Import Crushing And Screening Equipment Manufacturers
1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR
L’augmentation des coûts opérationnels et les temps d’arrêt imprévisibles érodent les marges de votre projet? In aggregate production, traitement des minéraux, et recyclage, un concassage et un criblage inefficaces constituent le principal goulot d'étranglement. Les défis courants incluent:
Temps d'arrêt excessif pour la maintenance: Changements fréquents de doublure, défaillances de roulements, and conveyor issues halt your entire production line.
Gradation du produit incohérente: Poor screening efficiency and improper crushing chamber dynamics lead to offspec material, causing product rejection and revenue loss.
Coûts opérationnels élevés: Consommation d’énergie en hausse par tonne, couplé à une fréquence élevée de remplacement des pièces d’usure, a un impact direct sur vos résultats.
Configuration d'usine rigide: Les systèmes fixes ne peuvent pas s'adapter à l'évolution des matières premières ou aux exigences du produit final., limiter la flexibilité opérationnelle.
Votre équipement actuel répond-il à ces problèmes, ou est-ce la source d'eux? La bonne station de concassage primaire n'est pas qu'un achat; it’s a strategic decision for longterm site profitability.
2. APERÇU DU PRODUIT: PRIMARY CRUSHING AND SCREENING STATION
This primary crushing and screening station is a fullyintegrated, trackmounted or modular system designed for the initial size reduction of runofmine ore, roche de carrière, or demolition concrete. Its workflow is engineered for continuous heavyduty operation:
1. Alimentation: Material is deposited via excavator or wheel loader into a robust vibrating grizzly feeder.
2. Présélection & Écrasement: The grizzly bypasses fines directly to a conveyor while oversize material is directed into the highcapacity jaw crusher.
3. Concassage primaire: The jaw crusher performs the first mechanical reduction using compressive force.
4. PostCrushing Screening: Crushed material is conveyed to an integrated screen for immediate separation into required product fractions.
5. Stockpiling or Secondary Conveyance: Sized fractions are stockpiled or conveyed to the next stage of processing.
Champ d'application: Idéal pour l'exploitation minière de roches dures, carrières de granulats, projets de construction à grande échelle, et C&D recycling operations requiring highvolume primary reduction.
Limites: Non conçu pour le façonnage du produit final (concassage tertiaire) or processing highly abrasive materials without specific liner configurations. Feed size must adhere to crusher opening specifications.
3. CARACTÉRISTIQUES PRINCIPALES
Direct Drive Jaw Crusher | Base technique: Eliminates Vbelts and associated components | Avantage opérationnel: Reduces power transmission losses and removes routine belt tensioning/maintenance | Impact sur le retour sur investissement: Les données de terrain s'affichent jusqu'à 10% une consommation de carburant réduite et 15% less scheduled maintenance time.
Independent PreScreen Module | Base technique: Twodeck vibrating grid mounted ahead of the crusher | Avantage opérationnel: Removes fines and natural sand from the crusher feed, reducing chamber wear and increasing throughput of valuable midsize material | Impact sur le retour sur investissement: Can extend manganese liner life by up to 30% and increase total station output.
Réglage du réglage hydraulique (HSA) | Base technique: Wedgebased chamber adjustment via hydraulic cylinders | Avantage opérationnel: Allows operators to change the crusher closedside setting (CSS) en dessous 2 minutes for precise product size control without stopping the plant | Impact sur le retour sur investissement: Minimizes nonproductive time during product changeovers by over 90%.
HeavyDuty Feeder with Step Grizzly | Base technique: Reinforced feeder with stepped grizzly bars to prevent clogging | Avantage opérationnel: Ensures consistent feed flow even with sticky or claybound materials, preventing bridging and feeder stall | Impact sur le retour sur investissement: Maintains target throughput rates in challenging conditions, avoiding costly flow interruptions.
Integrated Plant Automation System (IPAS) | Base technique: PLCbased control with touchscreen interface monitoring all critical functions | Avantage opérationnel: Fournit des données en temps réel sur les taux de production, consommation d'énergie, and operational status; enables singlepanel control for setup and troubleshooting | Impact sur le retour sur investissement: Améliore l’efficacité globale de l’équipement (OEE) through better monitoring and reduces diagnostic time by an average of 50%.
Points de graissage centralisés | Base technique: Manifold system linking all major bearing points to a single station | Avantage opérationnel: Permet de sécuriser, rapid daily lubrication checks without requiring access around moving components | Impact sur le retour sur investissement: Standardizes preventive maintenance routines, enhancing bearing life and reducing lubricationrelated failures.
4. AVANTAGES CONCURRENTIELS
| Mesure de performances | Solution standard de l'industrie | This Primary Crushing & Screening Station | Avantage (% Amélioration) |
| : | : | : | : |
| Tonnes par heure (TPH) Efficacité| Reliant on optimal feed conditions only| Maintient >90% of rated TPH with variable/ sticky feed due to step grizzly design| +1520% sustained output |
| Coût des pièces d'usure par tonne| Based on standard manganese composition| Utilizes sitespecific alloy analysis for jaw liners in highabrasion applications| Jusqu'à 25% coût par tonne concassée |
| Installation / Configuration Time| Multiple machine positioning & cable connections required| Singlelift modules with prerigged electrical connections between units| 70% relocation time |
| Consommation d'énergie (kWh/tonne)| Direct mechanical drive with fixed speed motors| Loadsensing hydraulics & direct electric crusher drive adjust power to demand| 8% average energy use |
Based on comparative field trials in granite quarry applications.
5. SPÉCIFICATIONS TECHNIQUES
Type de concasseur primaire: Nordberg C106 Jaw Crusher
Ouverture d'alimentation: 1,060 mm x 700 mm (42” x 28”)
Taille maximale d'alimentation: 600 mm (24»)
Réglage du côté fermé (CSS) Gamme: 70 200 mm
Plage de capacité: Jusqu'à 500 MTPH (en fonction de la densité du matériau & CSS)
Unité de puissance: CAT C9 / C9.3 ACERT Tier 4 Moteur diesel final
Puissance totale installée: 224 kW
Feeder Type: Vibrating Grizzly Feeder VG43912V
Screen Module: Twodeck inclined screen TS303
Main Conveyor Width: 1,000 mm
Dimensions de transport (LxlxH): ~19m x ~3m x ~4m
Poids opérationnel: ~45 tonnes
Plage de température de fonctionnement: 25°C à +40°C
6. SCÉNARIOS D'APPLICATION
Agrandissement de la carrière de granulats de granit | Défi: Existing fixed primary plant could not service new pit face location without major infrastructure cost; mobile solutions lacked necessary throughput and prescreening. Solution: Deployment of a trackmounted primary crushing and screening station fed directly by excavator at the new face. Résultats: Eliminated need for costly ramp construction and dump truck haulage to old plant. A atteint un débit constant de 380 Mtph of minus200mm base material with improved yield of valuable railway ballast fraction due to integrated screening.
Projet d'infrastructure à grande échelle (Dam Construction) | Défi: Processing riverrun gravel with high sand content led to rapid crusher wear choke points in traditional setups. Solution Implementation of a modular primary station featuring an independent prescreen module ahead of the jaw crusher Results Prescreen removed over 25% of sand/fines prior to crushing reducing abrasive wear Throughput increased by18% as crusher processed only oversize Wear part replacement intervals extended by approximately40%
7 CONSIDÉRATIONS COMMERCIALES
Pricing for a primary crushing station varies significantly based on configuration:
- Base Configuration Includes core jaw crusher basic feeder engine chassis essential conveyors PLC start/stop controls Tier pricing typically begins in range appropriate for this capital equipment class
- Dust suppression system package including water tank spray bars
- Magnet installation over discharge conveyor ferrous metal removal
- Radio remote control unit for independent feeder/crusher operation from ground level
- Extended wear part kits stock
- Comprehensive Extended Warranty covering major components years unlimited hours
- Scheduled Maintenance Plan providing fixed cost annual inspections parts labor
- On Site Operator Training Program days hands instruction
Optional Features That Add Value:
Forfaits de services disponibles:
Financing Options Flexible capital solutions include equipment leasing long term rental purchase leaseback structures tailored support cash flow management project timelines
8 FAQ
What type/size of excavator is recommended as a feeder?
A minimum operating weight class excavator equipped with suitable bucket capacity ensure consistent choke feeding maximize crusher efficiency productivity
How does this system handle reinforcing bar rebar in concrete demolition waste?
While jaw can process reinforced concrete integrated overband magnet discharge conveyor effectively removes liberated ferrous metals protecting downstream conveyors secondary crushers
What are typical delivery lead times after order confirmation?
Standard configurations have confirmed lead time weeks subject build slot availability engineering review Custom modular designs may require additional weeks detailed engineering fabrication
Is operator training provided with purchase?
Yes comprehensive onsite training program conducted commissioning covers daily operation routine maintenance safety procedures troubleshooting using actual plant systems
Can this station be integrated into existing fixed plant circuit as temporary primary unit?
Yes stations are designed standalone mobility can be positioned feed directly into existing secondary tertiary circuits via discharge conveyor ideal use during planned upgrades maintenance existing primary crushers