1. PAINPOINT DRIVEN OPENING

Are your iron ore processing margins being eroded by inconsistent feed, excessive maintenance, and unplanned downtime? For plant managers and engineering contractors, standard crushing solutions often fall short under the relentless demands of abrasive, hightonnage iron ore applications. Consider these common operational challenges:

High Abrasion Costs: Standard manganese steel wear parts degrade rapidly under continuous taconite or hematite processing, leading to frequent liner changes, high consumable costs, and lost production hours.
Unscheduled Downtime: A primary crusher failure or a blocked secondary chamber can halt your entire beneficiation line, costing tens of thousands per hour in lost throughput.
Inconsistent Product Size: Fluctuations in feed size or hardness can cause crusher overload or underutilization, producing offspec material that disrupts downstream grinding and separation efficiency.
Energy Inefficiency: Older crushing circuits with poor chamber design or inadequate power utilization consume excessive energy per ton of ore processed, directly impacting operational expenditure.

Is your operation equipped to handle variable ore characteristics while maintaining optimal size reduction and minimizing total cost of ownership? A purposeengineered bespoke iron ore crushing plant is not a luxury—it is a strategic investment in predictable, profitable production.

2. PRODUCT OVERVIEW

A bespoke iron ore crushing plant is a fully customized stationary or semimobile crushing circuit engineered from the ground up for the specific characteristics of your ore body and production goals. It moves beyond catalog equipment to integrate optimized machinery, layout, and control systems.

Operational Workflow:
1. Primary Gyratory Crushing: Runofmine (ROM) ore is reduced to a manageable top size (typically 250mm) in a heavyduty, abrasionresistant primary crusher designed for high availability.
2. Secondary & Tertiary Cone Crushing: Utilizing specialized cone crushers with fortified liners and advanced chamber geometries, material is progressively reduced to a consistent feed (often 25mm) for downstream milling.
3. PreScreening & Scalping: Integrated vibrating grizzlies and screens remove fines and oversize material prior to each crushing stage, increasing circuit efficiency and protecting machinery.
4. Material Handling & Transfer: Customdesigned conveyors with impactresistant idlers and belt scrapers ensure reliable transfer between stages with minimal spillage and dust generation.
5. Centralized Process Control: An integrated automation system monitors load, power draw, and product size in realtime, allowing for dynamic adjustment to maintain peak performance.

Application Scope & Limitations:
This solution is engineered for largescale iron ore mining operations with dedicated processing facilities requiring high availability and throughput exceeding 2,000 mtph. It is less suitable for smallscale, exploratory, or highly mobile operations where lower capital expenditure outweighs longterm operational efficiency gains.

3. CORE FEATURES

Patented Liner Geometry | Technical Basis: Optimized crushing chamber profiles based on DEM (Discrete Element Modeling) simulation | Operational Benefit: Produces a more consistent product curve with fewer fines generation and reduced risk of crusher packing | ROI Impact: Improves downstream grinding circuit efficiency by up to 8% through optimized feed size distribution.

Automated Setting Regulation System (ASRi) | Technical Basis: Hydroset mechanism controlled by realtime pressure and power sensors | Operational Benefit: Automatically compensates for liner wear and fluctuating feed conditions to maintain closedside setting (CSS) without manual intervention | ROI Impact: Maintains target throughput and product size 24/7, eliminating periodic output degradation between manual adjustments.

Modular Mainframe Construction | Technical Basis: Heavyduty sectionalized steel frame with precision machining interfaces | Operational Benefit: Enables critical structural components to be replaced or serviced without requiring a full frame changeout | ROI Impact: Reduces major overhaul downtime by up to 60% compared to traditional monolithic frames.

Integrated Dust Suppression & Sealing | Technical Basis: Positivepressure air curtains and strategically placed foam/dry fog systems at transfer points | Operational Benefit: Contains airborne particulate at source, protecting bearings and gears from abrasive dust ingress | ROI Impact: Extends mechanical component life by an average of 35%, reducing replacement part costs and failure risk.

Centralized Greasing & Lube System | Technical Basis: Automated, programmable lubrication unit with dedicated lines to all major bearing points | Operational Benefit: Ensures correct lubrication intervals and volumes are maintained consistently across the entire circuit | ROI Impact: Eliminates manual greasing errors, preventing an estimated 70% of bearingrelated failures.

HighStrength Alloy Wear Parts | Technical Basis: Proprietary metallurgy (e.g., Tivar liners, boronsteel hammers) developed specifically for iron oxide abrasion resistance | Operational Benefit: Wear life in primary and secondary applications demonstrates a 4050% improvement over standard manganese steel in field tests | ROI Impact: Lowers costperton for wear parts directly while reducing changeout frequency.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Bespoke Iron Ore Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Mechanical Availability (%)| 88 92% (scheduled & unscheduled) |> 95% (design target) |> +5% |
| Wear Part Consumption (kg/mt)| Varies widely; often benchmarked at 100% baseline| Consistent reduction demonstrated via alloy/design| 40% to 50% |
| Energy Consumption (kWh/mt)| Baseline per application/ore type| Optimized chamber design & drive efficiency| 15% to 20% |
| Product Size Consistency (% within spec)| +/ 15% fluctuation common over liner life| Maintained within +/ 5% via automated regulation| > +65% consistency |
| Mean Time Between Major Overhauls (hours)| ~12,000 16,000 operating hours| Design target >24,000 operating hours |> +50% |

5. TECHNICAL SPECIFICATIONS

Capacity/Rating: Engineered for throughputs from 2,500 to over 10,000 mtph, based on specific ore work index (Wi), feed size (F80), and required product size (P80).
Power Requirements: Total installed power typically ranges from 2 MW to 8 MW, utilizing highefficiency MV motors with VFD drives on key units for softstart capability and load management.
Material Specifications: Primary structure utilizes S355JR steel. Critical wear components employ proprietary alloys such as Martensitic Steel Castings for impact zones and specialized Chrome White Iron for extreme abrasion areas.
Physical Dimensions: As a bespoke system; overall footprint is optimized per site layout. A typical threestage circuit may require a layout area of approximately 80m x 40m.
Environmental Operating Range: Designed for ambient temperatures from 30°C to +50°C, with optional packages for arctic or tropical extremes. Dust emission control designed to meet <10 mg/Nm³ at stack.

6. APPLICATION SCENARIOS

Pilbara Region Hematite Operation | Challenge: A Tier1 miner faced escalating downtime due to premature failure of cone crusher bronze bushings in secondary crushing caused by dust ingress in arid conditions.| Solution: Implementation of a bespoke iron ore crushing plant featuring an enhanced sealing system on secondary/tertiary cones combined with centralized positivepressure air filtration.| Results: Bushing life extended from 6 months to over 24 months. Annual downtime related to cone crusher bearing service reduced by approximately 320 hours.

Canadian Labrador Trough Taconite Producer | Challenge: Highly abrasive magnetitebearing taconite was causing unsustainably high wear costs on primary jaw crusher liners (~22day life), creating logistical strain on changeouts.| Solution: Commissioning of a custom primary gyratory crusher station with a modified eccentric throw profile paired with ultrahighstrength alloy concaves/mantles.| Results:Liner service life increased to approximately 42 days—a ~90% improvement—reducing annual liner consumption costs by an estimated $1.8M CAD while freeing maintenance crews for other tasks.

West African Banded Iron Formation (BIF) Project Development Challenge:| A greenfield project required maximized plant uptime but faced severe constraints on skilled local maintenance personnel availability.| Solution:| Design of an integrated bespoke iron ore crushing plant focused on remote monitoring diagnostics,predictive maintenance scheduling,and modular component swapout design.| Results:| The system enabled planned maintenance tasks guided remotely by OEM specialists.Field data shows unplanned stoppages were maintained below <2%,and major component changeout times were reduced by ~40%.

COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are projectspecific but generally structured as follows:

Base Plant Package: Includes primary station,(secondary/tertiary modules,screening towers,and basic PLC controls.Capital investment typically starts in the multimillion dollar range scaled directly with throughput capacity.
Optional Features: Key upgrades include advanced process control systems(APC),comprehensive dust suppression systems(including baghouses),online particle size analyzers(PSD),and full modularization skiddingfor faster installation.
Service Packages: Available tiers include:
Planned Maintenance: Scheduled inspections,lube analysis,and wear part monitoring.
Performance Guarantee: Includes guaranteed availability,wears rates,and energy consumption metrics backed by service credits.
Full Circuit Contract: Fixed costperton service covering all labor parts,and planned/unplanned maintenancefor total budget predictability
Financing Options:: Project financing capital leasingand operating lease structures are available often provided through partnershipswith major industrial financial institutions

FAQ

Q1 How do you ensure technical compatibility between new bespoke equipmentand our existing downstream grinding circuit?
A Our engineering process beginswitha full auditofyour current downstream process parametersThe newcrushingplantis designedto deliverthe optimal P80product sizedistributionto maximize the efficiencyofyour existing SAGball millsor HPGRcircuitminimizing specific energy consumption downstream

Q2 Whatisthe typical implementation timelinefrom orderto commissioningfora turnkeybespokecrushingplant?
A Fora majorgreenfield installationthe total timeline averages1824monthsThis includesdetailedengineering(46mo)fabrication(912mo)and siteconstruction/commissioning(57mo).Modularized designs can reduce site erection timebyupto30%

Q3 Can you provide performance guaranteesonwear ratesandavailability?
A Yesperformancebased contractsare standardWe provideguaranteedfiguresfor mechanical availabilitywear partconsumptionin kgpermetric tonprocessedandspecific energyconsumptionTheseare backedbyoperational datafromyour specificore testing

Q4 How does the capital expenditure(Capex)fora bespokesolutioncompareto retrofittingorupgradingexistingstandardcrushers?
A Initial Capexis typicallyhigherHoweverthetotal costofownership(TCO)overa10yearperiod consistentlyproves lowerin industry analysesdue todramaticallyreducedoperatingexpenditure(Opex)downtimecostsand improveddownstreamefficiencyA detailedTCOmodelfor your operationis developedduringthe feasibilityphase

Q5 What levelofoperator trainingis requiredforthe centralizedcontrolsystem?
A We provide comprehensive trainingprogramsfor bothoperatorsandmaintenance techniciansfocusedonyour specificplantinterfaceTraining includesclassroominstruction simulatorfamiliarizationandonsite shadowingduringcommissioningTypicallythis involves~80hoursofcore trainingperkeypersonnel