1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing a midtolarge scale aggregate operation and facing consistent pressure to meet project deadlines while controlling capital and operational expenditure? The challenges of a 250300tph stone crushing plant are significant. Inconsistent feed material causes unexpected wear and downtime on critical components. Bottlenecks in one crushing stage throttle the entire line’s output, leaving capacity unrealized. Rising energy costs directly erode profit margins on every ton produced. En outre, frequent maintenance interrupts production schedules, and configuring a plant for multiple product specifications often requires manual adjustments and costly delays.

How do you achieve reliable 300tonperhour output without excessive maintenance overhead? Can your plant adapt to varying feed hardness and size without sacrificing final product gradation? Is your current solution delivering the expected return on investment through sustained availability and low costperton?

2. APERÇU DU PRODUIT

Ce produit est un complet, stationary 250300tph turnkey stone crushing and screening plant designed for highvolume production of aggregates for road base, béton, et l'asphalte. It is engineered for primary contractors and quarry operators requiring consistent, specificationgrade output.

Flux de travail opérationnel:
1. Concassage primaire: Gros aliments (≤750mm) est réduit par un concasseur à mâchoires robuste ou un impacteur primaire.
2. Secondaire & Concassage Tertiaire: Material is conveyed to cone crushers or secondary impactors for further size reduction and shaping.
3. Dépistage: Multipledeck vibrating screens precisely separate crushed material into required product sizes (par ex., 05mm, 510mm, 1020mm).
4. Manutention des matériaux: A network of conveyors with centralized control transfers material between stages and to final stockpiles.
5. Suppression de la poussière: Integrated spray systems at transfer points control particulate emissions, ensuring environmental compliance.

Champ d'application & Limites:
Portée: Idéal pour le hard rock (granit, basalte), calcaire, and river gravel applications. Suited for permanent installation in large quarry sites or major infrastructure project batching plants.
Limites: Non conçu comme équipement mobile ou semi-mobile. Feed size and material abrasiveness must align with configured crusher chamber selections for optimal performance.

3. CARACTÉRISTIQUES PRINCIPALES

Conception de patins modulaires | Base technique: Préassemblé, steelframed substructures | Avantage opérationnel: Réduit le temps d'installation sur site jusqu'à 40%, ensures precise factory alignment of motors and drives | Impact sur le retour sur investissement: Une mise en service plus rapide accélère la génération de revenus; standardized modules simplify future maintenance.

Système de contrôle de processus intelligent | Base technique: Automatisation basée sur PLC avec algorithmes de partage de charge | Avantage opérationnel: Optimizes crusher feed rates in realtime to prevent choking or running empty; monitors power draw for peak efficiency | Impact sur le retour sur investissement: Reduces energy consumption per ton by an estimated 815% et minimise les erreurs de l'opérateur.

HeavyDuty Wear Component Package | Base technique: Highchrome blow bars, manganese steel jaws/concaves, reinforced screen meshes | Avantage opérationnel: Prolonge les intervalles d'entretien de 3050% dans les applications abrasives, maintains consistent product gradation longer | Impact sur le retour sur investissement: Lowers costperton for wear parts and reduces downtime frequency for component changeouts.

MultiStage Dust Control Integration | Base technique: Strategically placed spray nozzles with solenoid valves tied to conveyor operation | Avantage opérationnel: Effectively suppresses dust at each transfer point, improving site visibility and operator health | Impact sur le retour sur investissement: Mitigates risk of environmental noncompliance fines and reduces cleanup labor.

Graissage centralisé & Système de lubrification | Base technique: Automated pump system with distribution lines to key bearing points | Avantage opérationnel: Ensures critical bearings receive correct lubrication on schedule without manual intervention | Impact sur le retour sur investissement: Empêche la défaillance prématurée des roulements, a leading cause of unplanned downtime.

HighCapacity Vibrating Screens with Deck Access System | Base technique: Large screening area with adjustable throw; passerelles intégrées & plates-formes | Avantage opérationnel: Maximizes screening efficiency; provides safe, easy access for mesh inspection and replacement | Impact sur le retour sur investissement: Improves final product quality control and enhances worker safety during routine checks.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (250300Usine de tph) | This 250300tph Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité des installations | 8588% (y compris la maintenance planifiée) | 92%+ (engineered design) | +47% disponibilité |
| Consommation d'énergie (kWh/tonne)| Varie considérablement; often not optimized per stage| Managed via intelligent load control| Jusqu'à 15% reduction demonstrable |
| Wear Life on Abrasive Rock| Standard manganese/chrome components| Premium alloy selection & optimisation de la chambre| +30% augmentation moyenne |
| Installation & Temps de mise en service| 812 weeks onsite assembly| ~57 weeks (modular skid design)| ~40% de réduction |
| Cohérence de la gradation du produit| Manual feed adjustment leads to variance| Automated setting regulation (ASRitype systems)| Variance improved by up to 25% |

5. SPÉCIFICATIONS TECHNIQUES

Designed Throughput Capacity: 250 300 tonnes métriques par heure (varies based on feed material hardness & répartition des tailles).
Options du concasseur primaire: Curseur de mâchoire (900x1200mm) ou concasseur à percussion primaire (Φ1600x2000mm).
Secondary/Tertiary Crusher: Two units of Hydraulic Cone Crushers (par ex., HPC315).
Screening Stations: Two units of TripleDeck HeavyDuty Vibrating Screens (2400x6000mm).
Puissance totale installée: Environ 800 950 kW.
Spécifications des matériaux clés: Main frame structure fabricated from Q345B steel; wear liners use Mn18Cr2 or equivalent highgrade alloys.
Empreinte globale de l’usine (L x l): ~120m x 85m (layout can be customized).
Plage de fonctionnement environnementale: Conçu pour une température ambiante de 20°C à +45°C; dust emission control meets standard regulatory limits (<20mg/m³ at property boundary).

6. SCÉNARIOS D'APPLICATION

Highway Construction Base Course Production | Défi: A national infrastructure project required consistent supply of three graded aggregates for road base layers from highly abrasive granite. The existing plant struggled with rapid wear and inconsistent sizing, threatening project timelines.| Solution: Implementation of this heavyduty configured plant featuring cone crushers with automated settings control and premium wear packages.| Résultats: Achieved sustained output of 280tph. Wear part life increased by over 35%, reducing changeout downtime. Product gradation consistency met strict highway authority specifications throughout the contract.

Commercial Limestone Quarry Expansion | Défi: A quarry expanding its market needed to increase finished product range without adding separate processing lines or excessive manual sorting.| Solution: Installation of this multistage plant with precise secondary/tertiary crushing circuits and highefficiency multideck screens.| Résultats:The plant reliably produces five distinct products simultaneously—from coarse aggregate to manufactured sand—at a combined rate exceeding 270tph, enabling entry into new concrete and asphalt mix markets.

7. CONSIDÉRATIONS COMMERCIALES

Our approach provides clarity in investment planning:

Niveaux de tarification: We offer three standard configurations:
Essentiel: Core crushing & screening modules for reliable singleproduct output.
Advanced: Includes automation systems, enhanced dust control, wider conveyor specification.
Prime: Full turnkey package with premium wear materials package extended warranty coverage

Fonctionnalités facultatives & Mises à niveau: Specific options include automated metal detection/rejection systems advanced rockonrock shaping chambers additional sound attenuation enclosures remote monitoring telematics packages

Forfaits de services: Choose from annual maintenance contracts providing scheduled inspections guaranteed spare parts delivery priority technical support Extended warranty plans are available covering major structural components

Options de financement: We work with established financial partners offer flexible leasing arrangements milestonebased project financing solutions tailored capital expenditure plans

8.FAQ

1.Q:What if our feed rock hardness exceeds the standard design parameters?
UN:The plant's core structural design accommodates high loads but we conduct a detailed feed material analysis during quotation For extremely hard or abrasive materials we specify upgraded wear component alloys chamber geometries ensure designed throughput longevity

2.Q How does this plant manage fluctuations in incoming feed size?
A The intelligent process control system regulates feeder speeds based realtime crusher motor load preventing choking This combined surge pile capacity before primary crusher smooths out typical frontend loader variation

3.Q What typical timeframe expected from order placement commissioning?
A For standard configuration lead time manufacturing shipping approximately months Onsite installation commissioning modular skid design typically requires weeks depending local civil works readiness

4.Q Are spare parts readily available longterm?
A Yes We maintain global inventory strategic wear parts provide guaranteed stockholding agreements as part service packages All major mechanical electrical components internationally standardized brands ensuring supply chain redundancy

5.Q Can existing equipment integrated into new plant?
A Potentially yes An initial audit your current conveyors screens can determine compatibility integration feasibility often possible especially material handling equipment reducing overall project cost

6.Q What ongoing operational staffing requirements?
A The automated central control system allows efficient operation primary operators monitoring stations Additional personnel required routine mechanical checks stockpile management but labor intensity significantly lower versus manually controlled plants

7.Q What key factors influence final price quotation?
A Final pricing determined specific equipment selection required options degree site preparation needed local regulatory compliance costs shipping logistics destination Comprehensive site survey forms basis fixedprice turnkey proposal