Ciblage: Commercial Buyers, Directeurs d'usine, and Engineering Contractors in Sand & Gravel Mining

1. Addressing Core Operational Challenges in Aggregate Production

Managing a sand and gravel operation requires balancing relentless production demands with stringent control over profitability. Industry data indicates that unplanned downtime and inconsistent product quality are primary drivers of eroded margins. Êtes-vous confronté à ces défis spécifiques?

Coûts élevés des pièces d’usure & Arrêts imprévus: Abrasive silica and aggregate materials degrade equipment rapidly. Frequent component failure on primary crushers or screens leads to production halts, costing an average of $1,800 per hour in lost output and emergency maintenance.
Inefficient Material Classification: Inaccurate sizing from underperforming screening equipment results in product contamination. This leads to load rejections, premium product being downgraded, and an inability to meet tight specifications for concrete or asphalt mixes.
Génération d’amendes excessives & Yield Loss: Improper crushing chamber geometry or excessive crusher speed creates more fine material than marketable product, directly reducing the yield of highvalue coarse aggregates.
Consommation d'énergie élevée par tonne: Plus vieux, nonoptimized crushing circuits can consume 3040% more power per ton of processed material, faire de l'énergie l'une des trois principales dépenses opérationnelles.
Rigid Plant Layout & Scalability Limits: Fixed conveyor systems and stationary primary units complicate site progression and make it difficult to economically process satellite deposits, limiting reserve life.

La question centrale est: how can your operation increase throughput tonnage while simultaneously gaining control over costperton metrics?

2. Présentation du produit: HighCapacity Mobile Cone Crusher Plant

This solution is a trackmounted, closedcircuit cone crusher and screening plant designed for secondary and tertiary crushing in sand and gravel applications. It processes feed material from a primary crusher into precisely sized aggregates.

Flux de travail opérationnel:
1. Acceptation des aliments: Sized feed (typiquement 5" / 125mm) from a primary jaw crusher is delivered via excavator or wheel loader into the integrated feed hopper.
2. ClosedCircuit Crushing & Dimensionnement: Material is crushed in the highperformance cone crusher chamber. The entire output is conveyed to an onboard sizing screen.
3. Product Separation: The tripledeck screen separates output into multiple specification products (par ex., ¾" ébrécher, concrete sand, drain rock).
4. Recirculation & Stockage: Oversize material is automatically recirculated back to the crusher inlet (closedcircuit operation). Onspec material is conveyed to designated stockpiles via radial conveyors.

Champ d'application & Limites:
Portée: Ideal for producing spec aggregates for road base, béton, asphalte, and drainage applications. Excels in processing hard, matériaux abrasifs comme le granit, quartzite, et gravier de rivière.
Limites: Not designed as a primary crusher for runofquarry shot rock exceeding recommended feed size. Optimal performance requires consistent feed gradation and controlled moisture content to prevent screen blinding.

3. Fonctionnalités principales: Engineered for Aggregate Profitability

Conception avancée de la chambre de concassage | Base technique: Laminated crushing principle with optimized kinematics | Avantage opérationnel: Produces a wellshaped, cubicle product with reduced flakiness index and controlled fines generation. | Impact sur le retour sur investissement: Increases saleable product yield by up to 15% by minimizing wasteful fines and improving particle shape for premium applications.

Onboard TripleDeck Screening System | Base technique: Highfrequency vibration with adjustable screen angle and throw | Avantage opérationnel: Enables simultaneous production of up to four calibrated products in a single pass with high separation accuracy. | Impact sur le retour sur investissement: Eliminates the need for standalone screening plants, reducing capital outlay and improving overall site footprint efficiency.

Direct Hydraulic Drive System | Base technique: Variablespeed hydraulic drive for the crusher and conveyors powered directly from the track engine | Avantage opérationnel: Élimine les courroies trapézoïdales, réducteurs, and clutch components prone to wear and failure. Provides softstart capability and overload protection. | Impact sur le retour sur investissement: Lowers maintenance costs by an estimated 40% on drive components and reduces risk of catastrophic failure from tramp metal.

Système de contrôle intelligent basé sur PLC | Base technique: Automated process control with realtime feedback on crusher load, consommation d'énergie, et la pression | Avantage opérationnel: Operators can optimize CSS (Réglage du côté fermé) onthefly for different products; system autoregulates feed rate to prevent chamber overload. | Impact sur le retour sur investissement: Maximizes throughput while protecting the machine; reduces operator skill dependency and training overhead.

Track Mobility & Installation rapide | Base technique: Heavyduty crawler tracks with hydraulic setup legs | Avantage opérationnel: Full plant relocation between processing zones or sites can be completed in under 30 minutes by a single operator. | Impact sur le retour sur investissement: Enables efficient mining of multiple pit faces or contract processing at disparate sites with one machine fleet, maximizing asset utilization.

4. Avantages compétitifs

| Mesure de performances | Norme de l'industrie (Fixed Plant / Older Mobile Design) | Mobile Cone Crusher Plant Solution | Avantage |
| : | : | : | : |
| Installation / Relocation Time | 816 heures (crew dependent) / 24 heures | 80% amélioration |
| Power Consumption per Tonne Crushed| ~2.1 kWh/t (secondary/tertiary stage)| ~1.7 kWh/t (fieldverified average)| ~19% improvement |
| Durée de vie des pièces d'usure (Revêtements en manganèse) | ~400k tonnes (variable based on abrasiveness) |>550k tonnes (in comparable abrasive feed) |>37% amélioration |
| Product Yield (+4 Mesh Spec Material)| Référence (~75%) |>85% with optimized chamber/screen combo |>13% increase in premium product |

5. Spécifications techniques

Modèle de concasseur: HighPerformance Cone Crusher
Recommended Maximum Feed Size: 125mm (5")
Crusher Drive Power: 300 kW (400 HP)
Total Installed Power (Usine): Tier IV Final / Stage V Compliant Diesel Engine
Capacité de la trémie: 8m³ (10.5 yd³)
Convoyeur de déchargement principal: Belt width 1200mm (48"), Repliage hydraulique & radial slew
Screen Size: Triple deck vibratory screen; area of each deck
Dimensions de transport (L x W x H): Approximately Length x Width x Height
Poids opérationnel: ~50 tonnes
Plage de température de fonctionnement: 20°C à +45°C (4°F à +113°F)

6.Scénarios d'application

LargeScale Alluvial Gravel Operation

Défi: A Midwest producer needed higher onspec yield from very abrasive river gravel while reducing plant footprint to comply with wetland setbacks.
Solution: Two mobile cone crusher plants were deployed in a parallel configuration downstream of primary jaws, replacing an aging fixed secondary circuit.
Résultats: Yield of +¼" chip increased by 12%. The mobile setup allowed progressive pit advancement without conveyor reengineering. Fuel consumption dropped by an estimated $11k monthly across both units.

Granite Quarry Diversifying Product Lines

Défi: A quarry producing primarily road base sought to enter the concrete aggregate market but lacked precise sizing capability for washed chips.
Solution: Integration of one mobile cone crusher plant equipped with a highfrequency wash screen as a dedicated tertiary circuit.
Résultats: Enabled production of three new certified concrete stone products within six weeks of deployment without major site modification.Rejected loads due to gradation fell to near zero.

7.Considérations commerciales

Equipment pricing is structured around configuration options that match your specific material profile:

• Base Configuration Tier includes core cone crusher plant with standard screening media suitable for most general aggregate duties.
• Premium Abrasion Package Tier adds upgraded wear liners,crusher automation,and heavyduty conveyor belts—recommended for operations processing highsilica materials (>70% SiO2).
• Integrated Washing Module Tier incorporates spray bars,sump,and dewatering cyclone(s),essential for producing specification mason or concrete sand.Optional features include remote monitoring telematics,dust suppression cannons,and magnet systems.Service packages range from basic scheduled maintenance plans(parts+labor)to comprehensive fullservice contracts covering wear parts.Financing options including operating leases,tailored rentaltoown agreements,and projectspecific capital loans are available through established partners.

8.Foire aux questions

T1:What upstream equipment is required?
A1.This unit functions as secondary/tertiary stage machinery.It requires consistent,sized feed typically provided by a tracked jaw crusher or large stationary primary.A wheel loader or excavator is used for charging the integrated hopper.

T2:What are realistic production outputs?
A2.Tonnage varies significantly based on feed material hardness,crusher CSS setting,and desired product curve.In mediumhard abrasive gravel,a realistic spec range is between180250 tonnes per hour when producing two spec products plus recirculating load.Field data sheets are available upon request detailing specific test results.

T3:Quel niveau de formation des opérateurs est requis?
A3.The PLC control system simplifies operation.Basic training focuses on daily walkaround checks,screen media inspection/changing,and using the touchscreen interface.Most operators become proficient within three shifts.Comprehensive onsite training modules are included upon commissioning.

T4:What does routine maintenance involve?
A4.Daily greasing intervals have been engineered out.The focus shifts to weekly visual inspections of wear liners,belt tracking,and hydraulic system checks.Oil sample analysis intervals are recommended at500hour increments.Predictive maintenance via remote monitoring further schedules interventions based on actual condition rather than fixed hours.

Q5:What lead time can we expect from order placement?
A5.For standard configurations,inventory allows delivery within810 weeks.Customconfigured units require1216 weeks lead time.A detailed project timeline will be provided upon application review