Cibler les goulots d’étranglement primaires du concassage: Le coût élevé du compromis

Are your aggregate production targets consistently undermined by primary crushing limitations? Operational data across mining, carrière, and largescale construction reveals three persistent, des défis coûteux: temps d'arrêt excessif for liner changes and maintenance, unpredictable throughput due to premature wear or blockages, et spiraling operational costs from energy consumption and parts replacement. When your primary jaw crusher underperforms, the entire downstream process—conveying, concassage secondaire, screening—suffers in efficiency.

Considérez votre opération actuelle: Is unplanned downtime costing you over 100 heures productives par an? Are you sacrificing material spec consistency due to uneven wear profiles? Is your costperton metric rising despite stable feed material? La solution ne réside pas dans une amélioration progressive, but in a fundamental reevaluation of your primary crushing asset. Le Concasseur à mâchoires JC5000 is engineered to address these exact pain points.

Présentation du produit: The JC5000 HeavyDuty Jaw Crusher

Le JC5000 est un robuste, singletoggle jaw crusher designed for highcapacity primary crushing of hard rock, minerai, et béton de démolition. Son flux de travail opérationnel est conçu pour la fiabilité:
1. Acceptation des aliments: Grand (500mm x 400mm) feed opening accepts runofmine/quarry material with minimal prescreening.
2. Concassage par compression: A deep crushing chamber and aggressive elliptical jaw motion apply intense compressive force to reduce material.
3. Contrôle des décharges: A hydraulic toggle tensioning and adjustment system allows for precise closedside setting (CSS) control to maintain product gradation.
4. Évacuation des matériaux: High inertia flywheels and an optimized discharge path ensure continuous material flow and prevent choking.

Champ d'application: Ideal for stationary plant installation in granite, basalte, minerai de fer, and abrasive recycled concrete applications. Limites: Not designed for ultrasoft or clayheavy materials without prescalping; requires a solid foundation and appropriate feeder matching for optimal performance.

Fonctionnalités principales: Ingénierie pour la supériorité opérationnelle

Chambre de concassage profonde & Cinématique agressive | Base technique: Angle de pincement optimisé et course longue à l'ouverture d'alimentation | Avantage opérationnel: Increased capacity per stroke and reduced bridging incidents | Impact sur le retour sur investissement: Higher throughput (tph) directly lowers fixed cost allocation per ton.

Système de réglage à bascule hydraulique | Base technique: Replaceable mechanical toggle plate with hydraulic assist for unblocking and adjustment | Avantage opérationnel: Les modifications CSS peuvent être effectuées en quelques minutes plutôt qu'en heures; safe clearing of stalled chambers | Impact sur le retour sur investissement: Réduit les temps d’arrêt de réglage d’environ 80%, protecting against costly stall damage.

Heavily Reinforced Frame Design | Base technique: Fabricated from hightensile steel plate with finite element analysis (FEA) optimisation | Avantage opérationnel: Durabilité exceptionnelle sous chargement cyclique; withstands uncrushable material events | Impact sur le retour sur investissement: Extends structural life beyond industry norms, reducing longterm capital replacement risk.

TwinPath Lubrication System | Base technique: Dedicated grease lines to bearing ends with visible flow indicators | Avantage opérationnel: Ensures positive lubrication to critical bearings; simplifie les contrôles de maintenance de routine | Impact sur le retour sur investissement: Atténue la défaillance prématurée des roulements, a leading cause of catastrophic crusher downtime.

Boulonné (Non soudé) Boîtiers de roulement | Base technique: Precisionmachined housings bolted to crusher frame | Avantage opérationnel: Enables precise bearing alignment during assembly/service; facilitates field replacement if needed | Impact sur le retour sur investissement: Maintains optimal mechanical efficiency (powertocrush) and extends bearing service life.

Avantages compétitifs: Gains de performances mesurables

| Mesure de performances | Norme industrielle pour les mâchoires comparables | Solution de concasseur à mâchoires JC5000 | Avantage documenté |
| : | : | : | : |
| Durée de vie du revêtement (Granit abrasif) | ~120 000 tonnes par ensemble | ~150 000 tonnes par ensemble | +25% amélioration |
| Débit avec le même CSS (tph) | Référence 100% | 115120% of baseline range| +1520% augmenter |
| Consommation d'énergie (kWh/tonne) | Référence 100%| ~92% of baseline average| Jusqu'à 8% réduction |
| Annual Scheduled Downtime (Heures) 5070 heures 3040 heures 4050% réduction |

Spécifications techniques

Ouverture d'alimentation: 500mm x 400mm (environ. 20" x 16")
Taille maximale d'alimentation: 425mm (16.7")
Réglage du côté fermé (CSS) Gamme: 75mm 200mm (3" 8")
Plage de capacité: 250 550 tonnes par heure (varying based on material type & CSS)
Exigence de puissance d'entraînement: 132kW 160kW Electric Motor
Poids du concasseur (hors moteur): Environ 28,000 kilos
Construction du cadre: Plaque d'acier de haute qualité avec nervures renforcées
Main Shaft/Bearings: Forged alloy steel shaft; roulements à rotule sur rouleaux pour usage intensif
Plage de température de fonctionnement: 20°C à +45°C (4°F à +113°F)

Scénarios d'application

Hard Rock Quarry Expansion Challenge:

Une carrière de granit nécessaire pour augmenter le débit du circuit primaire de 20% without expanding its footprint or changing feed size.
Solution:
Two JC5000 Jaw Crushers replaced three older units.
Résultats:
Le débit a augmenté de 22%. La disponibilité des plantes est passée de 86% à 93% due to reduced liner change frequency. Energy cost per ton dropped by 7%.

Grande échelle C&D Recycling Plant Challenge:

A recycling facility processing demolition concrete faced extreme wear costs and unpredictable blockage clearing causing daily delays.
Solution:
JC5000 Jaw Crusher installed as the primary breaker.
Résultats:
Manganese liner life increased by 30%. The hydraulic toggle system cleared average blockages in under 10 minutes contre 90+ minutes previously. Product cubicity improved downstream processing efficiency.

Considérations commerciales

The JC5000 Jaw Crusher is positioned as a premium capital asset with total lifecycle cost advantages.

Niveau de tarification de l'équipement de base: Reflects its heavyduty construction class. Final pricing is configurationdependent (par ex., motor supplier choice).
Fonctionnalités facultatives & Forfaits:

Automated Grease System
Wear Package Spare Parts Kits
Installation & Supervision de la mise en service
Onsite Operator Training Modules

Forfaits de services:

1. Basic Warranty Coverage – Standard parts & labor warranty period.
2. Extended Service Plan – Covers scheduled inspections and discounted parts.
3. Full Performance Contract – Includes guaranteed liner life metrics & availability targets with fixed annual maintenance cost.

Options de financement: Location-acquisition, location simple, and project financing structures are available through partnered financial institutions to match various CAPEX strategies.

Foire aux questions

T1: Is the JC5000 compatible with our existing plant feed system and secondary crusher?
A1: The JC5000 requires standard heavyduty apron or vibrating feeder compatibility. Our engineering team provides a full interface review based on your required product size distribution to ensure optimal integration with your secondary circuit.

Q2 What is the expected operational impact on our maintenance crew?
A2 Your crew will benefit from simplified procedures like hydraulic CSS adjustment which reduces physical labor risks Training is provided on the specific maintenance access points designed into the JC5000 structure

Q3 How does the pricing structure account for optional features?
A3 We provide transparent modular pricing allowing you select only necessary options This ensures you pay for capability not bundled features you may not require

Q4 What are typical lead times from order placement commissioning?
A4 Lead times vary based on global supply chain conditions but typically range between 1624 weeks for complete delivery Factory acceptance testing prior shipment is standard procedure

Q5 Des garanties de performance sont-elles offertes?
A5 Yes performance guarantees based on mutually agreed feed material specifications can be included within formal purchase agreements These typically cover minimum throughput power consumption under defined conditions