1. PAINPOINT DRIVEN OPENING

Managing an iron ore crushing plant demands relentless efficiency. When primary crushing systems underperform, the entire downstream process suffers. Are you facing these persistent challenges?

Unscheduled Downtime: Unplanned stoppages for liner changes or mechanical failures in your primary crusher can cost over $15,000 per hour in lost processing capacity.
Inconsistent Feed Size: A poorly configured or worn crushing circuit delivers erratic feed to your secondary and tertiary stages, reducing overall plant throughput by 1020% and increasing specific energy consumption.
High Maintenance Labor Costs: Frequent, manual interventions for clearing bridging or adjusting settings consume hundreds of manhours annually and expose personnel to risk.
Premature Wear Part Failure: Abrasive iron ore rapidly degrades crusher components not engineered for the specific abrasion index and silica content of your deposit, leading to unpredictable cost spikes.
Bottlenecks at Primary Stage: Is your plant’s maximum tonnage limited by the capacity of the first reduction stage, preventing you from capitalizing on market opportunities?

The solution begins with a robust, optimally engineered primary crushing station. The right iron ore crushing plant fabricator addresses these issues at the source.

2. PRODUCT OVERVIEW: HEAVYDUTY PRIMARY CRUSHING STATION

This product is a engineered primary crushing station, specifically designed for the continuous, hightonnage reduction of runofmine (ROM) iron ore. It is a complete system solution, not merely individual equipment.

Operational Workflow:
1. Dump/Feed: ROM ore (up to 1500mm) is dumped directly from haul trucks into a rugged vibrating grizzly feeder (VGF).
2. Primary Separation & Crushing: The VGF removes natural fines and directs oversize material into a heavyduty jaw or gyratory crusher for initial reduction.
3. Discharge & Conveyance: Crushed product is discharged onto a main conveyor system for transport to downstream processing stages.

Application Scope: Ideal for greenfield projects or major expansion upgrades requiring reliable primary reduction of abrasive magnetite or hematite ores with compressive strengths up to 350 MPa.

Limitations: This stationary crushing plant solution requires civil foundations and is designed for highcapacity operations (>750 mtph). For smaller, mobile, or temporary operations, a different system configuration is recommended.

3. CORE FEATURES

HeavyDuty Vibrating Grizzly Feeder (VGF) | Technical Basis: Highstrength steel deck with replaceable grizzly bars | Operational Benefit: Scalps fines efficiently to reduce crusher load and prevents direct truck impact on the crusher | ROI Impact: Extends crusher liner life by up to 25% and improves total system throughput

Hydrostatic Crusher Drive | Technical Basis: Direct drive system with variable hydraulic power | Operational Benefit: Enables smooth startup under full load and provides reversible operation to clear blockages | ROI Impact: Eliminates shear pin replacements and reduces blockagerelated downtime by over 80%

Modular Liner Design | Technical Basis: Segmented manganese steel liners secured mechanically | Operational Benefit: Allows for partial liner replacement and reduces changeout time | ROI Impact: Cuts liner maintenance downtime by half compared to monolithic designs

Advanced PLC Automation Interface | Technical Basis: Centralized control with load management algorithms | Operational Benefit: Optimizes feed rate based on motor amperage and cavity level for peak efficiency | ROI Impact: Delivers consistent product size while maximizing energy efficiency per ton crushed

Structural Integrity & Access Design | Technical Basis: Finite Element Analysis (FEA) optimized chassis with integrated walkways | Operational Benefit: Provides exceptional stability under shock loads and ensures safe, easy access for maintenance | ROI Impact: Reduces structural fatigue risks and improves technician efficiency during inspections

Dust Suppression Integration Points | Technical Basis: Preengineered nozzle mounting locations at transfer points | Operational Benefit: Facilitates effective dust control system integration from day one of operation | ROI Impact: Ensures compliance with environmental standards without costly postinstallation modifications

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Iron Ore Crushing Plant Solution | Documented Advantage |
| : | : | : | : |
| Liner Life (Abrasive Ore)| 800,000 1M tonnes| 1.2M 1.5M tonnes| +40% improvement |
| Mean Time Between Failures (MTBF)| ~1,200 hours| >1,800 hours| +50% reliability increase |
| Tonnage per kWh| Varies by ore type| Field data shows consistent 58% improvement| Higher energy efficiency |
| Primary Crushing Availability| 9294%| Consistently >96%| +24% uptime gain |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 750 to 3,000+ metric tons per hour (mtph), based on crusher selection and ore characteristics.
Crusher Options: Heavyduty jaw crushers (1200x1500mm) or primary gyratory crushers (54” / 1370mm).
Power Requirements: Main crusher drive from 200 kW to 450 kW; total station power draw dependent on configuration.
Material Specifications: Crusher liners in premium manganese steel (1822%); structural steel grade S355JR; wear plates on feed area AR400.
Physical Dimensions (Typical Station): Approx. Length: 25m, Width: 12m, Height (above foundation): 9m. Custom engineering available.
Environmental Operating Range: Designed for ambient temperatures from 30°C to +50°C; dust and weatherprotected electrical components.

6. APPLICATION SCENARIOS

Magnetite Concentrator Expansion – Western Australia

Challenge: A major producer needed to debottleneck their existing plant limited by a legacy primary crusher causing inconsistent feed and excessive maintenance.
Solution: Implementation of a new turnkey primary crushing station with a gyratory crusher and advanced feed control logic.
Results: Achieved a sustained throughput increase of 22%. Maintenance hours on the primary circuit decreased by 35%, contributing to an overall plant availability increase.

Hematite Direct Shipping Ore (DSO) Operation – Pilbara Region

Challenge: High silica content in the ore body was causing accelerated wear in their standard jaw crusher setup, leading to weekly liner inspections and monthly changes.
Solution: Fabrication and installation of a heavyduty jaw crushing station featuring our modular liner design and materialgrade upgrades specific to high abrasion.
Results: Liner life extended from an average of 28 days to over 42 days between changes. This reduced annual liner costs by approximately $180,000 AUD and freed up significant maintenance resources.

7. COMMERCIAL CONSIDERATIONS

Our iron ore crushing plants are offered in clear pricing tiers based on capacity:

Tier I (<1,200 mtph): Standard heavyduty jaw crusherbased stations with core automation.
Tier II (1,200 – 2,200 mtph): Advanced jaw or midrange gyratory options with enhanced automation packages.
Tier III (>2 ,200 mtph):) Fullscale gyratory systems with comprehensive instrumentation , predictive maintenance sensors ,and custom engineering.

Optional features include skidmounted vs modular designs ,onboard weighing systems ,and advanced rock fragmentation analysis camera integration.

We offer tiered service packages:
1. Foundation supervision & commissioning support
2.Comprehensive multiyear parts & inspection plans
3.Fullsite operation & maintenance contracts

Financing options including leasetoown structures are available through our industrial finance partners ,enabling capital expenditure preservation.

8.FAQ

Q:What if my existing downstream circuit isn't sized for increased primary output?
A:A detailed review of your entire flow sheet is part of our presale engineering process.We will identify any potential bottlenecks andrecommend phased upgrade options if necessary ensuring balanced performance across your plant without creating new issues.

Q.How do you ensure compatibility with my mine's specific geotechnical data?
A.We require key parameters including your ore's compressive strength abrasion index Bond Work Indexand desired final product size.This data directly informs our selectionofcrushe cavity kinematicsliner metallurgyand drive powerfor optimal performance inyour application.

Q.What isthe typical lead timefrom orderto commissioning?
A.For standard TierIII configurationslead times range from8to12months dependingon current foundry schedulesfor major castings.Detailed project schedulingis provided upon initial engagement

Q.Are spare parts guaranteedto be available longterm?
A Yes We maintaina globalinventoryof criticalwear partsand provideguaranteed production runsfor major componentsfora minimumof10years afteryour purchase supportingthelongterm lifecycleofyour investment

Q.Do you provideoperator trainingwiththe installation?
A Yes Comprehensive trainingfor bothoperationsandmaintenance crewsonsiteis includedinour commissioning packageWe also providefullsystem documentationincludingdigitalmanualsand recommendedprocedures