1. PAINPOINT DRIVEN OPENING

Are your limestone quarrying operations struggling with the balance between productivity and cost control? Common challenges include:

High Drilling & Blasting Costs: Inefficient fragmentation leads to excessive explosive use, secondary breaking requirements, and increased wear on primary crushers.
Frequent Downtime for Maintenance: Unplanned equipment failures in harsh, abrasive limestone dust environments halt your entire processing chain.
Low Loader & Hauler Efficiency: Poorly sized or inconsistent feed material from the face reduces cycle times and increases fuel consumption per ton.
Rising Operational Overheads: Labor, energy, and consumable costs are compressing your profit margins on every cubic meter extracted.
Strict Environmental & Community Compliance: Managing noise, vibration, and dust emissions is increasingly critical for maintaining your social license to operate.

How can you reduce your costperton without sacrificing reliable output? The answer lies in optimizing the initial extraction and primary reduction phases with purposeengineered equipment.

2. PRODUCT OVERVIEW

The core of a costeffective limestone mining operation begins with a highperformance Primary Jaw Crusher specifically configured for abrasive rock. This equipment serves as the first critical size reduction stage, directly impacting downstream efficiency.

Operational Workflow:
1. Excavated limestone shot rock is fed via dump truck or loader into the crusher’s vibrating grizzly feeder (VGF).
2. The VGF removes fines and bypasses subsize material, directing only oversize rock to the crushing chamber.
3. A robust, oscillating jaw exerts immense compressive force to break large boulders into manageable, consistently sized output.
4. Crushed material is discharged onto a main conveyor for transport to secondary crushing or stockpiling.

Application Scope: Ideal for stationary primary crushing plants in largescale quarrying. Best suited for compressive strength rock under 350 MPa.

Limitations: Not designed as a mobile unit for frequent relocation. Feed size must be controlled within the crusher’s designed maximum opening.

3. CORE FEATURES

HeavyDuty Frame & Welded Structure | Technical Basis: Finite Element Analysis (FEA) optimized stress distribution | Operational Benefit: Eliminates frame fatigue cracking under cyclical loading; withstands decades of highimpact forces | ROI Impact: Extends structural service life beyond 20 years, eliminating premature capital replacement costs.

AbrasionResistant Jaw Dies & Cheek Plates | Technical Basis: Highgrade manganese steel with optimized tooth profile geometry | Operational Benefit: Maintains effective nip angle longer, ensuring consistent throughput and product gradation between changes | ROI Impact: Reduces liner changeout frequency by 1525%, lowering parts inventory and labor hours dedicated to maintenance.

Hydraulic Toggle Adjustment System | Technical Basis: Integrated hydraulic cylinders replace traditional mechanical shims | Operational Benefit: Allows operators to adjust the crusher discharge setting safely in minutes versus hours, even while empty | ROI Impact: Minimizes noncrushing time for product size adjustments; improves responsiveness to changing product demand.

HighStroke Elliptical Motion | Technical Basis: Aggressive elliptical jaw motion at the feed opening | Operational Benefit: Promotes accelerated rock breakage at the top of the chamber, reducing bridging and improving overall throughput capacity | ROI Impact: Increases processed tons per hour (TPH) by 510% within the same machine footprint compared to standard kinematics.

Integrated Motor Base & Belt Guard | Technical Basis: Unified baseplate design with fully enclosed belt guards | Operational Benefit: Simplifies installation alignment, reduces site fabrication work, and enhances operator safety around drive components | ROI Impact: Cuts installation time and costs by up to 30% while ensuring compliance with global safety standards from day one.

Centralized Greasing Point & Labyrinth Seals | Technical Basis: Singlepoint lube system for all major bearings; multistage sealing barriers | Operational Benefit: Enables routine bearing lubrication in under 10 minutes; effectively excludes limestone dust from bearing housings | ROI Impact: Prevents costly bearing failures—the leading cause of unplanned crusher downtime—extending mean time between failures (MTBF) significantly.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Average | Our Primary Jaw Crusher Solution | Documented Advantage |
| : | : | : | : |
| Availability (Uptime %) | 88 92% | 94 96%| +4% improvement |
| Manganese Wear Life (Million Tons) | 0.8 1.2 MTon| 1.4 1.6 MTon| +30% improvement |
| Power Consumption (kWh/Ton) for hard limestone| 0.8 1.0 kWh/Ton| 0.65 0.75 kWh/Ton| ~20% improvement |
| Discharge Setting Adjustment Time from open to closed side| ~24 hours (mechanical)| <15 minutes (hydraulic)| ~90% time savings |

Field data based on comparative installations in comparable limestone formations.

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: 300 – 1,500 Metric Tons per Hour (MTPH)
Feed Opening Range: Up to 1500mm x 1200mm (59" x 47")
Max Feed Size: Up to ~85% of gape width
Drive Power Requirement: 90 kW – 250 kW (125 HP – 350 HP), depending on model
Crusher Weight (Frame & Flywheels): From ~25,000 kg to ~70,000 kg
Key Material Specifications:
Main Frame: Fabricated steel plate, stressrelieved
Jaw Dies / Cheek Plates: Premium Manganese Steel (14%,18%,22%)
Shaft / Bearings: Forged alloy steel / Spherical roller bearings
Toggle Plate / Beam: Ductile cast iron / Alloy steel
Operating Temperature Range: 20°C to +45°C (4°F to +113°F)
Dust Mitigation: Prepared for water spray nozzle integration on VGF and feed chute

6. APPLICATION SCENARIOS

LargeScale Aggregate Quarrying Operation

Challenge A major Midwest producer faced escalating costs from secondary breaking and premature wear on cone crushers due to poor primary fragmentation from an aging jaw crusher.
Solution Installation of a highcapacity primary jaw crusher with an aggressive stroke profile optimized for their specific limestone geology.
Results Product gradation from the primary stage improved immediately; +12% increase in total plant throughput was achieved within one quarter due to reduced bottlenecks downstream.

Cement Plant Integrated Quarry

Challenge A cement plant needed higher reliability from its captive quarry crusher to ensure consistent raw meal supply; unplanned stops were halting kiln feed preparation.
Solution Replacement with a new generation jaw crusher featuring centralized lubrication and enhanced sealing systems specifically for highdust environments.
Results Crusher availability increased from an average of 95%. Annual maintenance labor hours dedicated to the primary station were reduced by an estimated two full weeks per year.

7. COMMERCIAL CONSIDERATIONS

Our primary jaw crushers are offered in three valueengineered tiers:

1. Standard Duty Tier: For consistent feed with moderate abrasiveness/impact risk.
2.
3.HeavyDuty Tier (Recommended for most limestone applications): Includes all features listed in Section III as standard.
4.ExtremeDuty Tier: For operations with highly variable feed or exceptionally hard/abrasive inclusions; includes upgraded components throughout.

Optional features include automated grease systems, motor starters/VFDs integrated into control panels, wear monitoring systems via IoT sensors,and custom discharge conveyor flanges.Financing options include capital purchase,direct leasetoown agreements,and tailored service contracts covering planned maintenance,inspections,and guaranteed parts availability.Service packages are structured around guaranteed uptime agreements,supported by our global network of field service engineers specializing in mineral processing equipment

FAQ

Q What is required for foundation installation?
A Detailed civil engineering drawings are provided specific t o each model These designs account f or dynamic loads Our team offers optional site review services prior t o pour

Q How does this unit integrate int o my existing plant layout?
A Our engineering department can review your current flow sheet an d conveyor heights We provide comprehensive interface drawings t o ensure smooth integration minimizing retrofit costs

Q What is th e typical lead time f or delivery?
A Lead times vary based o n model specification an d customization Standard heavy duty models typically ship within weeks following order confirmation

Q Are training programs available f or our operations an d maintenance staff?
A Yes Comprehensive onsite training covering safe operation routine maintenance procedures troubleshooting an d liner change out protocols i s included with every installation

Q Do you offer performance guarantees?
A Yes we provide guaranteed capacity throughput based o n agreed feed material analysis along with mechanical warranties covering all major components against defects i n materials an d workmanship