1. PAINPOINT DRIVEN OPENING

Are your iron ore processing operations constrained by inconsistent feed size, unplanned maintenance, and rising energy costs? Inefficient primary crushing creates bottlenecks that ripple through your entire beneficiation circuit, directly impacting throughput and profitability. Consider these common challenges:
Excessive Downtime: Unplanned stoppages for liner changes or mechanical repairs in your primary crusher can cost thousands per hour in lost production.
High Operating Costs: Inefficient crushing cycles and excessive power draw from poorly matched equipment inflate your costperton metric.
Product Quality Variability: Inconsistent output size distribution from the primary stage overloads downstream screening and secondary crushing, reducing overall plant efficiency.
Abrasive Wear Costs: 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. PRODUCT OVERVIEW: 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 (ROM) iron ore, typically reducing material from up to 1.5meter feed down to a conveyable product for further processing.

Operational Workflow:
1. ROM iron ore is dumped into a heavyduty vibrating grizzly feeder (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.

Application Scope & Limitations:
Scope: Ideal for greenfield installations or expansion projects requiring capacities from 1,500 to over 10,000 tonnes per hour (tph). Suited for magnetite, hematite, and other ironbearing ores.
Limitations: This is a primary crushing solution; secondary and tertiary crushing require additional circuit design. Feed size must be controlled within the crusher's designed maximum intake dimensions.

3. CORE FEATURES

HeavyDuty Vibrating Grizzly Feeder (VGF) | Technical Basis: Highstrength steel construction with adjustable grizzly bars | Operational Benefit: Scalps fines to bypass the crusher, reduces wear, and ensures even feed distribution for optimal cavity utilization | ROI Impact: Increases effective crusher capacity by up to 15% and extends wear life of primary liners

Hydrostatic Crusher Drive System | Technical Basis: Direct hydraulic drive for the main shaft | Operational Benefit: Provides smooth startup under load, reversible operation to clear blockages, and infinite variable speed control for optimal throughput | ROI Impact: Eliminates costly shearing of mechanical drive components; field data shows a 30% reduction in blockagerelated downtime

Modular Liner Design | Technical Basis: Segmented manganese steel liners secured with boltin systems | Operational Benefit: Enables partial liner replacement and significantly reduces changeout time compared to monolithic liners | ROI Impact: Reduces liner maintenance downtime by approximately 40%, lowering labor costs and increasing availability

Advanced Chamber Geometry | Technical Basis: Computermodeled nip angle and crushing chamber profile | Operational Benefit: Optimizes compressive force application for iron ore’s fracture characteristics, improving reduction ratio and particle shape | ROI Impact: Delivers a more consistent product size, reducing recirculation load and energy consumption in downstream stages

Centralized Automated Lubrication | Technical Basis: Programmable system delivering precise grease volumes to all critical bearings | Operational Benefit: Ensures optimal bearing health regardless of operator intervention, protecting against contaminant ingress in dusty environments | ROI Impact: Industry testing demonstrates a direct correlation with a 60% increase in major bearing service life

RockBreaker Integration Platform | Technical Basis: Reinforced chassis with preengineered mounting points | Operational Benefit: Allows for safe installation of stationary rock breaker to address hangups at the crusher inlet without manual intervention | ROI Impact: Mitigates a major safety risk and prevents prolonged stoppages due to bridging

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average Jaw/Gyratory) | Our Iron Ore Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Scheduled Runtime) | 9294% | 96%+| +34% |
| Liner Change Time (Hours) | 2436 hrs (full set) | 1418 hrs| ~45% faster |
| Tonnage per kWh (Energy Efficiency) Baseline = 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% |
| Mean Time Between Failure (MTBF) Major Components| ~4,000 hours| 5,500+ hours| +37% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 1,500 tph to 10,000+ tph.
Crusher Type Options: Heavyduty jaw crusher or primary gyratory crusher.
Feed Size Maximum: Up to 1,500mm (59").
Discharge Setting Range: 150mm 300mm (6" 12"), adjustable based on model.
Power Requirements: Total installed power ranges from 450 kW to over 1.2 MW depending on capacity selection; designed for highvoltage supply (6.6kV typical).
Material Specifications: Main frame fabricated from hightensile steel; wear liners manufactured from ASTM A128 manganese steel; shafting from forged alloy steel.
Physical Dimensions (Module): Approximate footprint range: Length 2540m x Width 812m x Height 810m.
Environmental Operating Range: Designed for ambient temperatures from 30°C to +50°C; dustsealed bearings and components standard.

6. APPLICATION SCENARIOS

Greenfield Magnetite Concentrator Project

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．
Results Achieved sustained throughput of 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．