1. PAINPOINT DRIVEN OPENING

Managing an iron ore crushing circuit presents distinct, costly challenges. Are you experiencing any of these operational and financial pressures?

High Abrasion Costs: The extreme abrasiveness of iron ore, particularly hematite and magnetite, leads to rapid wear on crusher liners, hammers, and mantles. This results in frequent, expensive component replacement and significant unplanned downtime for maintenance.
Throughput Bottlenecks: Inconsistent feed size or capacity mismatches between primary, secondary, and tertiary crushing stages limit overall plant throughput. This bottleneck directly constrains production volume and revenue potential.
Unpredictable Downtime: Component failures or the need for liner changes often occur with insufficient warning, disrupting the entire downstream processing chain—from grinding to beneficiation—and impacting shipment schedules.
Energy Inefficiency: Older or improperly configured crushing equipment consumes excessive power per ton of material processed, making energy one of the highest variable costs in your comminution circuit.
Product Quality Issues: Inconsistent final product sizing, with too many fines or oversized lumps, negatively impacts downstream grinding efficiency and pelletizing or sintering performance.

Is your current setup maximizing availability and minimizing cost per ton? The right iron ore crushing plant is not just a purchase; it’s a strategic investment in predictable throughput and controlled operational expenditure.

2. PRODUCT OVERVIEW

Our engineered Iron Ore Crushing Plant solutions are complete, semifixed or modular systems designed for primary, secondary, and tertiary reduction of runofmine (ROM) iron ore. These plants are configured to transform large, abrasive feed (up to 1500mm) into a consistent, conveyable product typically under 30mm for direct feed to grinding circuits or beneficiation.

Operational Workflow:
1. Primary Dumping & Grizzly: ROM ore is dumped into a hopper with a grizzly section, allowing naturally sized fines to bypass the primary crusher, increasing efficiency.
2. Primary Crushing: A heavyduty jaw crusher or gyratory crusher performs initial size reduction to a manageable diameter for conveying.
3. Secondary & Tertiary Crushing: Cone crushers equipped for abrasive service further reduce the material in closedcircuit configurations with sizing screens to ensure precise product specification.
4. Material Handling & Stockpiling: A network of heavyduty conveyors transfers crushed product between stages and to designated stockpiles.

Application Scope & Limitations:
These plants are engineered specifically for hard rock mining applications processing iron ores (magnetite, hematite). They are less suitable for soft or nonabrasive materials where different crusher technology would be more costeffective. Optimal performance requires proper mine planning to manage feed size distribution within design parameters.

3. CORE FEATURES

Advanced Liner Technology | Technical Basis: Highchrome white iron alloys & optimized profile design | Operational Benefit: Liner life extended by 3050% compared to standard manganese steel in abrasive iron ore service | ROI Impact: Reduces liner change frequency and associated labor/downtime costs directly lowering cost per ton.

Intelligent Crushing Chamber Automation | Technical Basis: Hydroset or similar hydraulic adjustment systems with realtime pressure monitoring | Operational Benefit: Allows operators to adjust crusher settings remotely under load to maintain product size during wear | ROI Impact: Maintains consistent product quality for downstream processes and maximizes throughput without manual intervention.

Modular Skid Design | Technical Basis: Preassembled structural steel skids with integrated walkways and maintenance platforms | Operational Benefit: Reduces onsite civil works and installation time by up to 40% | ROI Impact: Faster commissioning accelerates timetorevenue; modules facilitate future plant reconfiguration or relocation.

Centralized Greasing & Lube System | Technical Basis: Automated singlepoint lubrication system with failsafes and blockage indicators | Operational Benefit: Ensures critical bearings receive correct lubrication without manual greasing, preventing premature failures | ROI Impact: Eliminates a major source of unplanned downtime and extends major component lifecycles.

HeavyDuty Vibrating Grizzly Feeder (VGF) | Technical Basis: Robust deck construction with replaceable liners and high Gforce capability | Operational Benefit: Removes fines prior to primary crushing while handling sticky ores without clogging | ROI Impact: Increases effective primary crusher capacity by up to 15% by eliminating fines processing where not needed.

Dust Suppression Integration Points | Technical Basis: Preplumbed water line connections at all transfer points compatible with foam/dust suppression systems | Operational Benefit: Minimizes airborne particulate at source for improved site safety and environmental compliance | ROI Impact: Reduces health risks and potential regulatory penalties while preserving equipment health.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Abrasive Ore) | Our Iron Ore Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life (Primary/Secondary) | Based on Standard Manganese Steel / Basic Cones | HighChrome Alloy Liners & Optimized Chamber Design| +35% Average |
| Plant Availability (%)| ~8588% (Scheduled & Unscheduled Downtime) |>92% (via Predictive Monitoring & Modular Maintenance)| +57 Percentage Points |
| Energy Consumption (kWh/t) Varies by ore competency.| Baseline Reference System| Efficient Drive Systems & Optimized Flow Design| Reduction of 812% |
| Installation & Commissioning Time| Full OnSite Fabrication & Assembly| Preassembled Skid Modules & PlugandPlay Wiring| Reduction of ~35% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 500 TPH to over 2,500 TPH nominal throughput.
Power Requirements: Primary crusher drive motors from 200kW up to 600kW; total plant connected load varies by configuration. Designed for highvoltage (6.6kV/11kV) motor supply where applicable.
Material Specifications: Crusher liners utilize ≥27% chrome iron alloys; structural steel is Grade S355JR; wear plates on chutes/hoppers are AR400 minimum.
Physical Dimensions (Example Primary Module): Approx. Length: 18m x Width: 8m x Height: 9m (excluding feeder). Modular design allows flexible layout adaptation.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; dustprotected electrical enclosures (IP65); suitable for operation up to 3000m altitude with motor derating considerations.

6. APPLICATION SCENARIOS

Magnetite Concentrator Expansion Challenge:

A magnetite producer needed to debottleneck their existing circuit ahead of new grinding lines.Solution Implementation:
A semimobile tertiary crushing plant was installed in closed circuit with fine screens.Results:
Produced a consistent 8mm feed for HPGR circuits.This increased overall concentrator throughput by 22% while reducing specific energy consumption in downstream grinding by an estimated 9%.

Direct Shipping Ore (DSO) Operation Challenge:

A DSO mine faced high costs from frequent jaw crusher liner changes due to highly abrasive banded iron formation.Solution Implementation:
Replacement of standard jaw plates with our proprietary highchrome alloy liners within their existing primary station.Results:
Liner life increased from approximately 550k tons to over 800k tons.This extended campaign life reduced annual planned downtime events by two cycles,yielding an annual saving on liner costs alone exceeding budget projections.

7. COMMERCIAL CONSIDERATIONS

Our Iron Ore Crushing Plants are offered in tiered configurations:

Standard Duty Tier: For lowercapacity (<1000 TPH) or less severe abrasion applications.Focuses on core reliability with essential features.
Heavy Duty Tier: Recommended for mainstream operations processing >1000 TPH of abrasive ores.Includes all core features listed above as standard.
Ultra Duty Tier: For megaprojects requiring maximum availability.Includes advanced predictive monitoring sensors,bucketstyle maintenance platforms,and premium component packages.

Optional features include automated wear part measurement systems,mobile lifting beams,and integrated water spray systems.Comprehensive service packages range from basic commissioning support through fullsite operation & maintenance contracts.Financing options including leasetoown models can be structured over typical asset lifespans(715 years),aligning payment schedules with production cash flow.

8. FAQ

1.Q:What if my existing infrastructure uses different conveyor widths or electrical voltages?
A.All our modular plants can be engineered at the interface points(discharge height,belt width,motor control voltage)to match your site's existing specifications ensuring compatibility

2.Q.How does this solution impact my ongoing manpower requirements?
A.Field data shows that centralized lubrication,easier access designs,and longer component life reduce routine maintenance hours by approximately20%.The system does not typically require additional operational staff

3.Q.What is the typical delivery lead time?
A.For standard heavyduty tier configurations lead times range from812 months from order placement factoring engineering procurement fabrication testing

4.Q.Are spare parts guaranteed available?
A.We maintain strategic global inventory hubs specifically for critical wear parts like liners.Customers can opt into guaranteed spare part holding agreements

5.Q.Can you provide performance guarantees?
A.YES we offer contractual guarantees on key metrics including rated throughput power consumption under defined conditionsand major mechanical component warranty periods

6.Q.Do you assist with foundation drawings
and installation supervision?
A.Detailed foundation general arrangement drawingsare provided as part of the engineering package.Onsite supervision during erectionand commissioning is available as a service option

7.Q.How do you handle aftersales technical support?
A.Support is provided through regional service engineers supplementedby24/7 remote diagnostic access via equipment telemetrywhere opted