1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Managing a highvolume limestone operation demands consistent output and predictable costs. Encore, traditional extraction and primary crushing methods often introduce bottlenecks that directly impact your bottom line. Êtes-vous confronté à ces défis persistants?

Alimentation incohérente vers le traitement en aval: Variable fragment sizes from the primary blast or initial breakage cause chokeups in secondary crushers, leading to unplanned downtime and reducing overall plant throughput.
High Wear Costs in Primary Crushing: Abrasive limestone rapidly degrades standard manganese steel crusher jaws and liners, ce qui entraîne de fréquents, costly replacement parts and laborintensive changeout procedures.
Excessive Fines Generation at the Primary Stage: Creating too many sub10mm fines during initial size reduction is inefficient, wasting energy on material that has already reached specification and devaluing your product stream.
Rigid Operational Workflow: Fixed primary crushing stations limit flexibility to follow optimal quarry faces, increasing haulage distances for haul trucks and raising fuel and maintenance expenses.
Inefficacité du scalping: Inadequate removal of clay, sable, and fine contaminants before primary crushing reduces crusher efficiency and can contaminate highpurity limestone products.

Addressing these issues requires a reevaluation of your primary reduction technology. Is your first crushing stage optimized for maximum availability and costperton efficiency?

2. APERÇU DU PRODUIT: MOBILE PRIMARY JAW CRUSHER FOR LIMESTONE

This solution is a trackmounted mobile jaw crusher, engineered specifically for highcapacity primary crushing in limestone quarrying applications. It is designed to be the first mechanical reduction point after drilling and blasting, processing runofquarry stone into a consistent, produit transportable pour transformation secondaire.

Flux de travail opérationnel:
1. Haul trucks dump shot limestone directly into the vibrating grizzly feeder (VGFF VGF).
2. The VGF scalps out natural fines and contaminants while evenly feeding the robust jaw crusher.
3. The jaw crusher performs highinertia compression crushing, reducing limestone boulders to a predefined top size.
4. Crushed material is discharged onto a wide main conveyor for transport to the next stage or a stockpile.
5. The entire unit can be repositioned via remotecontrolled track drive to minimize truck cycle times as the quarry face advances.

Champ d'application & Limites:
Portée: Ideal for largescale limestone quarries requiring 4001,500 tons per hour primary capacity. Suited for shot rock with a maximum feed size up to 1m³. Effective in operations prioritizing quick relocation and fast setup.
Limites: Not designed for extremely abrasive silicarich stone or very hard igneous rock without significant wear component specification adjustments. Requires regular planned maintenance intervals for optimal lifecycle cost.

3. CARACTÉRISTIQUES PRINCIPALES

Direct Drive Jaw Crusher | Base technique: Hightorque electric motor coupled directly to the crusher via fluid coupling | Avantage opérationnel: Élimine le glissement et l'entretien de la courroie trapézoïdale, delivers up to 95% power transmission efficiency for consistent crushing force | Impact sur le retour sur investissement: Reduces energy consumption by an estimated 812% par rapport aux systèmes traditionnels à entraînement par courroie, réduire les coûts d’exploitation directs.

QuarryGrade Vibrating Grizzly Feeder (VGFF VGF) | Base technique: Heavyduty stepped grizzly bars with boltin sections | Avantage opérationnel: Effectively removes fines (50mm) avant d'écraser, reducing crusher wear and preventing chamber packing | Impact sur le retour sur investissement: Extends jaw die life by 1525% by preventing abrasive grinding of alreadysized material.

Système de réglage à bascule hydraulique | Base technique: Les vérins hydrauliques à double effet remplacent les plaques à bascule mécaniques | Avantage opérationnel: Allows operators to adjust crusher closedside setting (CSS) in minutes for product size changes or clear blockages safely | Impact sur le retour sur investissement: Réduit de plus de temps les temps d'arrêt pour les ajustements de routine 80%, augmentation de la disponibilité annuelle des machines.

Métallurgie des composants d’usure | Base technique: Isotropic alloy steel jaw dies with optimized tooth profile | Avantage opérationnel: Provides extended service life in abrasive limestone applications through superior workhardening properties | Impact sur le retour sur investissement: Increases tons crushed per die set by 3040%, reducing part cost per ton and inventory requirements.

Système de contrôle de processus intelligent | Base technique: PLCbased system with load management algorithms | Avantage opérationnel: Automatically regulates feed rate based on realtime crusher motor amperage, optimizing throughput while protecting from overloads | Impact sur le retour sur investissement: Maximizes yield within power constraints; les données de terrain montrent un 58% increase in average throughput versus manual operation.

Suivre la mobilité & SetUp Automation | Base technique: Hydraulic folding conveyors and remotecontrolled track movement | Avantage opérationnel: Enables full site relocation and operational readiness in under 30 minutes without external equipment | Impact sur le retour sur investissement: Reduces nonproductive moving time, allowing closer followup on quarry faces to cut haul truck fuel costs by thousands annually.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Installation fixe / Basic Mobile Jaw) | This Mobile Primary Jaw Crusher Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Déménagement & Temps d'installation| 816 heures (grues, external power) | 90% plus rapide |
| Power Transmission Efficiency| ~85% (VBelt Drive Systems) | ~95 % (Système d'entraînement direct) | ~12% more efficient |
| Mâchoire Die Vie (Calcaire Abrasif)| Référence (Manganèse standard) | Optimized Alloy Steel Design & Profil| +35% durée de vie plus longue |
| Downtime for CSS Adjustment/Clearance| 24 heures (réglage manuel des cales)| <20 minutes (réglage hydraulique)| ~90% de réduction |
| Fines Scalping Efficiency| Grizzly bypass or limited prescreening| Stepped VGF with controlled bypass gate| +25% effective removal |

5. SPÉCIFICATIONS TECHNIQUES

Désignation du modèle: MPJ1200L
Type de concasseur: Concasseur à mâchoires primaire à bascule unique
Ouverture d'alimentation: 1200mm x 800 mm
Taille maximale d'alimentation: 1000mm longueur du bord
Réglage du côté fermé (CSS) Gamme: 100mm 250mm (réglable hydrauliquement)
Plage de capacité: Jusqu'à 650 tonnes par heure (dépendant du CSS & densité du matériau)
Puissance motrice: Étage 4 Final / Stage V dieselelectric; Electric crusher drive motor: 160 kW
Convoyeur principal: Largeur: 1400mm; Hauteur de décharge: ~4m (réglable hydrauliquement)
Mangeoire vibrante pour grizzlis: Longueur: 4000mm; Grizzly Section Length: 2500mm; Spacing: 50/80mm step grizzly
Suivre la mobilité: Hydraulic track drive with remote control capability
Poids opérationnel: Environ 78 tonnes
Plage de fonctionnement environnementale: Température ambiante: 20°C à +45°C; Designed for dust suppression system integration.

6. SCÉNARIOS D'APPLICATION

HighPurity Calcium Carbonate Quarrying | Challenge A major producer needed to reduce silica contamination from overburden clay in their primary crushed product while increasing plant uptime. Manual clearing of clogged primary chambers was causing weekly downtime events.| Solution Implementation of an MPJ1200L unit with its aggressive stepped grizzly feeder was deployed ahead of the fixed secondary circuit.| Results The VGF effectively scalped out over 90% of clay contaminants before crushing. Crusher blockages were eliminated, increasing monthly available operating hours by 18%. Product purity entering the washing plant improved significantly.

MultiPit Contract Mining Operation Challenge A contracting firm servicing several regional limestone quarries faced prohibitive costs establishing fixed primary crushing at each shortduration site. Truck haulage distances were escalating fuel costs.| Solution Deployment of a trackmounted mobile primary jaw crusher that could be relocated between sites on lowloaders within a single shift.| Results By positioning the crusher at the active face in each quarry, average haul truck cycle distance was reduced by 60%. This led to a direct 22% reduction in fleet fuel consumption across all sites, dramatically improving project margins.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification & Fonctionnalités facultatives:

Equipment investment is structured around core configuration with optional enhancements:
Configuration de base (MPJ1200L Core Unit): Includes standard features as specified.
Enhanced Durability Package (Facultatif): Includes upgraded wear liners on hopper/VGF/chutes (1015% prime), dust encapsulation skirts, and extendedlife bearing specifications.
Automation & Monitoring Package (Facultatif): Incorporates advanced telematics for remote health monitoring, automatic lubrication system feedback, and production tracking integration via onboard weighing.

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