1. PAINPOINT DRIVEN OPENING

Are your iron ore processing margins being squeezed by inconsistent feed, excessive downtime, and rising operational costs? Plant managers and engineering contractors face persistent challenges that directly impact the bottom line. Are you experiencing:
Unplanned Downtime: Frequent, unpredictable breakdowns in primary crushing due to tramp steel or uncrushable material, halting your entire processing line for hours.
Throughput Bottlenecks: Inefficient crushing stages causing backlogs, limiting overall plant capacity and failing to meet offtake agreements during peak demand.
High Maintenance Costs: Constant wear part replacement in abrasive iron ore applications, coupled with laborintensive servicing routines that drain maintenance budgets.
Product Quality Variability: Inconsistent final product sizing (lump/fines ratio) leading to premium price penalties and customer dissatisfaction.
Energy Inefficiency: Crushing systems operating at nonoptimal levels, consuming excessive power per tonne of ore processed.

What if your primary crushing stage could become a predictable, highavailability asset instead of a recurring cost center?

2. PRODUCT OVERVIEW

The Bespoke Iron Ore Crushing Plant is a engineered primary and secondary crushing system specifically configured for the highabrasion, hightonnage demands of magnetite or hematite processing. Unlike standard modular plants, each system is designed from the ground up based on your ore characteristics (Abrasion Index, UCS), required capacity, and site logistics.

Operational Workflow:
1. Primary Dumping & PreScreening: RunofMine (ROM) ore is received at a rugged dump hopper with a grizzly feeder to scalp out oversize material and direct subgrizzly fines to a bypass conveyor.
2. Primary Crushing: A heavyduty jaw crusher or gyratory crusher reduces the ROM ore to a manageable size for downstream conveying.
3. Secondary Crushing & Screening: Material is conveyed to a secondary cone crusher circuit in closed configuration with sizing screens to ensure precise product control before proceeding to beneficiation.

Application Scope: Ideal for greenfield sites or major expansion projects requiring 1,500 to 10,000+ tonnes per hour capacity. Best suited for operations with consistent longterm mine plans.

Limitations: Not recommended for smallscale or exploratory operations with rapidly changing ore bodies. Site requires adequate preparation for foundation and crane access.

3. CORE FEATURES

HeavyDuty Apron Feeder | Technical Basis: Overlapping manganese steel flights driven by rugged tractortype chains | Operational Benefit: Handles direct dump from 200ton haul trucks without damage, provides even feed regulation to crusher | ROI Impact: Eliminates feeder damage downtime; improves crusher cavity fill for up to 15% higher throughput efficiency.

Tramp Metal & Cavity Clearance System | Technical Basis: Automated hydraulic release and clearing cylinder on primary crusher | Operational Benefit: Clears blockages or uncrushable material in minutes without manual intervention | ROI Impact: Reduces downtime events from hours to minutes, protecting crusher from catastrophic damage.

Liner Life Optimization | Technical Basis: CADdesigned crushing chamber profiles and alloyed manganese steel liners specific to your ore's abrasiveness | Operational Benefit: Achieves predictable wear life cycles, allowing for planned maintenance shutdowns | ROI Impact: Extends liner life by 2035% over generic liners; reduces annual consumable cost per tonne.

Centralized Greasing & Condition Monitoring | Technical Basis: Automated lubrication system with flow sensors and vibration monitors on critical bearings | Operational Benefit: Ensures optimal bearing health, provides early warning of potential failures | ROI Impact: Prevents major bearing failures; reduces manual greasing labor by estimated 80%.

Modular Conveyor Design | Technical Basis: Bolttogether heavyduty conveyor sections with impact cradles at loading zones | Operational Benefit: Enables faster installation and future reconfiguration if plant flow needs change | ROI Impact: Cuts installation time by up to 30%, reducing timetoproduction.

Dust Suppression Integration | Technical Basis: Nozzle system integrated at transfer points, tied into crusher actuation | Operational Benefit: Significantly reduces airborne particulate from initial crushing stages | ROI Impact: Maintains regulatory compliance, improves site working conditions and reduces cleanup costs.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Modular Plant) | Bespoke Iron Ore Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Plant Availability | 8590% (planned & unplanned) | 9496% target availability | +510% more productive uptime |
| Tonne/Hour Efficiency| Rated capacity often at ideal conditions| Capacity guaranteed based on your specific ore AI & density| +1015% consistent throughput |
| Energy Consumption| Fixed speed drives across motors| HVSI crushers & variable frequency drives (VFDs) on feeders/conveyors| Up to 12% lower kWh/tonne |
| Wear Cost per Tonne| Generic liner designs standard| Orespecific chamber design & liner metallurgy| 2035% reduction demonstrated |
| Installation Timeline| Sequential assembly on site| Large preassembled skids tested before shipment| 2530% faster commissioning |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 1,500 TPH to over 10,000 TPH of crushed iron ore.
Primary Crusher Options: Jaw Crusher (1,600mm x 2,000mm) or Primary Gyratory Crusher (60”+). Selection based on feed size and capacity requirement.
Secondary Crusher Options: Highcapacity cone crushers with hydraulic adjustment and clearing.
Power Requirements: Total installed power typically ranges from 1.5MW to 6MW+ depending on configuration. Designed for connection to highvoltage mine grid supply (6.6kV/11kV).
Material Specifications: Critical wear components utilize premium alloys (e.g., TeroTec® manganese steel). Structural steel is Grade S355JR for durability.
Physical Dimensions: Plant footprint is sitespecific but designed for optimal accessibility around crushers and conveyors for maintenance.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +50°C. Dust encapsulation and insulation/heating packages available for extreme climates.

6. APPLICATION SCENARIOS

Greenfield Magnetite Project in Pilbara Region

Challenge: A new mine required a 4,500 TPH primary crushing plant capable of handling highly abrasive ore with minimal water usage due to arid conditions.
Solution: Implementation of a bespoke plant featuring a gyratory primary crusher, dry screening presorting, and fully enclosed conveyors with baghouse filtration.
Results: Achieved nameplate capacity within one month of commissioning. Dust emissions maintained below stringent regulatory limits despite dry processing. Wear part life met projected targets within 5%.

Existing Hematite Operation Expansion

Challenge: An existing operation needed to debottleneck its process line; the original primary crusher was causing throughput limitations and excessive maintenance shutdowns.
Solution: A bespoke secondary crushing circuit was designed downstream of the existing primary stage using highperformance cone crushers in closed circuit with multideck screens.
Results: Overall plant throughput increased by 22%. Final product sizing consistency improved significantly (+40%), securing premium lump ore pricing from buyers.

7. COMMERCIAL CONSIDERATIONS

Our bespoke plants are capital investments engineered for longterm operational payback.

Pricing Tiers: Quotations are projectspecific based on detailed client specifications (BOM). Budgetary estimates are provided after initial scoping.
Standard Configuration: Includes core crushing units,surge bins,and basic PLC control.Price range indicative only:$8M $15M USD
Advanced Configuration: Includes automation systems,predictive condition monitoring,and advanced dust control.$12M $25M+ USD

Optional Features: Onboard weighing systems,mobile sampling stations,crusher cavity vision systems,total turnkey erection services.

Service Packages:

Platinum Support: Includes remote monitoring,a dedicated service engineer,two scheduled maintenance visits/year,and guaranteed parts delivery within specified timeframe.This package typically adds ~35% CAPEX annually but can reduce unplanned downtime by up to an additional ~50%.

Gold Support: Scheduled maintenance visits/year plus priority parts support.This package typically adds ~23% CAPEX annually

Parts Agreement: Guaranteed wear parts supply at fixed pricepertonne over an agreed period.This stabilizes operating costs

Financing Options: We work with major international equipment finance partners offering leasetoown structures operating leases over typical terms

FAQ

Q1 How do you ensure this bespoke plant will work with our existing downstream processing equipment?
A Our engineering process begins with a comprehensive audit of your entire flow sheet including existing conveyors bin capacities We model the entire system using dynamic simulation software ensuring the new crushing plant integrates without creating bottlenecks elsewhere

Q2 What is the typical implementation timeline from order placement?
A For most projects detailed engineering requires months followed by months manufacturing shipping Site preparation must occur concurrently Commissioning typically takes weeks This timeline varies significantly based on scale complexity permitting requirements

Q3 Can you guarantee performance metrics like throughput energy consumption?
A Yes performance guarantees are contractually stipulated following analysis testing They are based on agreedupon standards such as specific Bond Work Index values Abrasion Index values provided during design phase These guarantees form part of our commercial proposal

Q4 How does financing through your partners work?
A Our finance partners provide capital equipment leasing solutions that preserve your working capital Typical agreements involve monthly payments structured as an operating lease often providing potential tax benefits A formal credit application separate from equipment purchase agreement required

Q5 What training do you provide?
A We provide comprehensive training programs covering normal operation routine maintenance troubleshooting safety procedures Training conducted both during Factory Acceptance Testing FAT commissioning period Documentation includes detailed operation manuals parts lists schematic diagrams