1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are your iron ore processing margins being eroded by persistent operational bottlenecks? Plant managers and procurement specialists face significant challenges in primary crushing stages that directly impact the entire downstream circuit. Les points douloureux courants incluent:
Temps d'arrêt excessif: Unplanned stoppages for liner changes and maintenance on underspecification crushers, coûtant des centaines d'heures de production par an.
Coûts d'usure élevés: Rapid abrasion of crushing components in the face of hard, abrasive magnetite or hematite ores, leading to unsustainable consumables expenditure.
Débit incohérent: Feed size fluctuations and material bridging causing chokefed or starved crushers, preventing consistent tonnage targets.
Regulatory Compliance Risk: Operating nonCE marked equipment exposes your project to legal liability, insurance complications, and potential site shutdowns in regulated markets.

How do you secure a robust primary crushing solution that ensures reliable throughput, controls operational costs, and meets stringent EU safety directives—all within a constrained capital budget?

2. APERÇU DU PRODUIT

Our solution is a CE Marked Stationary Primary Crushing Plant engineered specifically for hard rock iron ore applications. This turnkey module is designed for the initial size reduction of runofmine (ROM) iron ore to a consistent product for downstream conveying and processing.

Flux de travail opérationnel:
1. ROM ore is fed via dump truck or loader into a rugged vibrating grizzly feeder.
2. The feeder removes sub100mm fines via a grizzly section and evenly introduces oversize material to the primary jaw crusher.
3. The crusher reduces the ore to a nominal 150200mm product, which is discharged onto a main plant conveyor.

Champ d'application: Ideal for greenfield installations or replacement of aging primary crushers in mediumtolarge scale iron ore operations processing magnetite, hématite, or goethite ores.

Limites: This plant configuration is designed for primary crushing duty only. For full circuit needs, secondary/tertiary crushing and screening modules are required. Maximum feed size and capacity are bound by model specifications.

3. CARACTÉRISTIQUES PRINCIPALES

Concasseur à mâchoires robuste | Base technique: Reinforced manganese steel jaws with optimized nip angle geometry | Avantage opérationnel: Sustained high reduction ratios (typiquement 6:1 à 8:1) on abrasive ore with minimal wear flat development | Impact sur le retour sur investissement: Extended liner life reduces consumable costs by an estimated 1525% versus standard designs.

Mangeoire à grizzlis intégrée | Base technique: Pont en acier à haute résistance avec barres grizzly réglables | Avantage opérationnel: Prescreening increases effective crusher capacity by removing fines, reduces crusher cavity wear, and prevents plugging | Impact sur le retour sur investissement: Improves overall plant throughput efficiency and protects the crusher from unnecessary abrasion.

Sécurité certifiée CE & Système de contrôle | Base technique: Full compliance with EU Machinery Directive 2006/42/EC, featuring guarded drive units, emergency stop circuits, and lockout/tagout points | Avantage opérationnel: Provides a verifiable safety framework, protects personnel, and ensures market access in regulated regions | Impact sur le retour sur investissement: Mitigates project risk from noncompliance penalties and simplifies insurance procurement.

Conception modulaire montée sur patins | Base technique: Preassembled structural steel skid with integrated walkways and maintenance platforms | Avantage opérationnel: Significantly reduces civil works and onsite assembly time—plant can be operational within weeks of delivery | Impact sur le retour sur investissement: Lowers total installed cost by up to 30% compared to traditional fieldbuilt foundations and structures.

Lubrification centralisée & Système hydraulique | Base technique: Singlepoint greasing lines for key bearings and integrated hydraulic system for adjustment & clairière | Avantage opérationnel: Simplifies routine maintenance schedules; enables quick setting adjustment and tramp iron release without downtime | Impact sur le retour sur investissement: Reduces planned maintenance time by approximately 20%, augmentation des heures de fonctionnement annuelles disponibles.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Typical NonCE Plant) | Notre solution d'usine de concassage de minerai de fer marquée CE | Avantage (% Amélioration) |
| : | : | : | : |
| Durée de vie du revêtement (Minerai abrasif)| ~450,000 MT throughput per set| ~600,000 MT throughput per set| +33% |
| Temps moyen entre les pannes (MTBF)| ~800 heures| ~1 200 heures| +50% |
| Installation & Temps de mise en service| 812 semaines| 35 semaines| ~60 % plus rapide |
| Consommation d'énergie par tonne| Référence (100%)| Environ 9295% de la ligne de base| 58% réduction |
| Regulatory Market Access| Requires extensive retrofit & documentation| Full CE compliance from delivery| Eliminates retrofit cost & delay |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: 400 1,200 tonnes par heure (TPH), dependent on feed size distribution and ore characteristics.
Type de concasseur primaire: Concasseur à mâchoires à bascule unique.
Ouverture d'alimentation: Up to 1,500mm x 1,200mm.
Taille maximale d'alimentation: Up to 1,050mm edge length.
Discharge Setting Range: 150 250mm CSS (Réglage du côté fermé).
Exigences d'alimentation: Puissance totale installée environ 300 450 kW (crusher motor + moteur d'alimentation + auxiliaires).
Spécifications matérielles: Crusher jaws in premiumgrade Manganese Steel (14%18%); nuance d'acier de construction S355JR; wear plates on feed hopper.
Dimensions physiques (Skid): Environ. Longueur: 16m x Largeur: 5m x Hauteur: 6m (varies by model).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dust suppression system connections standard.

6. SCÉNARIOS D'APPLICATION

MidSized Magnetite Operation Expansion

Défi: A Nordic mine needed to expand primary capacity but faced high local labor costs for extended onsite construction. Regulatory requirements mandated full CE compliance.
Solution: Installation of a preassembled skidmounted CE marked iron ore crushing plant with integrated dust suppression.
Résultats: The plant was commissioned in under four weeks postdelivery. It achieved permitted throughput immediately while reducing projected installation costs by approximately €150k.

Hematite Processing Plant Modernization

Challenge An aging processing facility suffered from constant unplanned downtime in its primary section due to crusher failures and excessive liner wear on hard hematite ore.
Solution Replacement of the legacy primary setup with our heavyduty jaw crusher plant featuring centralized lube systems and reinforced liners.
Results Field data shows liner life improved from an average of ~380k tonnes to over 550k tonnes. Annual planned maintenance events were reduced from five to three directly increasing annual available operating time

Considérations commerciales

Equipment Pricing Tiers are structured around throughput capacity core drive power
Niveau I (900 TPH): Highcapacity configuration with premium components

Optional Features include advanced condition monitoring sensors onboard weighing systems automated grease systems specific wear package upgrades for highly abrasive ores

Service Packages range from basic commissioning support up through comprehensive multiyear scheduled maintenance plans including liner changeout services performed by factorytrained technicians

Financing Options are available including leasing structures that preserve capital expenditure lines or progressbased payment plans aligned with project milestones

FAQ

Q Is this plant compatible with my existing secondary circuit conveyors
A Yes The discharge height conveyor interface points can be adapted during engineering Standard discharge heights are provided but modifications are possible prior to build

Q What is the expected impact on my overall plant availability
A Based on historical performance data this design improves primary section availability typically achieving >94 due primarily to increased component life reduced unscheduled stops

Q Does CE marking cover the entire electrical system
A Yes Full CE certification encompasses all mechanical electrical control aspects ensuring conformity with relevant EU directives essential for projects requiring European certification

Q Are wear parts readily available globally
A We maintain strategic parts inventories in key mining regions Lead times for critical wear parts like jaw liners average less than days supported by our global logistics network

Q What commercial terms are standard
A Standard terms involve progress payments against engineering milestones factory acceptance testing FAT shipment Final payment is due upon completion of successful site commissioning