1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

L’augmentation des coûts opérationnels et les temps d’arrêt imprévisibles érodent les marges de votre projet? Pour les directeurs d’usine et les entrepreneurs en ingénierie, le circuit de concassage et de criblage est souvent à l’origine de goulots d’étranglement critiques. Les défis courants incluent:
Coûts de maintenance élevés: Frequent bearing failures, screen cloth changes, and conveyor belt wear from improper material flow can consume 1520% of your annual operating budget.
Temps d'arrêt imprévus: A primary crusher failure or screen box structural issue can halt an entire site, costing tens of thousands per hour in lost production and labor.
Flux de matériaux inefficace: Poorly matched equipment leading to recirculating loads, chokefeeding, or underutilization reduces overall system capacity by up to 30%.
Gradation du produit incohérente: Offspec aggregate or mineral product results in costly recrushing, stockpile segregation issues, and rejected loads.
Consommation d’énergie en hausse: Plus vieux, mechanically inefficient drives and components directly increase your kWhperton cost, a key metric under constant pressure.

Is your operation equipped to minimize these risks while maximizing throughput and product quality? The foundation lies in selecting robust, intelligently engineered équipement de concassage et de criblage.

2. APERÇU DU PRODUIT

This content outlines the critical considerations for stationary and trackmounted équipement de concassage et de criblage, the core machinery for reducing raw feed material (par ex., roche de carrière, béton recyclé, mineral ore) en tailles d'agrégats spécifiées. Le flux de travail opérationnel est un processus continu:
1. Réduction de la taille primaire: Large feed material is reduced by jaw or gyratory crushers.
2. Material Transport & Scalping: Conveyors move material to vibrating screens that remove undersize material prior to secondary crushing.
3. Concassage secondaire/tertiaire: Cone or impact crushers further reduce material to required dimensions.
4. Projection finale & Tri: Multideck screens accurately separate crushed material into precise product fractions (par ex., ¾” chip, sable manufacturé).
5. Stockage & ReCirculation: Onspec product is conveyed to stockpiles; oversize material is recirculated back into the circuit.

Le champ d'application inclut les carrières, exploitation minière, construction & recyclage de démolition, et production de granulats. Key limitations involve feed material abrasiveness (impacting wear life) et spécifications du produit final requises (dictating circuit design).

3. CARACTÉRISTIQUES PRINCIPALES

Géométrie de chambre brevetée | Base technique: Computermodeled kinematics and cavity profiles | Avantage opérationnel: Optimized nip angle and crushing stroke for higher reduction ratios with less wear on manganese surfaces | Impact sur le retour sur investissement: Jusqu'à 12% lower costperton in abrasive applications due to extended liner life.

Modular Screen Media System | Base technique: Quicktensioning wedgelock design with polyurethane damping | Avantage opérationnel: Screen deck changes completed in under 2 hours versus a typical 68 hour shift, with consistent tension for longer cloth life | Impact sur le retour sur investissement: Reduces labor hours for maintenance by ~70% per changeout, augmentation de la disponibilité des plantes.

Graissage centralisé & Surveillance des conditions | Base technique: Automated lube points with flow sensors feeding a central PLC | Avantage opérationnel: Ensures critical crusher and screen bearings receive precise lubrication without manual intervention; alerts operators to blockages | Impact sur le retour sur investissement: Prevents an estimated 85% of bearingrelated failures, avoiding associated downtime costs.

Hybrid Power Drive System | Base technique: Dieselelectric configuration with onboard genset or external grid connection capability | Avantage opérationnel: Operators can select the most costeffective power source; electric mode reduces fuel consumption by 100% when grid power is available | Impact sur le retour sur investissement: Field data shows average energy cost savings of 2540% in hybrid mode versus dieselonly operation.

HeavyDuty Feeder with PreScreening Section | Base technique: Grizzly feeder with integrated stepped grizzly bars or punch plate section | Avantage opérationnel: Removes natural fines and subproduct size material before the primary crusher, reducing chamber volume usage and wear | Impact sur le retour sur investissement: Increases effective primary crusher throughput by up to 15% by eliminating precrushed material.

Reinforced Structural Frame Design | Base technique: Analyse par éléments finis (FEA) optimized steel fabrication with highstress zone reinforcements | Avantage opérationnel: Withstands continuous highcycle loading without frame fatigue or cracking common in highproduction environments | Impact sur le retour sur investissement: Eliminates unplanned structural repairs, protecting asset lifespan over a 15+ year service period.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Notre concassage & Screening Solution Documented Performance | Avantage (% Amélioration) |
| : | : | : | : |
| Crusher Liner Wear Life (Roche Abrasive) | ~450,000 tons per set (Cone Crusher Mn18) | ~520,000 tons per set (Proprietary Mn22 Alloy) | +15% Durée de vie plus longue |
| Screen Box Sideplate Vibration Fatigue Failure Mean Time Between Failure (MTBF) | ~8,000 operating hours before weld repair required| >14,000 operating hours before inspection advised| +75% Improved Durability |
| Consommation d'énergie (kWh per Ton Processed) Baseline for a 300tph Circuit| ~0.85 kWh/Ton Average| ~0.72 kWh/Ton Documented Average| 15% Coût énergétique réduit |
| Coût total de possession (Coût total de possession) sur 5 Years (Entretien + Parties + Temps d'arrêt)| Indexed at 100% for comparison| Estimé à 7882% of benchmark TCO| 18% à 22% Lower TCO |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Plantes stationnaires de 150 à plus 1,200 tonnes par heure (TPH). Trackmounted mobile units from 200 à 500 TPH.
Exigences d'alimentation: Primary crushing units typically require 150400 kW drives. Full electric stationary plants may require a total connected load of 8002,500 kVA selon échelle.
Spécifications matérielles: Fabriqué à partir d'acier de construction S355JR; highwear components utilize HB500 abrasionresistant steel liners; crusher jaws/cones in premium manganese steel (Mn18Cr2/Mn22Cr2).
Dimensions physiques (Example Mobile Unit): Transport length approx.16m; Operating length approx.19m; Max height approx.4m; Operating weight approx.45 tonnes.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 25°C à +45°C; dustprotected bearings (IP65+); capable of operating at altitudes up to 3,000 meters with engine deration.

6. SCÉNARIOS D'APPLICATION

Projet d'agrandissement de la carrière de granit

Challenge A major quarry needed to increase production by 40% without expanding their permitted footprint or adding a second processing shift.
Solution Implementation of a new tertiary crushing stage featuring a highspeed cone crusher paired with a tripledeck fine screen in closed circuit.
Results Achieved target throughput increase within existing footprint. The closedcircuit design reduced recirculating load by over half compared to the old layout while improving cubicity of the chip products.

Urbain C&D Recycling Operation

Challenge Processing highly variable construction demolition waste led to frequent jamming in the primary impact crusher from uncrushable rebar matts and excessive fines clogging screens.
Solution Deployment of a heavyduty jaw crusher as primary stage for better tramp metal tolerance and an aggressive linear stroke screen ahead of secondary processing for fines removal.
Results Unplanned stoppages due to feeding issues decreased by approximately90%. The removal of fines early in the circuit significantly improved efficiency of downstream sorting equipment.

7 CONSIDÉRATIONS COMMERCIALES

Equipment pricing tiers are structured around capacity capability:
Niveau I (600 TPH): Customengineered stationary crushing and screening plants.

Optional features include advanced dust suppression systems automated metal detection/ ejection magnetic head pulleys extended conveyor systems

Service packages range from basic warranty support through comprehensive multiyear maintenance agreements including scheduled parts kits

Financing options are available including capital lease operating lease commercial loans tailored

8 FAQ

What level of ground preparation is required for installing this equipment?
Stationary plants require engineered concrete foundations Mobile track mounted units require stable compacted ground but minimal civil work enabling rapid redeployment

How does your equipment interface with our existing conveyors stackers?
Our engineering team provides detailed interface specifications for chute heights discharge trajectories belt widths ensuring compatibility

What is the typical lead time from order commissioning?
For standard mobile units lead time is typically weeks For large custom stationary plants detailed engineering procurement fabrication requires months

Fournissez-vous des garanties de performance?
Yes we offer guaranteed minimum capacity based on agreed feed material specifications Guarantees are backed by pre purchase material testing circuit simulation

What operator training technical support do you provide?
We include comprehensive onsite training for operations maintenance crews along with digital manuals Access remote diagnostic support via data link standard