1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your iron ore processing margins? Managing a crushing plant presents distinct challenges that directly impact your bottom line. Common pain points include:
Abrasive Wear Costs: The extreme abrasiveness of iron ore leads to rapid liner wear in crushers, resulting in frequent, costly replacements and excessive maintenance labor.
Unplanned Downtime: Component failure in critical crushing stages causes cascading production halts, with hourly downtime costs running into tens of thousands.
Inconsistent Throughput & Product Size: Fluctuations in feed size or hardness can lead to chokefeeding, cavity packing, and offspec product, creating bottlenecks for downstream grinding circuits.
High Energy Consumption: Inefficient crushing technology and poor chamber design force motors to work harder, directly increasing your kWhpertonne cost.
Logistical & Installation Complexity: Oversized, nonmodular plant designs lead to protracted site installation, higher civil works costs, and limited future flexibility.

How do you select a crushing plant contract manufacturer that provides robust equipment engineered for these specific challenges while guaranteeing project delivery on time and within budget?

2. PRODUCT OVERVIEW

As a certified contract manufacturer for iron ore crushing plants, we engineer, fabricate, and commission complete stationary and semimobile crushing solutions. Our scope includes primary gyratory or jaw crushers, secondary and tertiary cone crushers, screens, feeders, and full material handling systems integrated into a cohesive circuit.

Operational Workflow:
1. Primary Crushing: Runofmine ore is reduced to a manageable size (typically <250mm) using heavyduty primary crushers built for high throughput and tramp iron protection.
2. Secondary/Tertiary Crushing: Further size reduction occurs in cone crusher stages configured in closed circuit with screens to ensure precise product gradation for optimal grinding mill feed.
3. Screening & Material Handling: Vibrating screens classify material, with oversize recirculated and onspec product conveyed to stockpiles or nextstage processing.

Application Scope: Hard rock hematite and magnetite ores. Suitable for greenfield installations or brownfield plant expansion and modernization projects.
Limitations: Process design is specific to the ore's compressive strength, abrasion index (Ai), and moisture content. Solutions are not typically designed for highly sticky or claybound ores without prior washing/scalping stages.

3. CORE FEATURES

HEAVYDUTY LINER DESIGN | Technical Basis: Highchrome white iron alloys & optimized cavity profiles | Operational Benefit: Liner life extended by 3050% compared to standard manganese steel in abrasive iron ore applications | ROI Impact: Reduced liner inventory costs and less frequent changeout downtime

ADVANCED CHAMBER GEOMETRY | Technical Basis: Crusher chamber dynamics modeled for specific iron ore crushability | Operational Benefit: Maintains consistent product gradation curve and reduces risk of cavity packing | ROI Impact: Higher throughput of inspec material improves overall plant efficiency

INTEGRATED DUST SUPPRESSION | Technical Basis: Nozzle placement at transfer points aligned with material trajectory | Operational Benefit: Significant reduction of airborne dust without overwetting material | ROI Impact: Lowers health & safety compliance risks and reduces cleanup costs

MODULAR PLANT ARCHITECTURE | Technical Basis: Preassembled skid or modulebased design | Operational Benefit: Reduces site installation time by up to 40% versus stickbuilt designs | ROI Impact: Lower field labor costs and faster timetoproduction

CENTRALIZED GREASE AUTOMATION | Technical Basis: Automated lubrication system with central monitoring | Operational Benefit: Ensures optimal bearing lubrication under highload conditions, preventing premature failures | ROI Impact: Eliminates manual lubrication errors and extends major component life

ROBUST STRUCTURAL FABRICATION | Technical Basis: Finite Element Analysis (FEA) on loadbearing structures | Operational Benefit: Withstands continuous highcycle loading and vibration inherent in iron ore crushing | ROI Impact: Minimizes structural fatigue cracks over the plant's lifecycle

PLCBASED PROCESS CONTROL | Technical Basis: Programmable Logic Controller with loadmanagement algorithms | Operational Benefit: Optimizes crusher power draw and automatically regulates feed rates | ROI Impact: Achieves up to a 15% reduction in specific energy consumption (kWh/tonne)

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Iron Ore Crushing Plant Solution | Documented Advantage |
| : | : | : | : |
| Liner Wear Life (Secondary Crushing) | 450,000 550,000 tonnes per set (for magnetite)| 650,000 750,000 tonnes per set (for magnetite)| +35% improvement |
| Plant Availability (Scheduled) | 9294% availability target| Design target of >96% availability| +3 percentage points |
| Specific Energy Consumption| Varies by circuit; baseline established per project| Field data shows typical reduction of 1015% vs. older designs| Up to 15% improvement |
| Installation & Commissioning Time| 68 months for midsize semimobile plant| 45 months through modular execution| ~40% reduction in time |
| Fines Generation (1mm)| Dependent on ore type; can be >12% in tertiary stage| Chamber optimization reduces generation by relative measure.| Up to 20% relative reduction |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Engineered for circuits from 500 to over 3,000 tonnes per hour (TPH).
Primary Crusher Options: Gyratory crushers (54"75") or Jaw crushers (1.5m x 2m+).
Secondary/Tertiary Crushers: Heavyduty cone crushers with capacities from 200 to 900 TPH each.
Power Requirements: Total installed power varies significantly by circuit; primary crusher drives range from 200 kW to over 600 kW.
Material Specifications: Critical wear components utilize ASTM A532 Class III Type A highchrome iron; structural steel is ASTM A36/A572.
Physical Dimensions (Example Module): A secondary crushing module may measure approx. L20m x W8m x H9m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust protection rating of IP65 for electrical components.

6. APPLICATION SCENARIOS

GREENFIELD MAGNETITE PROJECT IN WESTERN AUSTRALIA

Challenge:A new mine required a highavailability plant capable of processing very abrasive magnetite ore (Ai >0.5) with a tight product specification for downstream grinding.
Solution:A complete threestage crushing circuit was supplied featuring primary jaw crushing followed by two stages of cone crushing in closed circuit with doubledeck screens.
Results:The plant achieved a consistent product size of P80 =12mm at a sustained rate of 1,800 TPH. The specified liner technology achieved a confirmed life extension of 38%, contributing directly to an availability rate averaging 96.2% in the first year.

BROWNFIELD EXPANSION AT A BRAZILIAN HEMATITE OPERATION

Challenge:The existing singleline crushing circuit was the bottleneck preventing mine expansion; space constraints limited the footprint for any new installation.
Solution:A compact,semimobile tertiary crushing module was designed,fed from an existing stockpile.The module included a cone crusher,screen,and conveyor system on a single transportable frame.
Results:The addon module increased overall plant throughput by an additional600TPH without major modifications to existing infrastructure.Commissioning was completed within14weeks from delivery due to the preassembled modular design.

7.COMMERCIAL CONSIDERATIONS

Our engagement model as your contract manufacturer provides clear financial planning:

Pricing Tiers:
1.Basic Equipment Supply:Covers design,fabrication,and delivery of core crushing modules.Customer handles installation&commissioning
2.Turnkey Lite Supply includes supervisionof installation&mechanical commissioning assistedby customer's workforce
3.Full Turnkey EPC Project Full engineering procurementand construction management including civils E&I integrationand performance testing

Optional Features:
Online wear monitoring systems Automated belt misalignment switches Advanced vibration sensing packages Extended warranty packages covering major components

Service Packages:
Annual inspection&optimization contracts Onsite technical support agreements Remote process monitoring&diagnostics services Comprehensive spare parts holding agreements

Financing Options:
We work with accredited partners to offer equipment leasing solutions project financing or progressbased milestone payment plans tailoredto CAPEX approval cycles

8.FAQ

Q:What levelof testwork doyou requireto designourcrushingcircuit?
A We requirea representative sampleof yourorefor standard crushability testing including Bond Work Index Drop Weight Testand Abrasion Index Thisdatais essentialfor correctcrusher selectionand power sizing

Q Howdoesyourplantdesignadaptto variationsinore hardness?
A OurPLC controlsystemsare programmedwith loadmanagement algorithmsthat adjust feeder rates basedon realtimecrusher motor amperage This maintains optimalcavity conditionsand protects equipmentfrom tramp metalor suddenhardness spikes

Q Areyourmodules compatiblewith existingequipmentfrom otherOEMs?
A Yes oursystemscanbe interfacedwith existingconveyors screensor controlsystems We provideclearly definedinterfacepointsfor mechanical electricaland controlintegration duringthe engineeringphase

Q Whatisthe typicalleadtimefrom orderto commissioning?
A Fora standardtwostagecrushingmodule leadtimesrangebetween7and10months dependingon complexityand currentmanufacturingschedule Fullturnkeyprojectsrequireadditionaltimefor civilsand integration Detailed schedulesare providedwith projectquotations

Q Do youofferperformanceguarantees?
A Yes we provideguaranteeson throughput capacity finalproductgradationand specificpower consumption Theseare detailedin commercialcontractsbasedon agreedfeedconditions