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 ?? Pour les directeurs d’usine et les entrepreneurs en ingénierie, une usine de concassage de pierre de 250 300 tph est un atout essentiel, Pourtant, les défis opérationnels courants ont un impact direct sur vos résultats.. Consider these frequent issues:
Débit incohérent & Temps d'arrêt: Unplanned stoppages due to feeder blockages, crusher overloads, or conveyor misalignment can cost thousands per hour in lost production and idle labor.
Haut opérationnel & Coûts d'entretien: Remplacement fréquent des pièces d'usure, consommation d'énergie élevée par tonne produite, and the need for specialized maintenance crews steadily increase your cost per aggregate ton.
Mauvaise forme du produit & Contrôle des gradations: Inconsistent output leads to excess fines or outofspec material, reducing the market value of your end product and causing rejections.
Disposition rigide de l'usine & Limites d'évolutivité: Fixed designs struggle to adapt to changing feed material hardness or required product mixes, forcing costly retrofits or operating below optimal capacity.

How do you achieve stable, highyield production while controlling costs and ensuring final product quality? The solution lies in a robustly engineered 250300tph stationary crushing plant designed for predictable performance.

2. APERÇU DU PRODUIT

This solution is a complete stationary stone crushing and screening plant engineered for a nominal output of 250 à 300 tonnes métriques par heure (tph) de granulat fini. It is designed as a primarytotertiary processing system for mediumhard to hard stones like granite, basalte, et du calcaire.

Flux de travail opérationnel:
1. Concassage primaire: Matière première de grande taille (≤750mm) is reduced by a heavyduty jaw crusher or gyratory crusher.
2. Secondaire & Concassage Tertiaire: The primary crushed material is further processed by cone crushers for size reduction and improved particle shape.
3. Dépistage & Classification: Vibrating screens separate material into precise size fractions, routing oversize back to crushers and directing onspec product to final stockpiles.

Champ d'application: Idéal pour les opérations de grandes carrières, major infrastructure project support (autoroutes, chemins de fer), and commercial aggregate supply yards requiring highvolume, sortie cohérente.

Principales limites: Feed material hardness must be within specified limits (par ex., jusqu'à 300 Résistance à la compression MPa). Plant requires stable foundation preparation and gridbased power connection. Not designed for mobile or frequent relocation.

3. CARACTÉRISTIQUES PRINCIPALES

Intelligent Feed Control System | Base technique: Entraînement à fréquence variable (VFD) on primary feeder with level sensors | Avantage opérationnel: Prevents crusher cavity overload and minimizes bridging, ensuring smooth material flow | Impact sur le retour sur investissement: Réduit les temps d'arrêt imprévus jusqu'à 15% and improves crusher liner life

Laminated Crushing Chamber Design | Base technique: Multilayer crushing cavity geometry in cone crushers | Avantage opérationnel: Produces superior particle shape with lower flakiness index and controlled fines generation | Impact sur le retour sur investissement: Increases premium product yield by 812%, enhancing sales revenue

Graissage centralisé & Système hydraulique | Base technique: Singlepoint lubrication stations with automated timers and pressure monitoring | Avantage opérationnel: Ensures critical bearing points are serviced consistently, reducing failure risk | Impact sur le retour sur investissement: Lowers bearingrelated breakdowns by an estimated 25% and extends service intervals

HighStrength Modular Conveyor Framework | Base technique: CADoptimized truss design using hightensile steel | Avantage opérationnel: Offre une stabilité exceptionnelle sous charge, reducing vibration and misalignment issues | Impact sur le retour sur investissement: Decreases conveyor maintenance time by approximately 20% over the plant lifecycle

PLCBased Automated Process Logic | Base technique: Contrôleur logique programmable avec interface homme-machine (IHM) for sequence control and interlocking | Avantage opérationnel: Allows singleoperator oversight of startup/shutdown sequences and provides fault diagnostics | Impact sur le retour sur investissement: Optimizes power use during operation cycles and reduces labor requirements for plant control

HeavyDuty Vibrating Screen with QuickChange Decks | Base technique: Rubber shear mounts and sidetensioned screen media attachment system | Avantage opérationnel: Provides efficient sizing with reduced noise/vibration transmission; enables faster screen cloth replacement | Impact sur le retour sur investissement: Cuts screen maintenance downtime by up to 40% par événement de changement

Système de suppression de poussière intégré | Base technique: Nozzle arrays at transfer points connected to a highpressure pump system | Avantage opérationnel: Effectively controls airborne particulate at primary dust generation sources | Impact sur le retour sur investissement: Assure le respect de la réglementation environnementale, avoiding potential fines and improving site working conditions

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (250300Usine de tph) | This 250300tph Stone Crushing Plant Solution | Avantage (% amélioration) |
|||||
| Overall Equipment Effectiveness (OEE) | ~76% | Target ≥84% | +10.5% |
| Consommation d'énergie (kWh/tonne traitée) | Varie considérablement; baseline = X | Optimized system design reduces baseline |7% à 12% |
| Durée de vie des pièces d'usure du concasseur (Revêtements en manganèse)| Based on abrasive feed | Improved chamber design & sélection d'alliage |15% Coût par tonne |
| Temps moyen entre les pannes (MTBF) Key Conveyors ~1,200 hours ~1,650 hours +37.5% |
| Product Shape Index (Flakiness) Typiquement >20% Maintient <15% 25% Improvement in Cubicity |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité nominale: 250 – 300 tph (varies based on feed material hardness & required product gradation).
Options du concasseur primaire: Curseur de mâchoire (PE900×1200) ou concasseur giratoire; Feed Opening up to 750mm.
Concasseurs secondaires/tertiaires: Multicylinder Hydraulic Cone Crushers.
Équipement de dépistage: Tripledeck heavyduty circular motion vibrating screens; Total screening area ≥20m².
Puissance totale installée: Environ 550 – 650 kW (dépend de la configuration).
Spécifications des matériaux clés: Primary frame construction Q345B steel; Highwear components use Mn18Cr2 or equivalent alloys; Conveyor belts rated for minimum PIW 800.
Empreinte globale de l’usine (Lxl): Approximately 85m x 65m (dépendant de la mise en page). Height restrictions apply (~25m max).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; Dust emission control achieves ≤20mg/m³ at key points.

6. SCÉNARIOS D'APPLICATION

Projet d'agrandissement de la carrière de granit

Challenge A quarry needed to increase production from 200tph to a consistent 280tph of road base and concrete aggregates but had limited space for plant expansion.
Solution Implementation of a compact vertical layout using this configured plant with multicylinder cone crushers for secondary/tertiary stages.
Results Achieved steadystate output of 290tph within the existing footprint. Product cubicity met the highest local specification standards.

LargeScale Highway Construction Support

Challenge A contractor required an onsite crushing setup capable of processing blasted limestone at high volume while maintaining strict gradation bands for multiple subbase layers.
Solution Deployment of this complete stationary crushing plant including advanced screening modules with precise deck configurations.
Results The plant supplied over 1.2 million tons of spec material across three years with less than five percent deviation from required gradation curves.

7. CONSIDÉRATIONS COMMERCIALES

Our solutions are offered in tiered configurations:
Niveau de configuration standard: Comprend des modules de concassage de noyau,screening units,and basic PLC control.Priced as a turnkey package.
Niveau haute efficacité: Adds intelligent feed systems,crusher automation settings,and premium wear materials.Initial investment yields lower longterm operating costs.
Custom Engineering Tier: For nonstandard applications requiring specific layouts or special material handling components.Priced upon project engineering review.

Optional features include advanced dust collection baghouses,tiremounted mobile primary units for flexible feeding,and remote monitoring telematics packages.Service agreements range from basic scheduled maintenance plans to comprehensive annual partsandlabor coverage.Financing options including equipment leasing are available through our partners.

8. FAQ

What are the primary power requirements?
A stable threephase industrial power supply is required.Total connected load typically ranges from550to650kW.Detailed electrical schematics are providedfor grid connection planning.

Can this plant process river gravel or very abrasive materials?
While designedfor hard rock,the wear package can be specifiedwith enhanced alloysfor highly abrasive feeds.Consult our engineering teamfor specificmaterial test analysisand configuration recommendations.

What is the typical installationand commissioning timeline?
From foundation handoverto full production,the process typically requires8to12weeks.This includes mechanical erection,electrical connection,system calibration,and operator training conductedby our engineers.

Do you provide spare parts support globally?
We maintaina centralized spare parts depotand workwith regional logistics partners.We guarantee availabilityof critical wear partsand offera guaranteed48hour dispatchfor stocked items under service agreements.

How does thisplant handle variationsin feed sizeor hardness?
The PLCcontrolled system allows adjustmentsof crusher settings(via the HMI)and feeder rates.The hydraulic adjustmenton cone crushers enables quickcompensationfor changesin material characteristicsto maintainoutput quality