1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Gérez-vous une opération de production de granulats à moyenne ou grande échelle et faites-vous face à des goulots d'étranglement persistants qui érodent la rentabilité ?? Common challenges with conventional setups include:
Débit incohérent: Fluctuations in feed material hardness or size leading to unpredictable 250300 Sortie TPH, causing downstream delays.
Temps d'arrêt excessif: Frequent maintenance stops due to component wear or system failures, directly costing over $5,000 par heure de perte de production et de main d'œuvre.
Complexité opérationnelle élevée: Multiple standalone units requiring separate setup, étalonnage, and operator oversight, increasing labor costs and error potential.
Inflexible Product Specification Changes: Difficulty adapting to changing market demands for different aggregate sizes without significant reconfiguration time.

How do you achieve a steady 250300tph output with lower costperton, maximize equipment uptime, and gain the flexibility to meet varied product specs? The answer lies in a purposeengineered 250300tph stone crushing plant.

2. APERÇU DU PRODUIT

This product is a complete stationary crushing and screening solution engineered for continuous, production en grande série de granulats. It is designed as an integrated circuit to reliably process hard rock (granit, basalte) and abrasive materials into precisely graded final products.

Flux de travail opérationnel:
1. Concassage primaire: Matière première de grande taille (jusqu'à 750 mm) est réduit par un concasseur à mâchoires primaire robuste.
2. Secondaire & Concassage Tertiaire: Material is conveyed to cone crushers for further size reduction, ensuring cubical product shape.
3. Dépistage & Classification: Vibrating screens separate material into required size fractions.
4. Stockage & Convoyage: Finished products are conveyed to designated stockpiles via radial stackers.

Champ d'application & Limites:
Portée: Idéal pour les opérations de grandes carrières, grands projets d'infrastructures (autoroutes, chemins de fer), et alimentation commerciale pour centrales à béton/asphalte. Suited for processing granite, calcaire, pierre de rivière, and other similar minerals.
Limites: Not designed for very soft or sticky materials like clay without preprocessing. Requires stable foundation and adequate electrical supply. Feed size must comply with primary crusher opening specifications.

3. CARACTÉRISTIQUES PRINCIPALES

Système de contrôle intelligent | Base technique: Centralized PLC with touchscreen HMI | Avantage opérationnel: Enables singlepoint monitoring and control of the entire 250300tph stone crushing plant flow, reducing operator workload by an estimated 30% | Impact sur le retour sur investissement: Faster troubleshooting and optimized performance reduce nonproductive time by up to 15%

Station principale robuste | Base technique: Deepchamber jaw crusher with reinforced frame and oversized bearings | Avantage opérationnel: Consistently handles tough feed conditions with less risk of bridging or premature wear | Impact sur le retour sur investissement: Extended service intervals on wear parts lower maintenance costperton by an average of 18%

Réglage hydraulique & Clairière | Base technique: Integrated hydraulic systems on cone crushers | Avantage opérationnel: Allows operators to adjust CSS or clear cavities in minutes without manual disassembly | Impact sur le retour sur investissement: Réduit les temps d'arrêt pour les ajustements de routine jusqu'à 80% par rapport aux systèmes manuels

MultiStage Screening Precision | Base technique: HighG force vibrating screens with deck tensioning systems | Avantage opérationnel: Delivers sharp product separation and high screening efficiency even under highload conditions | Impact sur le retour sur investissement: Reduces recirculating load and improves final product yield, maximizing saleable material output

Suppression de la poussière intégrée | Base technique: Strategically placed spray nozzles fed by a highpressure pump system | Avantage opérationnel: Contrôle efficacement la poussière aux points de transfert, améliorer la sécurité des sites et le respect de l'environnement | Impact sur le retour sur investissement: Avoids regulatory fines and reduces wear on machinery from abrasive dust

Conception structurelle modulaire | Base technique: Prefabricated walkways, plates-formes, and support structures | Avantage opérationnel: Simplifies installation and future reconfiguration or relocation of the plant | Impact sur le retour sur investissement: Cuts initial installation time by approximately 25%, accélérer les délais de production

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Conventional Setup) | Cette solution d'usine de concassage de pierre de 250 300 tph | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité moyenne | 8588% (arrêts planifiés/imprévus) | Les données de terrain sont cohérentes >92% availability over annual cycles| +5% amélioration |
| Consommation d'énergie par tonne| Based on disparate motor loads per unit| Optimized system design with loadsensing conveyors reduces total draw| Jusqu'à 12% plus efficace |
| Durée de vie des pièces d'usure (Primaire)| Varies significantly with abrasiveness| Proprietary alloy jaws & liners demonstrate longer life in controlled tests| +2030% durée de vie prolongée |
| Indice de forme du produit (Cubicité)| Dependent on secondary stage only| Multichamber cone crushing ensures controlled fracture across stages| Improved cubicity by ~15% |
| Temps de reconfiguration| Manual adjustment can take multiple shifts| Hydraulic settings allow major changes within a single shift|50% plus rapide |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité conçue: 250 300 tonnes métriques par heure (varie en fonction de la densité du matériau & dureté).
Concasseur primaire: Modèle de concasseur à mâchoires [par ex., PE900x1200], Ouverture d'alimentation 900 mm x 1 200 mm.
Concasseurs secondaires/tertiaires: Two units of Cone Crushers [par ex., HPC315], each with hydraulic adjustment.
Unités de dépistage: Two sets of TripleDeck Inclined Vibrating Screens [par ex., 3YK2870].
Exigence de puissance: Puissance totale installée environ 550650 kW; nécessite une alimentation industrielle stable.
Spécifications des matériaux clés: Châssis principal fabriqué en acier Q345B; Wear plates use Mn18Cr2 highmanganese steel; Conveyor belts rated for heavy impact (EP400/3).
Empreinte approximative (Lxl): ~85m x 45m (layout dependent on site specifics).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C avec des options de lubrification appropriées.

6. SCÉNARIOS D'APPLICATION

Projet d'agrandissement de la carrière de granit

Challenge A quarry needed to increase output from 180tph to a steady 280tph to fulfill a highway construction contract but had space constraints limiting extensive new foundations.
Solution Implementation of our compact modular design for a complete stationary crushing plant allowed integration into the existing flow. The focus was on the highcapacity cone crushers for secondary/tertiary stages.
Results The plant achieved sustained throughput of >290tph of granite aggregate meeting strict ASTM specs. The modular design cut installation time by six weeks versus traditional builds.

Commercial Aggregate Supplier Diversification

Challenge A regional supplier faced fluctuating demand between concrete chips (19mm) and road base material (40mm). Changing product specs with their old multiunit setup caused fullday production halts.
Solution A new integrated circuit featuring cone crushers with rapid hydraulic CSS adjustment was installed as their primary stone crushing plant solution.
Results Changeover time between major product specifications was reduced from over eight hours to under ninety minutes. This flexibility allowed the supplier to capture spotmarket contracts profitably.

7. CONSIDÉRATIONS COMMERCIALES

Nos solutions sont proposées dans des configurations à plusieurs niveaux:

1. Standard Configuration Includes primary jaw crusher secondary cone crusher tertiary cone crusher screens basic conveyors dust suppression steel structure control panel
2 Premium Configuration Adds automated grease lubrication systems metal detectors magnetic separators onboard generator compatibility more comprehensive walkways
3 Customized Configuration Engineered for specific feed materials or extreme output requirements e g additional pre screening scalping unit special wear liners

Optional Features Advanced rock level sensors remote monitoring telemetry package sound enclosures heated lube systems

Service Packages We offer tiered annual service agreements covering scheduled maintenance parts discounts priority technical support Operator training programs are included with every installation

Financing Options We work with international export finance partners can facilitate leasing structures or milestone based payment plans tailored for large capital equipment purchases

8 FAQ

Q What is the lead time from order confirmation delivery?
A For standard configurations lead time is typically weeks months depending on final specifications Custom designs require additional engineering time Detailed schedules are provided upon project initiation

Q How does this plant handle variations in feed material hardness?
A The core design uses robust crushers sized above nominal capacity providing headroom Cone crushers hydraulic overload protection automatically handle momentary hardness spikes preventing damage minimizing unplanned stops

Q What are the ongoing operational costs we should budget?
A Primary costs are energy wear parts replacement labor Field data indicates average cost per ton processed factoring these elements typically ranges X Y currency units depending local power rates Regular planned maintenance is critical controlling long term costs

Q Is technical training provided our operations team?
A Yes comprehensive onsite training conducted commissioning covers daily operation routine maintenance safety procedures basic troubleshooting Documentation includes detailed operation maintenance manuals English local language requested available

Q Can we integrate existing equipment like our current primary crusher into new system?
A Engineering assessment required determine compatibility control integration conveyor interfacing Many projects incorporate one two existing major units reduce overall investment cost feasibility study can confirm this option