1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks? Pour les directeurs d’usine et les entrepreneurs en ingénierie, a 250300tph crushing circuit is critical infrastructure, yet its performance gaps directly impact your bottom line. Les défis courants incluent:
Temps d'arrêt imprévus: Component failures in key crushers or screens halt your entire line, coûtant des milliers de dollars par heure en perte de production et en main d'œuvre inutilisée.
Débit incohérent: Fluctuations in feed material hardness or size lead to chokefeeding or cavitation, preventing you from reliably hitting your 300tonperhour target and fulfilling contracts.
Coûts opérationnels élevés: Consommation excessive de pièces d'usure, coupled with high energy consumption from inefficient crushing chambers and conveyors, érode les marges bénéficiaires.
Écart de qualité du produit: Inadequate screening or improper crusher settings result in offspec product, leading to material reprocessing or customer rejections.

La question centrale est: how do you achieve a steady 250300tph output with predictable operating costs and maximum plant availability? The answer lies not just in individual machines, mais de manière totalement intégrée et optimisée ODM 250300tph Stone Crushing Plant Assembly Plant.

2. APERÇU DU PRODUIT

The ODM 250300tph Stone Crushing Plant is a preengineered, stationary crushing and screening solution designed for highvolume production of aggregates for construction, base de route, et ballast ferroviaire. It represents a complete processing system assembled from coordinated modules.

Flux de travail opérationnel:
1. Réduction primaire: Matière première de grande taille (jusqu'à 750 mm) est constamment alimenté via un alimentateur vibrant pour grizzlis vers un concasseur à mâchoires primaire pour une réduction initiale de la taille.
2. Secondaire & Concassage Tertiaire: Le matériau broyé est transporté vers un concasseur à cône secondaire pour une réduction ultérieure.. A tertiary cone crusher or impact crusher module can be integrated for precise shaping and final size control.
3. Criblage des matériaux & Classification: Multiple decks of highefficiency vibrating screens separate the crushed stone into specified size fractions (par ex., 05mm, 510mm, 1020mm).
4. Stockage & Transport: Onspec product is transferred via radial stackers or fixed conveyors to designated stockpiles. Oversize material is recirculated back to the appropriate crusher.

Champ d'application & Limites:
Portée: Idéal pour le granit, basalte, calcaire, et autres matériaux à abrasivité moyenne à élevée. Suited for greenfield quarry sites or major plant upgrades requiring reliable, highcapacity output.
Limites: Non conçu pour les applications portables. Feed material with very high clay or moisture content exceeding design parameters may require preprocessing scrubbing modules.

3. CARACTÉRISTIQUES PRINCIPALES

Pré-assemblage modulaire | Base technique: Unitized skid/baseframe construction | Avantage opérationnel: Réduit le temps d'installation sur site jusqu'à 40%, minimizing weather delays and expediting commissioning | Impact sur le retour sur investissement: Des revenus plus rapides; lower labor costs for installation

Système de contrôle d'alimentation intelligent | Base technique: Entraînement à fréquence variable (VFD) on feeders paired with crusher amp monitoring | Avantage opérationnel: Régule automatiquement le débit d'alimentation pour éviter la surcharge du concasseur (étouffement) ou sous-utilisation (cavitation) | Impact sur le retour sur investissement: Protects crushers from damage; optimise la consommation d'énergie; ensures consistent throughput close to rated capacity

HeavyDuty Circuit Design | Base technique: Oversized conveyor belts, impact beds, and screen duty motors | Avantage opérationnel: Handles peak loads and surge conditions without transfer point spillage or premature component failure | Impact sur le retour sur investissement: Reduces cleanup labor and unplanned stoppages; extends mechanical component life

Graissage centralisé & Suppression de la poussière | Base technique: Automated lubrication points on all major bearings and integrated spray bars at transfer points | Avantage opérationnel: Ensures critical components are lubricated on schedule; suppresses airborne particulate at source | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements jusqu'à 30%; improves compliance with environmental health standards

Contrôle basé sur un API & Surveillance | Base technique: Automate programmable industriel avec interface homme-machine (IHM) in control cabin | Avantage opérationnel: Allows operators to start/stop sequence, monitor motor loads, belt alignment statuses, and bin levels from a single location | Impact sur le retour sur investissement: Enables operation with fewer personnel; provides diagnostic data for predictive maintenance planning

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (250300Usine de tph) | ODM Crushing Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité des installations | ~8588% (prévu & temps d'arrêt imprévu) | Cible >92% disponibilité | +47% amélioration |
| Efficacité énergétique| Fixed speed motors across conveyors & mangeoires| VFDs on feeders & select conveyors optimize power use| Jusqu'à 15% reduction in specific energy per ton |
| Wear Part Cost/Ton| Highly variable based on manual feed control| Optimized crushing chamber flow & automated feed reduces metalonmetal wear| Les données de terrain montrent 1020% coût par tonne inférieur |
| Chronologie d'installation| 812 weeks for field assembly & alignement| Major modules preassembled & aligned; timeline reduced| ~40% faster commissioning |

5. SPÉCIFICATIONS TECHNIQUES

Capacité conçue: 250 300 tonnes métriques par heure (varie en fonction de la densité du matériau & dureté).
Concasseur primaire: Jaw Crusher Model PEV900x1200 or equivalent. Feed opening up to 900mm x 1200mm.
Concasseur secondaire: MultiCylinder Hydraulic Cone Crusher (par ex., HPT300). Tertiary module available as option.
Module de dépistage: Tripledeck horizontal vibrating screen(s), total screening area ≥18m².
Exigence de puissance: Puissance totale installée environ 550 650 kW. Main voltage supply: AC380V/50Hz/3Ph (ou comme spécifié).
Spécifications des matériaux clés: Châssis principal fabriqué en acier Q345B; Highwear liners use Mn18Cr2 or equivalent alloy; Conveyor belting minimum EP400/3.
Dimensions physiques (Modulaire): Module primaire environ. L15m x L5m x H6m. Overall layout customizable per site plan.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C. Dust emission control meets standard regulatory limits.

6. SCÉNARIOS D'APPLICATION

Projet d'agrandissement de la carrière de granit

Défi: A quarry operator needed to increase output from 180tph to a consistent 280tph to fulfill a new highway contract but had limited space for plant expansion and needed minimal disruption during commissioning.
Solution: Implementation of an ODMdesigned modular crushing plant where the secondary/tertiary crushing module and screening tower were preassembled offsite.
Résultats: The modular approach cut field connection time by six weeks. The plant achieved rated throughput of 285tph within one week of commissioning, meeting the project's aggregate delivery schedule.

Traitement du calcaire pour l’alimentation des cimenteries

Défi: A cement producer's existing crushing circuit suffered from frequent plugging at the secondary crusher due to sticky clay content in the limestone seam, causing unpredictable downtime averaging 15 heures par semaine.
Solution: An ODM plant featuring an enhanced feed control system with cavitylevel sensors was installed alongside a heavierduty screen deck configuration prior to secondary crushing.
Résultats:The intelligent feed system adjusted rates during highclay conditions.The revised screening removed more fines prior to the cone crusher.Downtime related to plugging was reduced by over80%.

7.CONSIDÉRATIONS COMMERCIALES

Pricing tiers are structured around core configuration:
• Niveau de configuration de base:Covers primary jaw crusher,vibrating feeder,single cone crusher,module de dépistage,and basic conveyors.Suitable for less abrasive materials like limestone.Pricing typically quoted FOB factory port after final specification review
• Enhanced Configuration Tier Includes tertiary crushing stage,taller multistage screening towers,and full PLC automation with remote monitoring capabilities.Recommended for abrasive materials(granit,basalte)
• Optional Features Mobile truck loading stations,couvertures d'encapsulation de la poussière,wash plants addon modules,and advanced rockbreaker systems at primary hopper
• Service Packages Available options include annual scheduled maintenance plans,wear part supply agreements,and priority technical support packages which can help stabilize longterm operating costs
• Financing Options Flexible commercial terms can be discussed including leasing structures equipment financing through partners that allow capital preservation

FAQ

T1:What level of foundation work is required prior this plant’s installation?
A1:The modular skids require substantial concrete foundations designed according provided load drawings We supply complete foundation layout engineering drawings as part of technical documentation package Site civil works remain responsibility buyer

Q2 Can this plant configuration process recycled concrete aggregate(RCA)?
A2 Yes but must specified during design phase For processing RCA we recommend incorporating additional magnetic separatorfor rebar removaland potentially an impactcrusherrather than conefor tertiary stage due higher presenceof impurities Final product quality will depend input RCA feedstock cleanliness

Q3 How many operators are typically required run this tphplant?
A3 With centralized PLC control system one operatorin control cabin can manage entirecrushingscreening flow Typically two personnelare deployedfor ground patrol visual inspectionand routine manual tasks

Q4 Whatis typical lead timefrom order placementto shipment?
A4 Leadtime variesbasedon final specifications complexity Currentproduction leadtimesrange betweenweeksfor standardconfigurations Customizedmodulesmay extendthis period Detailed scheduleprovided upon project initiation

Q5 Are spare parts interchangeablewith otherbrandcrushers screens?
A5 Critical wear partslike jaw plates concavemantlesare machinedto original equipment specificationsand are notdirectly interchangeablewith other brands without modification We maintain comprehensiveinventoryof genuine spareparts ensureoptimal performanceand warranty compliance