Fda Approved Iron Ore Crushing Plant Catalog
1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR
Vos opérations de traitement du minerai de fer sont-elles limitées par une taille d'alimentation incohérente ?, entretien imprévu, and rising energy costs? Inefficient primary crushing creates bottlenecks that ripple through your entire beneficiation circuit, impactant directement le débit et la rentabilité. Considérez ces défis communs:
Temps d'arrêt excessif: Unplanned stoppages for liner changes or mechanical repairs in your primary crusher can cost thousands per hour in lost production.
Coûts d'exploitation élevés: Inefficient crushing cycles and excessive power draw from poorly matched equipment inflate your costperton metric.
Variabilité de la qualité des produits: Inconsistent output size distribution from the primary stage overloads downstream screening and secondary crushing, réduisant l’efficacité globale de l’usine.
Coûts d’usure abrasive: The highly abrasive nature of iron ore leads to rapid wear on crusher components, resulting in high spare parts consumption and labor for replacements.
Is your current primary crushing solution delivering the reliability and costefficiency required in today's market? The foundation of a profitable iron ore plant is a robust, highcapacity primary crushing circuit.
2. APERÇU DU PRODUIT: FDA Approved Iron Ore Crushing Plant
This product description details our engineered primary crushing station, specifically configured for hightonnage iron ore processing. This turnkey module is designed for the initial size reduction of runofmine (ROM) minerai de fer, typically reducing material from up to 1.5meter feed down to a conveyable product for further processing.
Flux de travail opérationnel:
1. ROM iron ore is dumped into a heavyduty vibrating grizzly feeder (VGFF VGF).
2. The VGF removes sub100mm fines via a scalping section and evenly feeds oversize material into the jaw crusher or gyratory crusher.
3. The primary crusher performs the initial compressive breakage of the ore.
4. Crushed product is discharged onto a main plant conveyor for transport to the next processing stage.
Champ d'application & Limites:
Portée: Ideal for greenfield installations or expansion projects requiring capacities from 1,500 à plus 10,000 tonnes par heure (tph). Suited for magnetite, hématite, et autres minerais de fer.
Limites: Il s'agit d'une solution de concassage primaire; secondary and tertiary crushing require additional circuit design. La taille de l'alimentation doit être contrôlée dans les limites des dimensions d'admission maximales conçues par le concasseur..
3. CARACTÉRISTIQUES PRINCIPALES
Mangeoire vibrante robuste pour grizzlis (VGFF VGF) | Base technique: Construction en acier à haute résistance avec barres grizzly réglables | Avantage opérationnel: Scalps fines to bypass the crusher, reduces wear, and ensures even feed distribution for optimal cavity utilization | Impact sur le retour sur investissement: Increases effective crusher capacity by up to 15% and extends wear life of primary liners
Système d'entraînement hydrostatique du concasseur | Base technique: Direct hydraulic drive for the main shaft | Avantage opérationnel: Fournit un démarrage fluide sous charge, fonctionnement réversible pour éliminer les blocages, et contrôle de vitesse variable infini pour un débit optimal | Impact sur le retour sur investissement: Eliminates costly shearing of mechanical drive components; les données de terrain montrent un 30% reduction in blockagerelated downtime
Conception de doublure modulaire | Base technique: Segmented manganese steel liners secured with boltin systems | Avantage opérationnel: Enables partial liner replacement and significantly reduces changeout time compared to monolithic liners | Impact sur le retour sur investissement: Reduces liner maintenance downtime by approximately 40%, réduire les coûts de main-d’œuvre et augmenter la disponibilité
Géométrie de chambre avancée | Base technique: Computermodeled nip angle and crushing chamber profile | Avantage opérationnel: Optimizes compressive force application for iron ore’s fracture characteristics, improving reduction ratio and particle shape | Impact sur le retour sur investissement: Delivers a more consistent product size, reducing recirculation load and energy consumption in downstream stages
Lubrification automatisée centralisée | Base technique: Système programmable fournissant des volumes de graisse précis à tous les roulements critiques | Avantage opérationnel: Ensures optimal bearing health regardless of operator intervention, protecting against contaminant ingress in dusty environments | Impact sur le retour sur investissement: Les tests industriels démontrent une corrélation directe avec un 60% increase in major bearing service life
RockBreaker Integration Platform | Base technique: Reinforced chassis with preengineered mounting points | Avantage opérationnel: Allows for safe installation of stationary rock breaker to address hangups at the crusher inlet without manual intervention | Impact sur le retour sur investissement: Mitigates a major safety risk and prevents prolonged stoppages due to bridging
4. AVANTAGES CONCURRENTIELS
| Mesure de performances | Norme de l'industrie (Average Jaw/Gyratory) | Notre solution d'usine de concassage de minerai de fer | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité (Exécution planifiée) | 9294% | 96%+| +34% |
| Temps de changement de doublure (Heures) | 2436 heures (full set) | 1418 heures| ~45 % plus rapide |
| Tonnage par kWh (Efficacité énergétique) Ligne de base = 100 Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score=|IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard)=105110| +510% |
| Temps moyen entre les pannes (MTBF) Composants majeurs| ~4 000 heures| 5,500+ heures| +37% |
5. SPÉCIFICATIONS TECHNIQUES
Plage de capacité: Configurable à partir de 1,500 tph à 10,000+ tph.
Options de types de concasseurs: Heavyduty jaw crusher or primary gyratory crusher.
Taille d'alimentation maximale: Up to 1,500mm (59").
Plage de réglage de décharge: 150mm 300mm (6" 12"), adjustable based on model.
Exigences d'alimentation: La puissance totale installée varie de 450 kW à plus 1.2 MW depending on capacity selection; conçu pour l'alimentation haute tension (6.6kV typique).
Spécifications matérielles: Châssis principal fabriqué en acier à haute résistance; wear liners manufactured from ASTM A128 manganese steel; shafting from forged alloy steel.
Dimensions physiques (Module): Approximate footprint range: Length 2540m x Width 812m x Height 810m.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 30°C à +50°C; dustsealed bearings and components standard.
6. SCÉNARIOS D'APPLICATION
Projet de concentrateur de magnétite Greenfield
Challenge A new mine required a primary crushing plant capable of processing very hard magnetite ore at >6，000 tph with extreme reliability， as any downtime would delay concentrator rampup． Initial designs using standard crushers projected high liner wear costs．
Solution Implementation of our gyratorybased FDA approved iron ore crushing plant with modular liners， hydrostatic drive，and an oversized heavyduty VGF．
Results Achieved sustained throughput of 6，200 tph during commissioning． Liner life exceeded projections by 18%，and plant availability averaged 96．5％in the first year．
Existing Hematite Processing Plant Expansion
Challenge An aging jaw crusher station was the bottleneck， limiting plant expansion goals． Frequent blockages caused erratic feed to downstream processes，and maintenance was laborintensive．
Solution Replacement with our turnkey FDA approved iron ore crushing plant module，designed as a direct retrofit into the existing flow sheet，including an integrated rockbreaker．
Results Primary throughput increased by 35％immediately． Blockages were reduced by over 90％，and automated lubrication cut scheduled maintenance hours by 25％per month．
7． CONSIDÉRATIONS COMMERCIALES
Equipment pricing is tiered based on capacity（tph）and selected core crusher type（jaw vs．gyratory）．
Niveaux de tarification：
Tier I（7，000 tph）：Configured with large gyratory crushers．
Fonctionnalités facultatives：
Capteurs avancés de surveillance de l'état (vibration)，température)
Intégration du système de suppression de poussière
Wear liner monitoring system
Forfaits de garantie prolongée
Forfaits de services：
A comprehensive selection is available including：
Inspection annuelle &optimization plans
Onsite parts inventory holding agreements
Remote diagnostics &technical support packages
Options de financement：
Flexible commercial leasing structures are available through partners，
allowing CAPEX preservation． Project financing may be considered
for largescale developments．
8． FAQ
Q What if my ROM feed size varies significantly？
A The heavyduty VGF和hydrostatic drive are specifically designed to handle variance．The reversible hydraulic drive can clear minor blockages automatically，
and chamber geometry accommodates reasonable fluctuation without significant efficiency loss．
Q How does this solution integrate with my existing control system？
A The FDA approved iron ore crushing plant module comes with its own PLCbased control panel which communicates via standard industrial protocols（Modbus TCP/IP，
Profibus）．It can operate as a standalone unit or be fully integrated into your central SCADA system．
Q What is the expected operational impact on my workforce？
A The design prioritizes safety和reduces manual labor．Features like centralized lubrication，
modular liners和remote diagnostics reduce time spent on hazardous tasks和routine checks，
allowing your team to focus on oversight和optimization．
Q Are there long lead times for critical wear parts？
A We maintain regional inventory hubs for fastmoving wear items like liner sets．
Using proprietary alloy specifications ensures consistent performance和availability．
Q Can you provide assistance with foundation design和civil works？
A Yes．With purchase we provide detailed foundation drawings，
load data和anchor bolt specifications required by your civil engineering contractor
for proper installation．
Q What are the commercial terms典型for such equipment？
A Terms are typically FCA our manufacturing facility．
Expédition、insurance和installation are quoted separately based on project location．
Payment milestones are tied to engineering approval、manufacturing completion、
and shipment．
Q Is operator training included？
A Comprehensive training on operation、entretien courant、
and safety procedures is included with installation commissioning，
conducted both at our facility during FAT和onsite during startup