H1: ODM Stationary Crushing & Usine de criblage: Engineered for Maximum Uptime and Tonnage

1. Addressing Your Core Operational Challenges in Aggregate Production

Managing a fixed crushing site presents distinct, des défis coûteux. Downtime isn't just lost production; it's missed contracts and eroding margins. Êtes-vous confronté:
Arrêts imprévus: Pannes de roulements, crusher blockages, and conveyor issues can halt your entire line. Every hour of downtime can cost thousands in lost revenue and idle labor.
Produit final incohérent: Fluctuations in feed material or improper calibration lead to offspec aggregate, entraînant le rejet du produit, coûts de recrudescence, et des relations clients endommagées.
Complexité de maintenance élevée: Disjointed equipment from multiple suppliers creates a spare parts nightmare and extends maintenance windows, straining your operational budget.
Flux de matériaux inefficace: Bottlenecks between crushing stages or screening units cap your plant's true capacity, forcing you to run longer hours at higher cost per ton.
Coûts opérationnels en hausse: Entraînements économes en énergie, consommation excessive de pièces d'usure, and high manual labor for monitoring directly reduce your profitability per cubic meter.

The question is not just how to crush rock, but how to build a reliable, predictable production asset. The solution lies in a fully integrated system designed from the ground up for synchronized performance.

2. Présentation du produit: The Integrated Stationary Crushing & Usine de criblage

The ODM Stationary Crushing & Screening Plant is a complete, hardwired processing circuit engineered for highvolume aggregate production in quarrying and mining applications. It transforms raw feed (0800mm) into precisely graded final products (par ex., 05mm de sable, 520mm agrégat).

Flux de travail opérationnel:
1. Alimentation primaire & Écrasement: Dump trucks feed a vibrating grizzly feeder which removes fines and directs oversize to a robust primary jaw crusher for initial size reduction.
2. Intermediate Processing & Dépistage: Crushed material is conveyed to a secondary cone crusher for further reduction. Output is then routed to a multideck vibrating screen for classification.
3. Product Sorting & Stockage: Onspec material from each screen deck is conveyed to designated stockpiles. Oversize is recirculated back to the appropriate crusher in a closedcircuit loop.

Champ d'application: Ideal for hightonnage production of aggregates for concrete, asphalte, and road base. Suitable for processing granite, basalte, calcaire, and other abrasive ores.

Limites: This is a fixedinstallation solution requiring foundational concrete works and grid power connection. Il n'est pas conçu pour des déménagements fréquents.

3. Fonctionnalités principales: L’ingénierie rencontre le retour sur investissement opérationnel

Modular Structural Frame | Base technique: Préfabriqué, hightensile steel sections with machined connection points | Avantage opérationnel: Permet plus rapidement, more precise onsite installation with reduced crane time and foundation work | Impact sur le retour sur investissement: Cuts installation timeline by up to 30%, reducing timetorevenue.

Système de contrôle PLC centralisé | Base technique: Contrôleur logique programmable avec interface homme-machine (IHM) panneau | Avantage opérationnel: Allows singleoperator monitoring and control of the entire flow from feeder to final conveyor; fournit des alertes de diagnostic | Impact sur le retour sur investissement: Reduces labor requirements by approximately 1 FTE per shift while improving response time to anomalies.

HeavyDuty Vibrating Screen with QuickDeck Change | Base technique: Rubbermounted screen box with tensioned wedgewire or polyurethane panels | Avantage opérationnel: Minimizes vibration transfer to structure; allows screen media replacement in hours vs. jours | Impact sur le retour sur investissement: Increases annual availability by ~2% and reduces maintenance labor costs.

Crusher Cavity Optimization | Base technique: Computeraided design of crushing chamber geometry matched to expected feed material | Avantage opérationnel: Maximizes reduction ratio per pass, improves product shape (cubique), and promotes even wear liner utilization | Impact sur le retour sur investissement: Boosts throughput by 515% while extending wear part life cycles.

Suppression de la poussière & Système de confinement | Base technique: Strategically placed spray nozzles at transfer points with encapsulation skirts | Avantage opérationnel: Maintient la conformité réglementaire pour les émissions de particules; protects bearings and motors from dust ingress | Impact sur le retour sur investissement: Avoids regulatory fines and reduces premature bearing failures by an estimated 40%.

Layered Walkways & Plateformes de maintenance | Base technique: Full perimeter access with safety handrails integrated into the plant design | Avantage opérationnel: Enables safe visual inspections, routine greasing, and component servicing without specialized scaffolding | Impact sur le retour sur investissement: Promotes proactive maintenance culture; reduces risk of safety incidents and associated downtime/costs.

4. Avantages compétitifs: Gains de performances quantifiables

| Mesure de performances | Référence des normes de l'industrie | ODM Stationary Plant Solution | Avantage documenté |
| : | : | : | : |
| Disponibilité des installations (Exécution planifiée) | 9092% | 9496%| +4% Amélioration |
| Consommation d'énergie par tonne traitée| Varie selon le type de roche| Optimized motor loads & des entraînements efficaces| Jusqu'à 12% Réduction |
| Coût des pièces d’usure par tonne métrique| $0.85 $1.10 USD| Matched chamber design & sélection d'alliage| 1520% Réduction |
| Installation & Temps de mise en service| 810 Semaines (from foundation)| Modular frame & unités préassemblées| ~30% Faster (67 Semaines)|
| Required Operating Labor per Shift| 34 Personnel| Centralized PLC control system| Réduit de 1 Operator |

5. Spécifications techniques

Plage de capacité de conception: 200 800 TPH (configurable based on model).
Exigence d'alimentation primaire: 400V/50Hz ou 480V/60Hz; Puissance totale installée: 350kW 800kW.
Spécifications des matériaux clés:
Revêtements de concasseur: Acier au manganèse (14%,18%,22%) or Chrome Iron Alloy options.
Plateformes d'écran:Tensioned Polyurethane or HighCarbon Steel Wire Mesh.
Bande transporteuse:Synthetic Fabric Ply (EP630/3) with minimum 12mm top cover.
Acier de construction:S355JR grade with hotdip galvanized finish on walkways.
Typical Physical Footprint (for a 350TPH plant): ~35m (L) x 22m (W) x 15m (H).
Plage de fonctionnement environnementale: Ambient temperature 20°C to +45°C; dust emission levels compliant with <10mg/Nm³ standards when used with suppression system.

6. Scénarios d'application

Projet d'agrandissement de la carrière de granit

Défi:A quarry needed to increase output by over 60% but had limited space for plant expansion within their existing lease boundary.Solution:Un compact,OEMdesigned threestage crushing circuit was installed,fitting into the footprint of an older twostage plant.The design included a large primary jaw crusher followed by two secondary cone crushers in parallel configuration feeding shared screens.This allowed higher throughput without increasing land use.The centralized control system was integrated into their existing site office via fiber optic cable.The new layout reduced internal haulage distances significantly.Retrofitted spray systems kept dust under control during blasting operations near residential areas.Finally,the modular construction allowed commissioning during planned seasonal shutdown minimizing disruption.Financing was secured through an equipment lease agreement preserving capital for other site improvements.Regular service visits ensured optimal performance throughout the warranty period leading them purchase an extended coverage plan.This holistic approach transformed their operational constraints into competitive advantage securing several large infrastructure contracts previously out reach due capacity limitations

Traitement du calcaire pour l’alimentation des cimenteries

Défi:A cement producer required consistent 25mm feed for their raw mill,but variations in quarry moisture content caused frequent clogging in their existing impact crusher.Solution:The implementation featured a primary jaw crusher followed by a heavyduty cone crusher equipped with automated setting regulation.Air cannons were installed at key hopper points,and conveyor skirts were extended.The PLC system was programmed to adjust feeder speed based on crusher motor load.Field data after six months showed clogging events reduced by over95%.Product consistency improved dramatically meeting the 25mm spec99.%of the time.This reliability allowed the cement kiln department optimize their own processes knowing raw material supply would be uninterrupted

Recyclage de projets d’infrastructures urbaines

Défi:A major road construction project mandated onsite recycling of demolished concrete to reduce truck traffic environmental impact but faced strict noise dust regulations tight urban site.Solution:A semimobile configuration was deployed featuring extensive acoustic enclosures around all major noise sources like crushers screens fully enclosed conveyors waterbased dust suppression systems every transfer point.The plant processed over500000tons recycled concrete aggregate meeting all stringent local environmental standards avoiding thousands truck movements city center

Considérations commerciales

Pricing is structured around plant capacity,niveau de personnalisation,and chosen component brands(e.g.,crusher motor manufacturer).Nous proposons trois niveaux principaux:

1.Niveau de configuration de base:Covers core functionality standard components proven reliability suitable budgetconscious operations seeking essential performance.Pricing typically ranges from$750000to$1million USD depending capacity

2.Niveau de performances(Recommandé):Includes features like centralized PLC automation premium wear liners enhanced dust suppression walkways platforms.Pricing typically ranges from$ million$ million USD

3.Niveau Premium clé en main:Fully customized solution including advanced predictive monitoring sensors extended warranty comprehensive operator training package civil engineering drawings support.Pricing determined specific project scope

Mises à niveau des fonctionnalités facultatives:
Advanced vibration monitoring sensors critical bearings
Systèmes de lubrification automatisés
Overband magnetic separator ferrous metal removal
Additional finished product conveyor stackers
Kit de démarrage de pièces de rechange

Forfaits de support technique:
Standard Warranty months parts labor excluding wear items
Extended Coverage Plans years available purchase
Annual Maintenance Contracts include scheduled inspections priority technical support discounted spare parts
OnDemand Field Service Technician dispatch available global network partners

Options de financement:
We work accredited financial partners offer:
Equipment leasing structures preserve working capital
Term loans competitive rates project financing
RentaltoOwn programs lower initial commitment

Section FAQ

What if my feed material hardness changes frequently?
Our cone crushers recommended Performance Tier feature hydraulic adjustment CSS clearing allow quick adaptation different rock characteristics without stopping process ensuring consistent output quality varying conditions

How does this integrate existing equipment like my primary excavator loaders?
Plants designed flexible feeding arrangements accommodate different loading methods We provide interface specifications hopper heights capacities ensure compatibility your current loading fleet minimizing integration issues

Quel délai de livraison typique mise en service?
For standard configurations lead time typically weeks exworks following deposit receipt Site commissioning supervised our engineers requires approximately weeks depending complexity local readiness

Les pièces de rechange sont-elles facilement disponibles dans le monde entier?
Yes maintain strategic inventory critical components partner global logistics providers ensure expedited shipping Additionally provide detailed part numbers crossreferences equivalent items facilitate local sourcing noncritical parts where appropriate

Proposez-vous une formation aux opérateurs?
Yes comprehensive training included Turnkey Tier optional others covers normal operation routine maintenance troubleshooting safety procedures Training conducted both our facility yours ensure competence confidence your team