sizing, causing bottlenecks in downstream grinding circuits and reducing pellet or sinter plant efficiency.
Alto consumo de energía por tonelada: Older or improperly configured crushing stages consume disproportionate power, directly impacting operational expenditure and carbon footprint.
Configuración de planta rígida: Fixed crushing circuits struggle to adapt to varying ore body characteristics or market demands for different product specifications, limitar la flexibilidad operativa.

Is your primary crushing station a source of cost or a driver of profit? The solution lies in precision engineering applied directly to the unique demands of iron ore.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

This content details a fully customizable, heavyduty stationary crushing plant solution engineered explicitly for hightonnage iron ore processing. The system is designed as a primary or primary/secondary stage unit, built around a core gyratory or jaw crusher configured for maximum abrasion resistance and volumetric throughput.

Flujo de trabajo operativo:
1. Managed Feed Intake: Runofmine ore is directed via heavyduty apron feeder to the primary crusher, ensuring a consistent, chokefed load for optimal crushing action.
2. Reducción de tamaño primario: The core crusher utilizes high inertia and optimized kinematics to reduce large lump ore (hasta 1,5 m) to a manageable conveyorable size.
3. Scalping primario & Eliminación de multas: A downstream heavyduty scalper removes natural fines prior to secondary crushing, increasing circuit efficiency and reducing unnecessary wear.
4. Trituración Secundaria & Closed Circuit Control (Opcional): A cone crusher module in closed circuit with a sizing screen allows precise control of final product gradation, typically to 50mm or 75mm for downstream milling.
5. Manejo Integrado de Materiales: Plant design includes robust conveyor systems, transfer points with impact beds, and dust suppression integration for complete material flow management.

Ámbito de aplicación: Designed for greenfield installations or major upgrades in magnetite (taconita) and hematite mining operations with annual capacity requirements from 5 a 25+ millones de toneladas.

Limitaciones: No apto para operaciones de bajo tonelaje. (< 1 Mtpa) or as a tertiary/quartzite crushing unit without significant specification review.

3. CARACTERÍSTICAS PRINCIPALES

Geometría del revestimiento patentada | Base técnica: Análisis de elementos finitos (FEA) & modelado de ropa | Beneficio operativo: Achieves more consistent product gradation throughout the liner life cycle, with reduced risk of bridging | Impacto del retorno de la inversión: Arriba a 15% longer liner life reduces direct parts cost and changeout downtime

Carga inteligente & Sistema de control de alimentación | Base técnica: Realtime motor power & hydraulic pressure monitoring with automated feeder response | Beneficio operativo: Maintains optimal crusher cavity loading, preventing overload stalls and emptycavity wear | Impacto del retorno de la inversión: Protege los componentes de la unidad de cargas de impacto.; Los datos de campo muestran una 712% reducción del consumo energético específico (kWh/tonelada)

Modular Plant Subframe Design | Base técnica: Atornillados, heavygauge steel modules with precisionmachined interfaces | Beneficio operativo: Enables faster onsite erection and future reconfiguration or relocation with minimal cutting/welding | Impacto del retorno de la inversión: Can reduce civil works and installation time by an estimated 30%, acelerando el tiempo de producción

Engrase centralizado & Fluid Systems | Base técnica: Singlepoint lubrication distribution blocks with monitoring points for all critical bearings | Beneficio operativo: Ensures correct lubrication intervals are met reliably, extending bearing service life in highdust environments | Impacto del retorno de la inversión: Lowers manual maintenance labor hours by ~25% per shift and decreases bearing failure risk

HeavyDuty Dust Containment Skirting | Base técnica: Multistage rubber skirting with adjustable tensioning on all conveyor transfers | Beneficio operativo: Dramatically reduces airborne dust at emission points, mejorar la seguridad del sitio y el cumplimiento ambiental | Impacto del retorno de la inversión: Lowers water consumption for suppression and reduces cleanup costs; minimizes risk of regulatory noncompliance penalties

Crusher Backing Material Integration | Base técnica: Automated dispensing system for epoxy resin backing during liner installation | Beneficio operativo: Ensures complete cavity fill without air pockets, maximizing liner stability and energy transfer | Impacto del retorno de la inversión: Eliminates premature liner failure due to improper backing, protecting major crusher body components

Plataformas de mantenimiento WalkIn | Base técnica: Integrated, OSHAcompliant platforms with handrails around all major service points (crusher top shell, motor, gavillas) | Operational Benefit Provides safe, direct access for inspection and component handling during planned maintenance| ROI Impact Reduces servicerelated safety incidents; improves maintenance efficiency by providing stable work areas

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Promedio) | Solución personalizada de planta de trituración de mineral de hierro | Ventaja (% Mejora) |
| : | : | : | : |
| Vida del revestimiento (Primary Mantle/Bowl) | ~1.2 Million Tonnes
Varía según la abrasividad del mineral.| ~1.5 Million Tonnes
Based on magnetite feed| +25% |
| Total Plant Availability (Tiempo de ejecución programado) | 9294%
Includes minor stops| >96%
Design target| +34 Puntos porcentuales |
| Consumo de energía específico
(kWh por tonelada triturada) Baseline Dependent
Varía según el diseño del circuito.| Field data indicates reduction of
712% vs. nonoptimized equivalent systems.| Arriba a 12% |
| Tiempo medio entre fallos (MTBF)
for Major Components
~2，000 horas
Drive/motor/bearing assemblies| >2，500 horas
Design target based on load management| +25% |
| Tiempo de inactividad por mantenimiento planificado
(per major liner change event)
4872 horas
Crew dependent|<36 hours target
Via modular liners & plataformas| 33% |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 2，500 a más 8，000 toneladas por hora (tph)， depending on feed size， ore work index，and product size requirement.
Opciones de trituradora primaria: trituradoras giratorias (54Abertura de alimentación de ”75”) o trituradoras de mandíbulas (60”x80”+). Selection based on required throughput， feed topology，y análisis de fragmentación.
Potencia motriz: Accionamientos de motores eléctricos que van desde 450 kW a 1，200 kilovatios，with Vbelt or direct drive configurations available。 Softstart systems standard。
Especificaciones de materiales：
Revestimientos de trituradora： Manganese steel alloy（14%18%）with optional chrome carbide overlay for extreme abrasion zones。
Acero estructural： Primary support structures use S355JR grade steel； highwear areas utilize AR400 abrasionresistant plate。
Rodillos transportadores： CEMA class E/F sealed bearings； impact idlers at loading zones。
Physical Dimensions （Modular）： Módulos diseñados para dimensiones estándar de contenedores de envío。 Typical primary station footprint： ~30m L x 15m W x 20m H （variable）。
Rango de operación ambiental：
Temperatura ambiente： 30°C to +50°C （with appropriate lube oil/heater packages）。
Emisiones de polvo： Designed to achieve <10 mg/Nm³ at containment points with integrated suppression。
Nivel de ruido： Compliant with <85 dB(A) at operator stations via acoustic enclosures。

6. ESCENARIOS DE APLICACIÓN

Greenfield Magnetite Concentrator｜Challenge： A new mine required a primary crushing plant capable of processing highly abrasive taconite at 6，000 tph，with strict product sizing (250milímetros) for SAG mill feed。 The remote location demanded high reliability due to limited local maintenance support。｜Solución： A customized gyratory crusherbased plant featuring our intelligent load control system， extendedlife liner package，and fully walkin maintenance modules was installed。 All lubrication and electrical cabinets were housed in heated enclosures。｜Resultados： La planta alcanzó la capacidad nominal dos semanas después de su puesta en servicio。 La vida útil del revestimiento superó las proyecciones en 8%， achieving over 1。6 million tonnes per set。 Availability has averaged 96。7% over the first three years of operation。

Hematite Processing Plant Upgrade｜Challenge An existing hematite operation experienced chronic bottlenecks due to an aging jaw crusher plant suffering from frequent bearing failures and poor throughput consistency (<2，200 tph)，limiting downstream beneficiation output。｜Solution We replaced the existing unit with a customized modular jaw plant featuring the centralized greasing system，heavyduty skirting，and an optimized feeder/crusher interface geometry tailored to the specific ore characteristics。｜Results Throughput increased consistently above design rate of 2，800 tph。 Bearingrelated unscheduled downtime was eliminated in the first year postinstallation。 Product size distribution became markedly more uniform (+/10%) mejorar la eficiencia del cribado aguas abajo。

7． CONSIDERACIONES COMERCIALES

Our approach is based on providing transparent value aligned with your production targets。

Niveles de precios
• Base Plant Configuration Includes core crusher motor feeders basic discharge conveyor structural supports walkways ladders
• Enhanced Configuration Adds intelligent control system dust suppression package premium liner options automated lubrication
• Turnkey Project Package Full engineering procurement construction management EPC/M including foundations electrical reticulation commissioning spares package

Características opcionales
• OnBoard Hydraulic Power Unit For setting adjustment/clearing
• Rock Breaker Boom System For oversize breaking at grizzly
• Advanced Predictive Monitoring Vibration temperature sensors linked to SCADA
• Modular Secondary/Tertiary Crushing Stage For future expansion

Paquetes de servicios
• Planned Maintenance Agreements Scheduled inspections parts supply labor rates defined upfront
• Performance Guarantee Contracts Uptime availability或throughput guarantees supported by remote monitoring
• Liner Service Programs Fixedcostpertonne agreements covering all wear parts

Opciones de financiación
We work with accredited partners to offer equipment leasing capital loans以及operational expenditure OpEx models where payment is tied directlyto verified production tonnage。

8． Preguntas frecuentes

Q What level of site preparation is required prior delivery？
A Our modular plants require prepared concrete foundations designed specificallyfor your soil conditions We provide full foundation drawings anchor bolt locations as partof basic engineering Minimal field welding should be required。

Q How does this solution integrate into my existing control room SCADA system？
A The plant control panel can be supplied asa standalone PLCbased systemor configuredto communicate via industrystandard protocols Modbus TCP/IP Profibus etc allowing full visibilityand control fromyour central facility。

Q Are performance guarantees offered？
A Yes subjectto mutually agreedupon feed material specifications we can contractually guarantee rated throughput capacity final product P80 sizing以及specific energy consumption targets。

Q What isthe typical lead timefrom order placementto commissioning？
A For standard configurations lead times range between914 months dependingon current manufacturingload Complex customizations may extendthis timeframe Detailed project schedules are provided upon initial technical review。

Q How do you address ongoing technical supportfor remote sites？
A We offer tiered support including24/7 remote diagnostics access trained regional service technicians以及comprehensive documentation Parts are strategically warehousedin key mining regions globallyto expedite delivery。

Q Can this plant be relocatedin future？
A Yes themodular bolted subframe designis specifically engineeredfor disassembly relocation andreassembly Minimally destructive techniquesare used preserving structural integrity Relocation feasibility studiesare availableas separate consultancy service。

Q What trainingis providedfor our operationsand maintenance teams？
A Comprehensive trainingis included covering normal operation shutdown procedures routine maintenance tasks troubleshooting We provide both classroom sessionsat our facility handson training during commissioningat yours alongwith detailed operational manuals