1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing a highvolume aggregate operation where consistent uptime and final product specification are critical to profitability? Operational challenges with primary crushing can create cascading inefficiencies across your entire plant. Les points douloureux courants incluent:
Temps d'arrêt imprévus: Frequent liner changes and unexpected mechanical failures in the primary station halt downstream processing, coûtant des milliers de dollars par heure en perte de production.
Gestion incohérente des aliments: Fluctuating feed size from the quarry face or bridging in the hopper leads to chokefeeding or starvation, reducing crusher efficiency and increasing wear unevenly.
Variabilité de la qualité des produits: Inability to precisely control the CSS (Réglage du côté fermé) or compensate for wear results in an outofspec primary crush, overworking secondary crushers and screens.
Coûts opérationnels élevés: Excessive energy consumption per ton, combined with high labor costs for manual adjustments and rapid wear part replacement, érode les marges bénéficiaires.
Configuration rigide: Fixed plants struggle to adapt to changing deposit profiles or new project specifications, limiting the return on your capital investment.

Votre station de concassage principale est-elle un actif fiable ou un goulot d'étranglement récurrent? The solution lies in selecting a stationary crushing plant engineered not just for capacity, but for predictable performance and total cost of ownership.

2. APERÇU DU PRODUIT: Premium Stationary Crushing Plant

This premium stationary crushing plant is a complete, hardrock optimized primary crushing system centered on a highperformance jaw crusher. Il est conçu pour une utilisation continue, heavyduty operation in quarrying, exploitation minière, and largescale infrastructure projects requiring consistent, hightonnage output of base material.

Flux de travail opérationnel:
1. Alimentation contrôlée: Oversized feed from haul trucks is received by a vibratory grizzly feeder, which scalps fines and ensures a consistent, regulated flow to the crusher.
2. Réduction primaire: The core jaw crusher utilizes compressive force to reduce feed material (jusqu'à 1200 mm) to a manageable firstbreak product.
3. Integrated Removal: A robust discharge conveyor efficiently removes crushed material from the crusher cavity for transport to downstream processes.

Champ d'application & Limites:
Portée: Ideal for processing abrasive materials like granite, basalte, et minerai de fer. Suited for highcapacity (5002,000+ TPH) permanent installations where longterm production stability is paramount.
Limites: Not mobile or trailermounted. Requires significant foundational civil works and initial capital investment. Optimal performance requires wellblasted feed material within the crusher’s designed maximum feed size.

3. CARACTÉRISTIQUES PRINCIPALES

Conception de cavité brevetée | Base technique: Dynamique cinématique & analyse par éléments finis | Avantage opérationnel: Achieves higher reduction ratios with less stress on components, producing a more cubical product at the primary stage. | Impact sur le retour sur investissement: Reduces load on secondary/tertiary circuits by up to 15%, réduire la consommation énergétique globale de l’usine.

Bascule hydraulique & Système de réglage | Base technique: Integrated hydraulic cylinder for tensioning and clearing | Avantage opérationnel: Allows operators to adjust the CSS safely and precisely in minutes under load or clear blockages remotely. | Impact sur le retour sur investissement: Réduit de plus de temps les temps d'arrêt pour les ajustements de routine 90% par rapport aux systèmes de cales manuels.

Cadre de base fabriqué robuste | Base technique: Welded steel construction with precision machined mounting surfaces | Avantage opérationnel: Provides absolute alignment stability for the crusher and motor, minimizing vibration and premature bearing wear. | Impact sur le retour sur investissement: Extends major component service life by an estimated 30%, deferring major overhaul costs.

Conduite intelligente & Conception du volant | Base technique: Highinertia flywheels coupled with VFDcapable motors | Avantage opérationnel: Maintains consistent crushing momentum during peak loads, ensuring smooth power transmission and peak efficiency. | Impact sur le retour sur investissement: Les données de terrain montrent un 712% reduction in kWh per ton of crushed material compared to standard configurations.

Suppression de la poussière intégrée & Scellage | Base technique: Multipoint sealing system with manifold for dust suppression spray bars | Avantage opérationnel: Contains dust at transfer points and within the crushing chamber, améliorer la conformité environnementale des sites et la santé des opérateurs. | ROI Impact Mitigates risk of regulatory fines and reduces cleanup labor costs.

Graissage centralisé & Points de surveillance | Base technique: Lube lines routed to a single access platform with pressure indicators | Avantage opérationnel Permet une sécurité, rapid daily maintenance checks and lubrication without requiring access around moving components.| ROI Impact Increases preventative maintenance adherence by crew improves bearing protection reducing unplanned stoppages

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | This Crushing Plant Solution | Avantage documenté |
| : | : | : | : |
| Disponibilité (Exécution planifiée) | 8892% | 95%+ | +5% amélioration |
| Porter la vie (Mn/Ton per Jaw Set) Granit| 80,000 100,000 tonnes| 130,000 150,000 tonnes| +40% amélioration |
| Efficacité énergétique (kWh/tonne) Hard-Rock| 0.8 1.1 kWh/tonne| 0.7 0.85 kWh/tonne| Jusqu'à 15% amélioration |
| Temps d'ajustement CSS (Mécanique vs hydraulique)| 60 90 minutes (cold)| <10 minutes (sous charge)| ~85% time savings |
| Temps moyen entre les pannes (MTBF) Composants majeurs| ~6，000 heures| ~8，500 heures| +40% augmentation de la fiabilité |

5.SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 500 to over2，200 tonnes métriques par heure， depending on model selection feed material
Type de concasseur: Heavyduty singletoggle jaw crusher
Ouverture d'alimentation: From1，200mm x830mm up to1，600mm x1，200mm
Puissance motrice: Electric motors from200 kW up to400 kW VFD compatible
Construction du cadre principal: Quenched tempered steel plate welded stressrelieved structure
Standard Feeder: Vibrating grizzly feeder with adjustable grizzly sections heavyduty exciter drive
Approximate Plant Footprint (Lxl): Varie selon la configuration; gamme typique：25m x15m foundation requirements provided
Plage de température de fonctionnement： Full functionality from 25°Cto+45°Cwith specified lubricants

6 SCÉNARIOS D'APPLICATION

Défi d’agrandissement de la carrière de granit： An existing quarry needed double primary capacity meet new highway contract specs but had limited space for expansion foundation work Solution： A compact highcapacity stationary crushing plant was installed parallel existing line featuring advanced dust suppression Results： Achieved96% availability first year met100%of new contract volume requirements while staying within site boundary limits reducing haul cycle times

Iron Ore Processing Plant Upgrade Challenge： Aging primary crusher caused frequent bottlenecks inconsistent feed size secondary ball mills increasing specific energy consumption Solution： Replacement with modern stationary plant featuring hydraulic adjustment intelligent drive control precise product sizing Results： Primary throughput increased22% achieved9% reduction kWh/ton mill feed stabilized leading annual energy savings exceeding$180，000

7 CONSIDÉRATIONS COMMERCIALES

Pricing structured around core configuration model size optional modules Service financing designed support longterm partnership

Niveaux de tarification des équipements
• Tier I Base Plant Includes crusher base frame motor starter feeder discharge conveyor walkways ladders
• Tier II Enhanced Package Adds automated grease system integrated dust suppression rock breaker boom platform advanced motor controls
• Tier III Turnkey Solution Includes full electrical control room design installation supervision commissioning support civil engineering drawings

Fonctionnalités facultatives
• Onboard weighing instrumentation product tracking
• Remote monitoring telematics package predictive analytics
• Special alloy liners specific highly abrasive applications
• Winterization packages extreme climates

Forfaits de services
• Platinum Plan： Comprehensive coverage including planned maintenance wear parts inspections priority support
• Gold Plan： Scheduled maintenance inspections recommended spare parts holding
• Silver Plan： Annual inspection technical support asneeded parts supply

Options de financement
Capital equipment leasing operating lease structures project financing available through partnered institutions tailored cash flow requirements

8 FAQ

What if my feed material hardness varies significantly？
The hydraulic toggle system allows quick CSS adjustment compensate changing rock characteristics maintain target product size without shutdown

How does this plant integrate with my existing secondary circuit？
Engineering team provides interface drawings conveyor specifications ensure compatibility belt speeds transfer heights can be customized match your layout

What is typical installation commissioning timeline？
From delivery site mechanical erection electrical connection dry commissioning typically requires812weeks depending site readiness complexity full turnkey management available

Are wear parts readily available globally？
Yes critical wear parts jaws side liners toggle seats stocked regional service centers supported guaranteed48hour emergency shipping program Platinum Gold plans

Can you provide detailed foundation load drawings？
Yes complete geotechnical data pack including dynamic static load diagrams anchor bolt templates concrete volume specifications issued upon order facilitate civil works planning