1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

L’augmentation des coûts opérationnels et les temps d’arrêt imprévisibles érodent vos marges de production globales? Pour les directeurs d’usine et les entrepreneurs en ingénierie, les principaux défis du concassage primaire se concentrent souvent sur trois domaines critiques:

Temps d'arrêt imprévus: Changements fréquents de doublure, pannes mécaniques inattendues, and clogged chambers halt your entire processing line. Industry data indicates that each hour of crusher downtime can cost over $10,000 en perte de production et de travail.
Coûts opérationnels en hausse: Are you constantly battling high energy consumption per ton of processed material, coupled with the escalating expense and frequency of wear part replacements?
Sortie incohérente & Qualité: Fluctuations in feed size or hardness resulting in poor product shape, uneven gradation, and increased recirculating load that bottlenecks secondary crushers and screens.

How do you achieve reliable throughput with predictable maintenance windows and lower costperton? The solution requires a robust foundation: a primary crushing station engineered for durability and efficiency.

2. APERÇU DU PRODUIT: ODM HeavyDuty Primary Jaw Crusher Plant

This product is a stationary or semimobile primary crushing plant centered on a heavyduty jaw crusher. It is designed as the first stage in mineral processing and aggregate production to reduce runofmine ore or blasted quarry rock to a manageable size for downstream conveying and processing.

Flux de travail opérationnel:
1. Alimentation: Dump trucks or loaders deposit raw material into a reinforced hopper.
2. Présélection (Facultatif): A grizzly feeder removes fines to bypass the crusher, améliorer l'efficacité et réduire l'usure.
3. Concassage primaire: The core jaw crusher utilizes compressive force to break large stones between a fixed and a reciprocating jaw plate.
4. Décharge: Crushed material is discharged onto a main conveyor belt for transport to the next stage of the circuit.

Champ d'application & Limites:
Portée: Idéal pour l'exploitation minière de roches dures (granit, basalte), quarrying for aggregate, and construction waste recycling with reinforced concrete. Suited for hightonnage primary reduction.
Limites: Not designed for abrasive metal ores better suited to gyratory crushers at very high capacities (>3000 tph). Requires prepared feed; maximum lump size is limited by crusher inlet dimensions.

3. CARACTÉRISTIQUES PRINCIPALES

Chambre de concassage profonde & Cinématique optimisée | Base technique: Increased nip angle and longer stroke | Avantage opérationnel: Enables higher capacity reduction in a single pass, améliorant le débit jusqu'à 15% par rapport aux conceptions conventionnelles | Impact sur le retour sur investissement: Higher output per operating hour directly lowers fixed cost allocation per ton.

Cadre principal fabriqué de manière robuste | Base technique: Construction en tôle d'acier soulagée avec nervures renforcées | Avantage opérationnel: Offre une durabilité exceptionnelle contre les charges de choc provenant d'un matériau incassable, minimiser la fatigue du cadre et le risque de panne catastrophique | Impact sur le retour sur investissement: Extends total plant service life, protects major capital investment.

Réglage hydraulique & Système de compensation | Base technique: Vérins hydrauliques intégrés pour la tension à bascule et le nettoyage de la chambre | Avantage opérationnel: Allows operators to adjust CSS quickly under load and automatically reverse the jaw to clear blockages without manual intervention | Impact sur le retour sur investissement: Réduit le temps de réglage de 70% and eliminates hours of dangerous manual clearing labor per incident.

Doublures d'usure BoltOn & Matrices à mâchoires modulaires | Base technique: Symmetrical design and standardized mounting hardware | Avantage opérationnel: Enables rotation/replacement of wear parts from one side of the crusher. Reduces liner inventory requirements through interchangeability | Impact sur le retour sur investissement: Réduit les temps d'arrêt pour maintenance programmée jusqu'à 40% and lowers spare part holding costs.

Interface d'automatisation basée sur un API | Base technique: Centralized control with sensors for power draw, CSS monitoring, and bearing temperature | Avantage opérationnel: Provides realtime operational data for predictive maintenance scheduling. Allows remote monitoring of key performance parameters | Impact sur le retour sur investissement: Prevents unplanned stops through condition monitoring; optimizes performance settings for variable feed conditions.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | ODM Jaw Crusher Plant Solution | Avantage documenté |
| : | : | : | : |
| Disponibilité (Temps de disponibilité) | 8590% (y compris la maintenance programmée) |> 93% disponibilité cible| +58% amélioration |
| Porter la vie (Mn13/18 Jaw Plates) on Granite| 120,000 150,000 tonnes| 180,000 220,000 tonnes| +4050% amélioration |
| Consommation d'énergie par tonne broyée| Varie selon le type de roche; ligne de base = 100%| Optimized kinematics reduce specific energy demand| Jusqu'à 12% réduction |
| Total Maintenance Hours per Year (Programmé)| ~250300 hours| ~160200 hours|<30% réduction |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de la gamme de modèles: 150 1,200 tonnes par heure (TPH), en fonction du matériau alimenté et du réglage du côté fermé (CSS).
Ouverture d'alimentation du broyeur: De 900 mm x 600 mm jusqu'à 1 500 mm x 1 200 mm.
Exigences d'alimentation: Moteur du concasseur principal de 75 kW à 250 kW. Total plant power including feeders and conveyors specified per configuration.
Spécifications matérielles: Main frame constructed from Q345B steel plate; jaw dies available in Mn13Cr2, Mn18Cr2, or custom martensitic alloys; Arbre forgé en acier allié à haute résistance (42CrMo).
Dimensions physiques (Typical Stationary Plant): Longueur ~18m; Width ~6m; Hauteur ~7m (varies significantly with model).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C. Norme sur le système de suppression des poussières; noise encapsulation optional.

6. SCÉNARIOS D'APPLICATION

Projet d'agrandissement de la carrière de granit

Défi: An existing quarry needed to increase primary output by over 60%. The existing plant suffered from excessive vibrationrelated cracks in the frame structure leading to frequent unscheduled repairs.
Solution: Implementation of an ODM heavyduty jaw crusher plant with a reinforced fabricated frame design rated at 650 TPH.
Résultats: After two years of operation at full capacity:
94% operational availability achieved.
0 structural integrity issues reported.
Costperton reduced by an estimated $1.15 due to higher throughput efficiency.

LargeScale Infrastructure Concrete Recycling

Défi: A contractor required onsite primary crushing of demolished concrete with high rebar content at multiple locations within an urban environment requiring rapid setup/teardown.
Solution: Deployment of a semimobile ODM jaw crusher plant variant equipped with an overband magnet for metal extraction.
Résultats:
95% pure aggregate produced onsite for reuse as road base.
30minute hydraulic clearing system successfully managed multiple rebar jamming events without major delay.
80% reduction in trucking costs associated with hauling demolition waste offsite.

7. CONSIDÉRATIONS COMMERCIALES

ODM provides tailored commercial solutions based on project scope:

Niveaux de tarification: Basé sur la capacité nominale (par ex., 500 TPH) level of automation integration included as standard or optional features such as dust suppression systems noise enclosures advanced condition monitoring packages extended warranty coverage beyond standard terms financing options available through partner institutions including leasetoown structures which can preserve capital expenditure budgets installation commissioning supervision packages are offered separately or bundled

8.FAQ

1.Q:What is the lead time for delivery?
A.For standard models lead time ranges from weeks depending on current production schedule Custom configurations may require additional engineering time

2.Q:Quelles sont les exigences d'installation typiques?
A.A prepared concrete foundation plan is provided along with full dimensional drawings Electrical connection specifications are detailed well in advance

3.Q:What level of technical support is provided during commissioning?
A.Commissioning support includes supervision by factorytrained engineers ensuring proper setup initial calibration operator training

4.Q:Quelles sont les conditions de paiement?
A.Terms are typically structured around milestones such as order confirmation preshipment inspection final acceptance after commissioning

5.Q:What factors most influence wear part life?
A.Primary factors include feed material abrasiveness compressive strength feed size distribution versus CSS setting consistent feeding practices