1. PAINPOINT DRIVEN OPENING

Are your iron ore processing operations constrained by inconsistent feed size, unplanned downtime, and spiraling maintenance costs? In a highvolume, abrasive material environment, the primary crushing stage dictates the efficiency of your entire downstream circuit. Common challenges include:

Excessive Downtime for Liner Changes: Frequent shutdowns to replace worn manganese steel in jaw crushers directly reduce annual throughput and increase labor costs.
Unplanned Stoppages from Tramp Metal: A single uncrushable contaminant can cause significant damage, leading to hours of lost production and expensive component repair.
Inconsistent Product Size Distribution: An improperly configured or overloaded primary crusher delivers poorly graded feed to secondary crushers and screens, creating bottlenecks and reducing overall plant yield.
High Operational Costs: The combined expense of power consumption for underoptimized equipment, replacement wear parts, and associated labor erodes profit margins.

Is your primary crushing station a reliable asset or a recurring bottleneck? The solution begins with selecting a robust system engineered for maximum uptime and lowest costpertonne.

2. PRODUCT OVERVIEW

The Wholesale Iron Ore Crushing Plant is a heavyduty, stationary primary crushing system designed for highcapacity reduction of runofmine (ROM) iron ore. Engineered for continuous operation in demanding environments, it serves as the foundational stage in mineral processing circuits.

Operational Workflow:
1. ROM iron ore (up to 1.5m lump size) is fed via dump truck or shovel into a rugged vibrating grizzly feeder (VGF).
2. The VGF removes sub100mm fines to bypass the crusher, reducing wear and improving efficiency, while directing oversize material into the primary crusher.
3. A robust jaw crusher or gyratory crusher performs the initial compression crushing, reducing ore to a nominal 250300mm product.
4. Crushed material is discharged onto a main conveyor for transport to secondary crushing or stockpile.

Application Scope & Limitations:
Scope: Ideal for greenfield mining projects, plant expansion upgrades, or replacement of aging, inefficient primary stations. Suited for processing magnetite, hematite, and other ironbearing ores.
Limitations: This is a primary crushing solution; full beneficiation requires downstream secondary/tertiary crushing, screening, and processing modules. Feed size must adhere to designed maximum dimensions.

3. CORE FEATURES

HeavyDuty Vibrating Grizzly Feeder (VGF) | Technical Basis: Highstrength steel construction with adjustable grizzly bars | Operational Benefit: Scalps fines to increase effective crusher capacity by up to 30% and protects the crusher from excessive wear caused by fines | ROI Impact: Reduces crusher liner wear costs and increases total system throughput without additional crushing power.

Hydrostatic Crusher Drive System | Technical Basis: Direct hydraulic drive for the main crusher versus traditional Vbelt systems | Operational Benefit: Provides smooth startup under load, reversible operation to clear blockages, and infinite variable speed control for optimal throughput | ROI Impact: Eliminates belt maintenance costs and reduces energy consumption during startup cycles by approximately 15%.

Modular Jaw Crusher Design | Technical Basis: Bolttogether frame sections and symmetrical jaw die configuration | Operational Benefit: Enables faster onsite assembly and allows jaw dies to be rotated endforend or swapped topforbottom to utilize 100% of the wear material | ROI Impact: Extends service intervals by up to 40% and reduces liner inventory requirements.

Integrated Tramp Metal Protection | Technical Basis: Hydraulic toggle relief system on jaw crushers or manifold system on gyratories | Operational Benefit: Automatically releases uncrushable material (e.g., drill bits, bucket teeth) without stopping the crusher, then resets to original setting | ROI Impact: Prevents catastrophic damage; field data shows an average avoidance of 50+ hours of unplanned downtime annually.

Centralized Greasing & PLC Automation | Technical Basis: Automated lubrication system with programmable logic controller (PLC) monitoring key parameters (power draw, pressure, temperature) | Operational Benefit: Ensures critical bearings receive precise lubrication without manual intervention and provides operational data for predictive maintenance | ROI Impact: Increases bearing service life by an average of 25% and allows for conditionbased maintenance scheduling.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Wholesale Iron Ore Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life (Manganese) | Fixed jaw design with partial wear utilization | Rotatable & reversible symmetrical jaw dies | +40% wear material utilization |
| System Availability| Mechanical drive with manual clearing procedures| Hydrostatic drive with reversible clearing & auto tramp release| +7% average availability |
| Energy Efficiency| Constant speed motor with peak startup loads| Variable hydrostatic drive with loadsensing control| 12% avg. kWh/tonne crushed |
| Installation Timeline| Welded monolithic base frame construction| Preassembled modular bolttogether sections| 35% field erection time |

5. TECHNICAL SPECIFICATIONS

Capacity Rating: Configurable from 1,500 to 3,500 tonnes per hour (TPH), depending on ore characteristics (density, abrasion index).
Primary Crusher Options: Jaw Crusher (1200x1500mm) or Primary Gyratory Crusher (54”).
Feed Opening: Accepts ROM feed up to 1.5m lump size.
Product Size Setting: Adjustable between 250mm 300mm discharge setting.
Power Requirements: Total installed power range: 450 650 kW. Designed for minegrade electrical supply (6kV/11kV).
Structural Material: Main frame fabricated from hightensile steel plate; liners are premium manganese steel.
Physical Dimensions (Typical Jaw Plant): Approx. Length: 18m x Width: 8m x Height: 8m (excluding feed hopper).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; dust suppression system ready.

6. APPLICATION SCENARIOS

Greenfield Magnetite Mine Development | Challenge: A new operation required a primary station capable of processing highly abrasive magnetite ore at >2,800 TPH with minimal planned downtime for maintenance in a remote location.| Solution: Implementation of our Wholesale Iron Ore Crushing Plant featuring a gyratory crusher with automated lubrication and modular component design.| Results: Achieved nameplate capacity within one week of commissioning. The modular design reduced installation time by five weeks. Predictive data from the PLC enabled scheduled liner changes during planned shifts only.

Existing Hematite Processing Plant Upgrade | Challenge: An aging jaw crusher station was causing bottlenecking due to frequent unplanned stops for tramp metal events and excessive liner wear every six weeks.| Solution: Replacement with our Wholesale Iron Ore Crushing Plant solution featuring hydrostatic drive tramp protection and reversible/rotatable jaw dies.| Results: Unplanned stoppages due to tramp metal were eliminated through automatic release cycles. Liner life extended from six weeks to nine weeks consistently through full die utilization.

7. COMMERCIAL CONSIDERATIONS

Our Wholesale Iron Ore Crushing Plant is offered in tiered configurations based on capacity:

Base Tier (Upgrade): Core plant structure with standard features.
Optional Features:
Advanced PLC automation package
Onboard dust suppression spray system
Spare parts starter kit
Extendedwear component packages

Service packages are available separately:
1. Commissioning & Operator Training Package
2 Annual Preventive Maintenance Inspection Package
3 Comprehensive Parts Supply Agreement

Financing options include direct capital purchase as well as structured leasing agreements designed for largescale industrial equipment procurement cycles.

8.FAQ

Q1 What level of site preparation is required prior to delivery?
A comprehensive foundation drawing package is supplied upon order confirmation detailing all necessary civil works including anchor bolt locations loadbearing requirements

Q2 How does this plant integrate with my existing secondary circuit?
The plant is engineered around standard discharge heights conveyor widths Our engineering team will review your existing layout specifications during quotation

Q3 What is the expected operational lifespan?
With proper preventive maintenance industry testing demonstrates structural components have an expected service life exceeding years Critical wear parts such as liners are consumables based on your specific ore abrasiveness

Q4 Are spare parts readily available?
We maintain regional inventory hubs dedicated stock levels are established based on your selected service package ensuring part availability

Q5 Can you provide performance guarantees?
Yes performance guarantees are provided based on agreed feed specifications including throughput capacity product size distribution power consumption These form part of our commercial proposal

Q6 What training do you provide?
We offer comprehensive training covering safe operation routine maintenance procedures troubleshooting diagnostics This can be conducted at our facility or onsite during commissioning