1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing a midtolarge scale aggregate production operation and facing consistent bottlenecks in your primary crushing circuit? The challenges of a 250300tph stone crushing plant are specific and costly. Inconsistent feed size from the quarry leads to crusher chokeups, causing unplanned downtime for clearing. Wear part consumption on secondary and tertiary stages escalates when the primary plant cannot maintain a steady, optimally sized output. En outre, achieving the target 250 à 300 tons per hour often requires running multiple smaller units at peak capacity, increasing fuel consumption, besoins en main d'oeuvre, and maintenance complexity. Are these issues impacting your plant's profitability: Is your effective throughput consistently below design capacity? Are your maintenance costs per ton higher than industry benchmarks? Is plant uptime falling short of your production targets? A properly engineered 250300tph stone crushing plant is designed to address these exact operational and financial pressures.

2. APERÇU DU PRODUIT

This solution is a complete stationary or semistationary crushing and screening circuit engineered for a nominal output of 250 à 300 metric tons per hour of finished aggregate products. Le flux de travail typique intègre plusieurs étapes clés: (1) Primary reduction via a robust jaw crusher or gyratory crusher to handle large feed material; (2) Intermediate screening and secondary crushing, often using a cone crusher, to refine material size; (3) Final tertiary crushing with another cone crusher or impact crusher for shaping and producing specific chip sizes; (4) Multiple stages of screening with vibrating screens to separate products into precise fractions (par ex., 05mm, 510mm, 1020mm); (5) Conveying systems interlinking all stages with transfer points designed for minimal spillage and dust generation. This plant configuration is suited for processing mediumhard to hard stone like granite, basalte, et du calcaire. Sa principale limitation est son caractère fixe ou semi-fixe; while highly efficient for dedicated quarry sites, it is not designed for rapid relocation like mobile units.

3. CARACTÉRISTIQUES PRINCIPALES

Système de contrôle d'alimentation intelligent | Base technique: Entraînement à fréquence variable (VFD) on feeder motors with level sensors | Avantage opérationnel: Automatically regulates feed rate to the primary crusher based on chamber load, preventing overload and underutilization | Impact sur le retour sur investissement: Reduces crusher stall events by an estimated 60%, protecting drive components and improving throughput consistency.

Laminated Crushing Chambers | Base technique: Multilayer manganese steel wear liners in jaw and cone crushers | Avantage opérationnel: Creates a rockonrock crushing action in the chamber, protecting the main frame and distributing wear more evenly across liner surfaces | Impact sur le retour sur investissement: Prolonge la durée de vie du revêtement jusqu'à 30%, abaissant directement le coût par personne pour les pièces d'usure.

Graissage centralisé & Automatisation des API | Base technique: Programmable Logic Controller with automated lubrication cycles for all major bearings | Avantage opérationnel: Ensures critical crusher and screen bearings receive precise lubrication without operator intervention, réduire le risque d'échec | Impact sur le retour sur investissement: Les données de terrain montrent un 25% reduction in bearingrelated downtime compared to manual greasing protocols.

Conception de plate-forme d'écran modulaire | Base technique: Quickly interchangeable screen media panels with tensioning systems | Avantage opérationnel: Allows your crew to change screen cloth configurations for different product specs in under half the time of traditional systems | Impact sur le retour sur investissement: Increases plant flexibility and reduces changeover downtime, supporting more product variants without sacrificing production days.

HeavyDuty Conveyor Specification | Base technique: CEMA Grade II idlers, lits d'impact aux points de chargement, and vulcanized belt splices | Avantage opérationnel: Minimizes belt wear, déversement, and tracking issues that cause frequent stoppages in conveying circuits | Impact sur le retour sur investissement: Lowers longterm conveyor maintenance costs by approximately 20% and improves overall plant material flow reliability.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme industrielle pour les usines de 250 300 tph | Notre solution d'usine de concassage de pierre de 250 300 tph | Avantage (% amélioration) |
| : | : | : | : |
| Disponibilité des installations | ~8588% (factoring scheduled & temps d'arrêt imprévu) | 92%+ (supported by component redundancy & predictive monitoring) | +5% à +8% |
| Consommation d'énergie par tonne| Varie considérablement; often overlooked in design. Our benchmark based on multimotor loads without optimization. Integrated drive optimization & highefficiency motors reduce total connected load by an estimated 15%. |
| Coût d'usure par tonne (Primaire)| À base d'alimentation en granit abrasif. Doublures en alliage haut de gamme & chamber design yield a documented 1825% lower cost. |
| Setup/Commissioning Time| For semistationary plants with multiple modules. Our preassembled skid modules & plugandplay cabling reduce field erection time by 30%. |

5. SPÉCIFICATIONS TECHNIQUES

Capacité nominale: 250 300 tonnes métriques par heure (varie en fonction de la densité du matériau & dureté).
Options du concasseur primaire: Curseur de mâchoire (par ex., Feed opening up to 1200x900mm) or Primary Cone Crusher.
Concasseurs secondaires/tertiaires: Typically two units of midtolarge size Cone Crushers.
Screening Stages: Typiquement 34 decks across multiple vibrating screens (par ex., 2400x6000mm).
Puissance totale installée: Environ 550 700 kW, selon configuration.
Spécifications des matériaux clés: Main frame construction from S355JR steel; crusher liners from Mn18Cr2 or equivalent highgrade manganese; screen mesh with hightensile wire.
Empreinte typique de l'usine: ~80m (L) x 45m (W), depending on stockpile configuration.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C avec des packs de chauffage/refroidissement en option pour les climats extrêmes.

6. SCÉNARIOS D'APPLICATION

Granite Quarry Supplying Infrastructure Projects | Défi: A quarry needed consistent supply of three certified aggregate products (cours de base, couche drainante, chip seal) at a minimum of 280tph for a highway project. Existing plant struggled with shape characteristics and could not maintain required throughput without excessive fines generation.

Solution: Implementation of a new 250300tph stone crushing plant featuring a primary jaw crusher followed by two cone crushers in secondary/tertiary roles with specialized crushing chambers for improved particle shape.
Résultats: Achieved steadystate production of 295tph meeting all gradation specifications. Improved particle shape increased compaction efficiency onsite reported by the contractor. Disponibilité moyenne des installations 93% over the project's duration.

Traitement du calcaire pour l’alimentation des cimenteries & Aggregate Sales | Défi: An integrated cement producer needed to optimize its quarry output to feed both its kiln (crushed raw material) and its aggregate sales division (sized products). The old singleline plant created conflicts between product streams.

Solution: A tailored twoline concept within the nominal capacity range allowed simultaneous production of kilnfeed material via one circuit while producing commercial aggregates via another parallel circuit sharing primary crushing.
Résultats: Eliminated production conflicts entirely. Kiln feed stability improved due to dedicated circuit control. Commercial aggregate sales volume increased by over $40k/month due to dedicated production time.

7. CONSIDÉRATIONS COMMERCIALES

A complete turnkey solution is typically offered in structured tiers:
Niveau de configuration standard: Includes core equipment as specified above with basic PLC control for start/stop sequencing.
Niveau de performances optimisé: Adds advanced process automation system (SCADA), premium wear liner packages, additional dust suppression points across conveyors/screens/crushers.
Extended Scope Tier: Incorporates civil engineering support plans as well as erection supervision services provided by our engineers during commissioning phase onsite alongwith comprehensive operator training programs covering routine maintenance procedures thoroughly documented beforehand

Financing options include capital expenditure purchase agreements alongwith leasing structures tailored specifically towards mining operations where payments align better against seasonal cash flows

Service packages range from annual inspection contracts up through full preventive maintenance programs which include scheduled supply replacement parts at preagreed rates ensuring budget predictability

8.FAQ

T1:What type foundation requirements does this kind stationary setup require?
A1:A solid reinforced concrete foundation designed according load data we provide specific site soil conditions must be assessed local engineering firm ensure stability long term operation minimal settlement risk

T2:What happens if my feed material hardness exceeds design parameters temporarily?
A2:The core crushing components are designed withstand reasonable fluctuations however sustained processing harder materials will increase wear rates may require adjusting closed side settings maintain product size potentially lowering throughput rate slightly until normal feed resumes

T3:What level staffing required operate this efficiently?
A3:A welldesigned automated system can be operated effectively from central control room typically requiring one trained operator per shift supplemented ground personnel conducting visual inspections routine checks

T4:What lead times expected delivery commissioning such complex system?
A4 From order placement delivery major components typically takes between months depending current manufacturing schedule Site erection commissioning require additional weeks based local conditions scope work involved

Q5:What provisions made controlling fugitive dust emissions comply regulations?
A5 Standard package includes water spray systems strategic transfer points enclosures around screens optional baghouse filter systems available meet stringent environmental standards specific region