Certified Top Ten Stone Crusher Machine Datasheet
Certified Top Ten Stone Crusher Machine Datasheet
1. PAINPOINT DRIVEN OPENING
Your primary crushing circuit is the bottleneck. Unplanned downtime from jaw plate failure or cone bushing burnout costs your operation an average of $2,500 to $5,000 per hour in lost production. Oversized feed material causes bridging, reducing throughput by 1520%. High wear rates on manganese liners force monthly replacements, adding $12,000+ in parts and labor per crusher annually. Dust generation exceeding 50 mg/Nm³ risks regulatory fines and operator health issues.
Can your current equipment handle a feed size of 1,200 mm while maintaining a consistent P80 of 150 mm? Are you achieving a reduction ratio of 6:1 without sacrificing power efficiency? The Certified Top Ten Stone Crusher Machine is engineered to address these specific operational constraints.
2. PRODUCT OVERVIEW
This equipment is a heavyduty, multistage jaw and cone crusher system designed for primary and secondary reduction of hard rock (granite, basalt, quartzite) and abrasive aggregates.
Operational Workflow:
1. Feed Intake: Material (up to 1,200 mm) enters the vibrating grizzly feeder, which scalps fines (150 mm) to bypass the jaw crusher.
2. Primary Crushing: The hydraulic jaw crusher reduces rock to 150200 mm using a highstroke eccentric shaft.
3. Secondary Crushing: Material is conveyed to a multicylinder hydraulic cone crusher for further reduction to 2040 mm.
4. Screening: Vibrating screens classify output into three fractions (05 mm, 520 mm, 2040 mm).
5. Recirculation: Oversized material returns to the cone crusher via a closedcircuit conveyor.
Application Scope: Suitable for stationary and mobile quarry operations, aggregate production, and mining precrushing.
Limitations: Not recommended for sticky clay materials (moisture >8%) without a dedicated washing system. Maximum feed moisture should not exceed 5% for optimal cone crusher performance.
3. CORE FEATURES
HighStroke Eccentric Jaw Design | Technical Basis: Optimized toggle plate geometry increases throw by 15% | Operational Benefit: Reduces bridging and improves nip angle for harder materials | ROI Impact: 10% increase in throughput per horsepower
MultiCylinder Hydraulic Cone | Technical Basis: Independent hydraulic cylinders adjust CSS (Closed Side Setting) under load | Operational Benefit: Instant adjustment for wear compensation without stopping production | ROI Impact: Eliminates 4 hours of manual adjustment downtime per week
Automatic Tramp Iron Relief | Technical Basis: Hydraulic accumulator system absorbs uncrushable objects (steel, drill bits) | Operational Benefit: Prevents catastrophic damage to main shaft and bowl liner | ROI Impact: Reduces repair costs by $8,000 per incident
HighChrome Blow Bars (Impact Crusher Variant) | Technical Basis: Ceramicinfused highchrome iron (HRC 5862) | Operational Benefit: 40% longer wear life compared to standard manganese | ROI Impact: Extends replacement intervals from 200 to 350 operating hours
Integrated Dust Suppression System | Technical Basis: Water spray nozzles at feed point and discharge chutes | Operational Benefit: Reduces respirable silica dust by 85% | ROI Impact: Compliance with OSHA PEL (Permissible Exposure Limit) of 50 µg/m³
VFDControlled Feed Conveyor | Technical Basis: Variable Frequency Drive adjusts belt speed based on crusher load | Operational Benefit: Prevents choke feeding and maintains consistent amp draw | ROI Impact: 7% reduction in energy consumption per ton
Modular Frame Construction | Technical Basis: Bolted and pinned connections, no welding required | Operational Benefit: Rapid assembly/disassembly for site relocation | ROI Impact: 30% faster setup time compared to welded frames
4. COMPETITIVE ADVANTAGES
| Performance Metric | Industry Standard (200300 TPH) | Certified Top Ten Solution | Advantage (% Improvement) |
| : | : | : | : |
| Reduction Ratio (Primary) | 4:1 | 6:1 | 50% higher reduction |
| Throughput (tph) | 250 | 320 | 28% increase |
| Power Consumption (kWh/ton) | 0.45 | 0.38 | 15.5% lower energy use |
| Liner Wear Life (hours) | 180 | 280 | 55% longer life |
| Dust Emissions (mg/Nm³) | 75 | 35 | 53% reduction |
| Mean Time Between Failures (hours) | 500 | 850 | 70% improvement |
5. TECHNICAL SPECIFICATIONS
| Parameter | Specification |
| : | : |
| Model | CTT320 (Primary Jaw) / CTT220 (Secondary Cone) |
| Feed Opening (Jaw) | 1,200 mm x 900 mm |
| Maximum Feed Size | 1,050 mm |
| Capacity Range | 250 350 metric tons per hour |
| Closed Side Setting (CSS) Range | 100 200 mm (Jaw) / 6 38 mm (Cone) |
| Motor Power | 160 kW (Jaw) / 220 kW (Cone) |
| Eccentric Shaft Speed | 260 RPM (Jaw) / 350 RPM (Cone) |
| Main Frame Material | ASTM A36 / S355JR steel plate, 25 mm thickness |
| Liner Material | Manganese steel (1214% Mn) / Highchrome iron (HRC 58) |
| Weight (Crusher Only) | 42,000 kg (Jaw) / 28,000 kg (Cone) |
| Operating Temperature Range | 20°C to +45°C |
| Hydraulic System Pressure | 160 bar (Cone) |
| Lubrication System | Forced oil circulation with 10micron filter |
6. APPLICATION SCENARIOS
Hard Rock Quarry (Granite) | Challenge: High silica content (65%) caused rapid wear on standard jaw dies, requiring replacement every 180 hours. | Solution: Implemented CTT320 with highchrome jaw plates and automatic CSS adjustment. | Results: Liner life extended to 320 hours. Throughput increased from 220 tph to 290 tph. Annual liner cost reduced by $18,000.
Secondary Crushing for Concrete Aggregates | Challenge: Inconsistent product gradation (P80 varied from 25 mm to 45 mm) causing rejection of 12% of output. | Solution: Installed CTT220 multicylinder cone crusher with realtime CSS monitoring. | Results: P80 stabilized at 22 mm ± 2 mm. Rejection rate dropped to 1.5%. Customer achieved a 4% premium on aggregate pricing.
Mobile Crushing Plant for Road Base | Challenge: Frequent relocation (every 6 months) required extensive welding and realignment of crusher frame. | Solution: Deployed modular frame CTT320 with bolted connections. | Results: Setup time reduced from 14 days to 9 days. Realignment costs eliminated. Overall project timeline shortened by 35%.
7. COMMERCIAL CONSIDERATIONS
Equipment Pricing Tiers (FOB Port):
- Standard Package (CTT320 Jaw + CTT220 Cone): $285,000 $320,000 (Includes base crushers, motors, Vbelts, and standard manganese liners).
- Premium Package: $365,000 $410,000 (Includes highchrome liners, hydraulic tramp iron relief, VFD feed conveyor, and dust suppression system).
- Turnkey Stationary Plant: $780,000 $950,000 (Includes crushers, screens, conveyors, control panel, and 12month commissioning support).
- Remote monitoring system (SCADA integration): $12,500
- Extended warranty (3 years / 10,000 hours): $18,000
- Spare liner kit (1 set jaw + 1 set cone): $22,000
- Basic: Annual inspection + phone support ($4,500/year)
- Advanced: Quarterly inspection + onsite repair within 48 hours ($12,000/year)
- Full Coverage: Monthly inspection + guaranteed 24hour parts delivery ($28,000/year)
- 30% down payment, balance over 36 months at 6.5% APR (subject to credit approval).
- Leasetoown option: $8,500/month for 48 months with $1 buyout.
Optional Features:
Service Packages:
Financing Options:
8. FAQ
Q: Can this crusher handle basalt with a compressive strength of 350 MPa?
A: Yes. The CTT320 jaw crusher is rated for materials up to 400 MPa. Field data from a basalt quarry in Norway shows consistent operation at 320 MPa with standard manganese liners.
Q: What is the typical lead time for delivery?
A: Standard packages ship within 810 weeks from order confirmation. Turnkey plants require 1620 weeks due to conveyor fabrication and electrical integration.
Q: How does the automatic tramp iron relief system work?
A: When an uncrushable object enters the cone crusher, hydraulic pressure spikes. The accumulator absorbs the force, allowing the bowl to lift 25 mm. The object passes through, and the system resets automatically within 3 seconds.
Q: What is the recommended power supply requirement?
A: 400V / 50 Hz / 3phase (or 480V / 60 Hz). A minimum of 400 kVA transformer is required for the combined jaw and cone system. We provide a detailed electrical load schedule with the technical manual.
Q: Are spare parts interchangeable with other brands?
A: No. The eccentric shaft geometry and bowl liner profile are proprietary. We maintain a 95% fill rate on parts from our regional warehouse. Standard manganese liners are stocked for immediate shipment.
Q: What is the expected annual maintenance cost?
A: For a single shift operation (2,000 hours/year), budget $18,000 $25,000 for wear parts (liners, cheek plates) and $4,000 for lubricants and filters. This excludes unplanned repairs.
Q: Can this equipment be integrated into an existing plant with a different brand crusher?
A: Yes. The feed and discharge chutes are designed with universal bolt patterns. We provide adapter plates for conveyor connections. A site survey is recommended to confirm compatibility.