1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing a midtolarge scale aggregate operation and facing persistent bottlenecks that erode profitability? Pour les directeurs d’usine et les entrepreneurs en ingénierie, le 250300 TPH capacity range is critical, yet often problematic. Les défis courants incluent:
Débit incohérent: Feed material variability causing output to fluctuate below the 250 TPH target, failing to meet project batching schedules and leading to costly penalties.
High PerTon Operating Costs: Premature wear on crusher liners and screens, combined with inefficient power distribution across multiple units, driving maintenance and energy expenses higher than budgeted.
Temps d'arrêt excessif pour la maintenance: Poorly coordinated plant layouts and components with staggered service intervals result in unplanned stops, reducing overall plant availability below 92%.
Product Quality Inflexibility: Inability to quickly adjust crusher settings and screen configurations to switch between railway ballast, base de route, and concrete aggregates without halting production.

How do you consolidate a reliable 300 TPH output from varied feed material while controlling operational costs and maximizing plant uptime? The solution lies in a holistically engineered stationary crushing and screening plant designed specifically for this duty cycle.

2. APERÇU DU PRODUIT

The OEM 250300tph Stone Crushing Plant is a complete, stationary crushing circuit engineered for highvolume production of certified aggregates from hard rock formations like granite, basalte, et pierre de rivière. It is designed as a primarytotertiary processing system for contractors and mining operations requiring consistent, highyield output.

Flux de travail opérationnel:
1. Réduction primaire: Dumpfed material is crushed by a robust primary jaw crusher, reducing large feed (≤750mm) to a manageable size for secondary processing.
2. Secondaire & Concassage Tertiaire: Material is conveyed to a cone crusher(s) pour une réduction supplémentaire de la taille, producing intermediate aggregates. A tertiary impact crusher may be integrated for shaping applications.
3. Classement des tailles: Crushed material is routed through multideck vibrating screens to precisely separate product sizes (par ex., 05mm, 510mm, 1020mm, 2031.5mm).
4. Recirculation & Stockage: Oversize material is automatically returned via closedcircuit conveyors for recrushing. Onspec product is conveyed to designated stockpiles.

Champ d'application & Limites:
Portée: Ideal for large infrastructure projects (autoroutes, chemins de fer), commercial concrete batching plants supply, and permanent quarry sites.
Limites: This is a stationary plant requiring foundational work and grid power connection. It is not suitable for frequent relocation. Optimal feed material should have an abrasion index (Aï) below .20 for expected wear part life.

3. CARACTÉRISTIQUES PRINCIPALES

Système de contrôle intelligent | Base technique: Centralized PLC with loadsharing algorithms | Avantage opérationnel: Monitors motor amperage and crusher pressure in realtime to optimize feed rates automatically | Impact sur le retour sur investissement: Prevents chokefeeding and cavity loss; field data shows up to an 8% increase in throughput efficiency.

Modular Component Design | Base technique: Standardized bolttogether modules with preengineered interfaces | Avantage opérationnel: Reduces civil works cost and accelerates onsite installation by approximately 30% | Impact sur le retour sur investissement: Lower capital outlay for site preparation; faster commissioning generates revenue sooner.

HeavyDuty Vibrating Feeder with Grizzly Section | Base technique: Highinertia feeder with adjustable grizzly bars | Avantage opérationnel: Removes natural fines prior to primary crushing and ensures steady, regulated feed | Impact sur le retour sur investissement: Reduces unnecessary work on the primary crusher; industry testing demonstrates a 1520% extension in jaw plate life.

Graissage centralisé & Système de lubrification | Base technique: Automated singlepoint lubrication lines to all major bearing points | Avantage opérationnel: Ensures consistent lubrication intervals during operation; eliminates manual greasing errors | Impact sur le retour sur investissement: Reduces bearing failure risk; documented increase in mean time between failures (MTBF) by over 25%.

HighEfficiency Cone Crusher Configuration | Base technique: Hydraulic adjustment and clearing systems with advanced chamber profiles | Avantage opérationnel: Allows quick CSS changes for product sizing without tools; automatic tramp release protects the machine | Impact sur le retour sur investissement: Minimizes adjustment downtime; improves yield of premium chip products by up to 12%.

Points d'intégration de la suppression de la poussière | Base technique: Preinstalled piping manifolds at transfer points with nozzle connections | Avantage opérationnel: Enables easy integration of water spray systems to control airborne particulate at source locations | Impact sur le retour sur investissement: Facilitates compliance with environmental regulations; reduces cleanup costs and operator exposure.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (250300Usine de tph) | OEM 250300tph Solution | Avantage (% amélioration) |
|||||
| Disponibilité globale de l'usine | ~91% | ≥94% | +3.3% |
| Consommation d'énergie par tonne | ~0.85 kWh/t | ≤0.78 kWh/t |8.2% |
| Wear Part Cost per Ton (Primaire) | $0.12 $0.18/t | $0.09 $0.14/t |25% (at midpoint) |
| Installation & Temps de mise en service | 1216 semaines | 811 semaines |31% |
| Product Yield within Specification ±5% ±2% +60% consistency |

5.SPÉCIFICATIONS TECHNIQUES

Capacité conçue: Guaranteed output of 250 tonnes par heure; capable of peak outputs up to 320 tph depending on feed material and product size configuration.
Exigences d'alimentation: Puissance totale installée environ 450500 kW. Requires stable grid connection or equivalent generator setup.
Spécifications matérielles: Handles compressive strength ≤350 MPa. Main frame constructed from Q345B steel; wear liners use Mn18Cr2 or equivalent highchromium iron.
Dimensions physiques (Disposition typique): Entire plant footprint ~70m (L) x 45m (W). Maximum height ~15m at conveyor discharge points.
Plage de fonctionnement environnementale: Designed for ambient temperatures from 20°C to +45°C with proper lubricants/fluids.

6\. SCÉNARIOS D'APPLICATION

Highway Base Course Production

Challenge A national contractor needed a guaranteed minimum of 280 TPH of Class II road base material (31.5mm) from abrasive basalt rock but faced constant liner wear issues causing unpredictable downtime.
Solution Implementation of the OEM plant featuring the heavyduty feeder/grizzly section paired with highefficiency cone crushers configured specifically for abrasive rock.
Results Wear part intervals increased by over two operating shifts between changes while maintaining consistent throughput of >290 TPH over an eightmonth project duration.

Commercial Aggregate Quarry Expansion

Challenge A quarry supplying multiple concrete plants required increased flexibility to produce four distinct aggregate products simultaneously without sacrificing total volume or resorting to manual sorting.
Solution The modular design allowed integration of an additional screen deck into the circuit alongside precise conveyor routing controls managed by the central PLC system.
Results The plant achieved simultaneous production of sand (04mm), chips (410mm), medium aggregate (1020mm),and drainage stone(2031\.5mm).Product changeover time was reduced from hours down to minutes via automated settings

7\. CONSIDÉRATIONS COMMERCIALES

Pricing tiers are structured around core equipment configuration:
• Tier I – Base Configuration Includes primary jaw secondary cone tertiary impactor basic screening module conveyors central control panel Starting price range
• Tier II – Enhanced Configuration Adds automated metal detection dust suppression system extended walkways service platforms Premium price range
• Tier III – Custom Configuration Incorporates specialized wear liners dual power source capability advanced particle shape analysis integration Custom pricing

Optional Features Include remote monitoring telematics package sound attenuation enclosures automatic sampler systems

Forfaits de services disponibles:
• Basic Warranty – Standard parts warranty covering manufacturing defects
• Comprehensive Service Plan – Includes scheduled maintenance inspections wear part kits priority technical support
• Full Operations Contract – Covers total operational maintenance including labor parts performance guarantees

Financing Options Flexible project financing leasing arrangements or leasetopurchase plans can be structured typically over threetosevenyear terms subject to credit approval

8\. FAQ

Q What are the primary electrical requirements?
A The complete plant requires a threephase supply at approximately kV depending on local infrastructure Total connected load will be provided in detailed specifications

Q Can this plant be integrated into an existing site layout?
A Yes The modular design allows adaptation within reason Our engineering team can review your site plan flow diagram

Q How many operators are required?
A Typically two personnel are sufficient one at the control cabin monitoring feeds one performing general inspection duties due automation level

Q What lead time can we expect after order placement?
A Lead times vary based configuration current order book Standard Tier I plants generally have delivery within months exworks

Q Are spare parts readily available globally?
A We maintain regional distribution centers critical wearing parts ensuring availability within hours major markets days elsewhere

Q Does price include installation supervision commissioning?
A Pricing exworks Supervision commissioning offered as separate service package recommended ensure optimal startup performance