1. PAINPOINT DRIVEN OPENING

Managing an iron ore crushing circuit presents distinct challenges that directly impact throughput, maintenance budgets, and plant availability. Are you facing:
Unplanned Downtime: Frequent, unpredictable failures of crusher components under extreme abrasive loads, leading to production halts that can cost tens of thousands per hour.
Excessive Maintenance Costs: The constant cycle of wear part replacement in primary and secondary crushing stages, with high labor costs and parts inventory tying up capital.
Inconsistent Product Gradation: Fluctuations in feed size and hardness leading to offspec product, causing bottlenecks in downstream grinding and processing stages.
High Energy Consumption: Inefficient crushing action that draws excessive power without corresponding output, inflating operational expenditure.
Rigid Plant Layout Limitations: Difficulty integrating new crushing stages into existing brownfield sites due to space constraints and complex material transfer requirements.

Selecting the right CE Marked iron ore crushing plant is a strategic decision to address these operational and financial pressures.

2. PRODUCT OVERVIEW

This product is a stationary or semistationary primary and secondary iron ore crushing plant, engineered for hightonnage, continuous duty processing of magnetite or hematite ores. The modular design integrates heavyduty crushers, feeders, screens, and conveyors into a coordinated system.

Operational Workflow:
1. Primary Size Reduction: Runofmine (ROM) ore is fed via a vibrating grizzly feeder to a primary jaw crusher, reducing material to a manageable size for conveying.
2. Secondary Crushing & Screening: Crushed ore is transported to a secondary cone crusher circuit. A closedloop system with vibrating screens ensures material is recirculated until the target product size is achieved.
3. Product Handling: Correctly sized ore is discharged via conveyor systems to stockpiles or directly to the next stage of beneficiation.

Application Scope & Limitations:
Scope: Ideal for greenfield installations or major expansions requiring 500 to 2,500+ tonnes per hour capacity. Suitable for both blasted rock and direct shovelfed operations.
Limitations: Not designed as a tertiary or fine grinding circuit. Feed size must conform to the rated maximum input dimension of the primary crusher. Requires professional civil engineering for foundation preparation.

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: Reinforced manganese steel jaws & oversized eccentric shaft | Operational Benefit: Sustained performance under shock loads from large feed material, reducing risk of catastrophic failure | ROI Impact: Extended service intervals lower costpertonne crushed by an estimated 1520%

Intelligent Load Management System | Technical Basis: Hydroset®type cavity clearing & automatic setting regulation | Operational Benefit: Prevents crusher stall from tramp metal or uncrushables; maintains consistent product size with minimal operator intervention | ROI Impact: Protects drive components from damage, avoiding unplanned downtime events

Modular Skid Design | Technical Basis: Preassembled structural steel frames with integrated walkways and ladders | Operational Benefit: Significantly reduces onsite installation time and civil works complexity | ROI Impact: Faster commissioning can bring revenuegenerating operations online weeks earlier

Advanced Dust Suppression Integration | Technical Basis: Strategically placed nozzle arrays with flow control tied to conveyor load sensors | Operational Benefit: Minimizes airborne particulate at each transfer point, ensuring compliance with site health and environmental standards | ROI Impact: Reduces housekeeping labor and mitigates risk of regulatory noncompliance fines

Centralized Greasing & Monitoring | Technical Basis: Automated lubrication system with PLC control and fault feedback for all major bearing points | Operational Benefit: Ensures optimal bearing life under highvibration conditions; alerts maintenance teams to potential issues before failure | ROI Impact: Directly extends mean time between failures (MTBF) for critical components

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our CE Marked Iron Ore Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Crusher Wear Part Life (Primary) | 800,000 1,200,000 tonnes | 1,400,000 1,800,000 tonnes | +40% (based on equivalent Taconite feed) |
| System Availability (Scheduled Runtime) | 9092% | 9496% (excluding planned maintenance) | +4 percentage points |
| Power Efficiency (kWh/tonne) Varies by ore hardness| Benchmark varies by site configuration| Field data shows consistent reduction through optimized chamber design & drive efficiency| Up to 8% improvement |
| Installation & Commissioning Time (Greenfield) ~20 weeks from delivery| ~14 weeks from delivery due to modularity| ~30% reduction in timetoproduction |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 500 TPH to over 2,500 TPH nominal throughput.
Primary Crusher Options: Jaw Crusher (900 x 1200mm to 1500 x 2000mm) or Gyratory Crusher models available based on feed size analysis.
Secondary Crusher Options: Heavyduty cone crushers with multiple cavity profiles for optimized shaping and size reduction.
Power Requirements: Total connected load typically between 800kW 2500kW depending on configuration; designed for highvoltage (6kV/11kV) motor supply.
Material Specifications: Highabrasion resistant steel in hoppers and chutes; AR400/500 liners at all critical wear points; certified structural steelwork.
Physical Dimensions (Example Configuration): Primary module approx. L18m x W8m x H7m; Secondary/Screening module approx. L25m x W10m x H9m.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C; dustproofed electrical enclosures (IP65); corrosionresistant coatings for coastal environments.

6. APPLICATION SCENARIOS

Greenfield Magnetite Mine Expansion

Challenge: A new mining operation required a highavailability plant capable of processing very abrasive magnetite ore with minimal initial capex on civil works.
Solution: Implementation of a fully skidmounted CE Marked iron ore crushing plant with primary jaw and secondary cone crushers.
Results: Plant commissioned in under 16 weeks from delivery. Achieved sustained throughput of 1,100 TPH with wear part life exceeding initial estimates by 22%, directly lowering operating costs.

Brownfield Hematite Processing Upgrade

Challenge: An existing plant’s aging crushing circuit caused persistent bottlenecks and excessive fines generation due to outdated technology.
Solution: Replacement of two old crusher stages with a single modern secondary cone crusher within our modular plant design, fitting into the existing footprint.
Results: Product gradation consistency improved by 35%, downstream mill throughput increased by 12%, and specific energy consumption in the crushing circuit fell by an average of 7%.

7. COMMERCIAL CONSIDERATIONS

Our CE Marked iron ore crushing plants are offered in defined configuration tiers:

Standard Tier: Proven base configurations for common capacity ranges (e.g., ~750 TPH). Includes core equipment with standard wear parts packages.
Optimized Tier: Customengineered solution based on your specific ore characterization data. Includes advanced automation package (PLC/SCADA interface) and upgraded wear material specifications.

Optional features include:
Onboard power generation packages
Advanced predictive monitoring sensors
Specialized liner profiles for specific product shaping
3D laser scanning for retrofit fit verification

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including guaranteed wear part performance.

Financing options include traditional capital purchase as well as longterm leasetoown structures designed to align payment schedules with your project’s cash flow timeline.

8. FAQ

Q1: Is this equipment compatible with our existing screening and conveying infrastructure?
A1: Yes. Our engineering team conducts interface analyses using your existing layout drawings to ensure compatibility regarding chute geometry, transfer heights, belt widths,and control system integration points.

Q2:What level of operational disruption should we expect during installation?
A2:The modular design minimizes disruption.For brownfield replacements,a wellplanned campaign typically requires a scheduled shutdown period of approximately four weeks for foundation work,followed by rapid module placementand connection.Field data indicates full integration within six weeks postshutdown commencement.

Q3:What are the typical payment terms?
A3.Standard commercial terms involve progress payments tied tomajor milestones such as contract signing,major component fabrication completion,and shipment.A typical structure involves30/40/30percent split across these milestones.Negotiable terms are availablefor largescale ordersor framework agreements.

Q4.How does the CE marking benefit us outside Europe?
A4.The CE mark signifies conformitywith stringent EU health,safety,and environmental directives.It provides independent verificationof robust designand manufacturing quality,many clients globallyspecify it asa de facto benchmarkfor equipment integrity regardlessof final installation location

Q5.What ongoing technical supportis provided after commissioning?
A5.All installations includea comprehensive training programfor your operationsand maintenance teams.We provide12 monthsof remote technical supportas standardwith optional extended service plans thatcan include periodic site inspectionsperformance auditsand spare parts management programs