1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

L'augmentation des coûts opérationnels et la disponibilité imprévisible érodent-elles vos marges de traitement du minerai de fer ?? Pour les directeurs d’usine et les entrepreneurs en ingénierie, the primary crushing stage is a critical bottleneck with direct consequences for your entire operation. Les défis courants incluent:

Temps d'arrêt excessif pour la maintenance: Les changements fréquents de revêtement et les réparations imprévues sur votre concasseur primaire interrompent l'ensemble du système d'alimentation., coûtant des milliers de dollars par heure en perte de production.
Coûts élevés des pièces d’usure & Consommation: Abrasive iron ore rapidly degrades crusher components, leading to unsustainable spending on manganese steel and arduous, laborintensive replacement cycles.
Réduction incohérente de la taille des aliments: Fluctuations in feed size or hardness can cause choke feeding or cavity flooding, reducing throughput and creating downstream processing instability.
Rigid Plant Layout Constraints: Fixed primary crushing stations lack mobility, complicating mine plan progression and requiring costly overburden removal or lengthy rehandling.

Is your current solution equipped to handle increasingly hard and abrasive ore bodies while maintaining costpertonne targets? A strategically selected private label iron ore crushing plant provides a tailored answer to these systemic challenges.

2. APERÇU DU PRODUIT

A private label iron ore crushing plant is a heavyduty, semistationary or modular primary crushing system engineered specifically for the highvolume, highabrasion reduction of runofmine (ROM) minerai de fer. These plants are manufactured under contract to meet precise operational specifications and are branded for the distributor or large contractor.

Flux de travail opérationnel:
1. Réception de ROM & Présélection: Direct dump from haul trucks onto a robust grizzly or scalping screen to bypass subfines material.
2. Réduction de la taille primaire: Oversize material is conveyed to a highcapacity jaw crusher or gyratory crusher for initial reduction to a manageable transport size (typiquement <250mm).
3. Primary Stockpiling: Crushed product is conveyed to a live stockpile, providing crucial surge capacity for downstream processing circuits.

Champ d'application: Ideal for greenfield site development, dedicated processing lines for specific ore types, or as a supplemental primary station for existing operations. Best suited for operations with a defined mine life and consistent feed characteristics.

Limites: Not designed as portable trackmounted units for frequent relocation. Maximum efficiency is achieved with proper feed control and consistent ore geology. Requires foundational civil works and integration engineering.

3. CARACTÉRISTIQUES PRINCIPALES

Châssis de concasseur robuste | Base technique: Analyse par éléments finis (FEA) répartition optimisée des contraintes | Avantage opérationnel: Élimine les fissures de fatigue du cadre sous les charges de choc provenant de matériaux incassables | Impact sur le retour sur investissement: Réduit le risque de défaillance structurelle catastrophique, extending asset service life beyond 10+ années

Système de flux de matériaux résistant à l'abrasion | Base technique: Hardox® or equivalent wear steel in hoppers, jupes, et chutes; ceramic lagging on critical pulley faces | Avantage opérationnel: Dramatically reduces material adherence and wearthrough in transfer points | Impact sur le retour sur investissement: Cuts maintenance welding/replacement frequency by up to 60%, lowering direct labor and parts costs

PLCBased Automated Control & Surveillance | Base technique: Centralized programmable logic controller with loadsharing algorithms and remote telemetry capability | Avantage opérationnel: Optimizes crusher power draw, prevents choke events, and provides realtime operational data | Impact sur le retour sur investissement: Améliore la cohérence du débit d'une valeur estimée 812% while enabling predictive maintenance scheduling

Convoyeur modulaire & Conception de passerelle | Base technique: Bolttogether sections with standardized dimensions | Avantage opérationnel: Enables faster installation onsite and allows future reconfiguration as mine layout evolves | Impact sur le retour sur investissement: Reduces initial construction time/cost by approximately 1520% versus fully welded structures

Lubrification centralisée & Système hydraulique | Base technique: Singlepoint lubrication lines to all major bearings; dedicated hydraulic power unit for crusher adjustment/clearing | Avantage opérationnel: Simplifies routine servicing intervals and enhances operator safety during maintenance tasks | Impact sur le retour sur investissement: Decreases scheduled maintenance downtime windows by an average of 30%

Collecteur de suppression de poussière intégré | Base technique: Nozzle system plumbed into primary transfer points, tied to conveyor operation sensors | Avantage opérationnel: Actively controls dust at source, améliorer la visibilité du site et le respect des réglementations environnementales | Impact sur le retour sur investissement: Atténue le risque d’amendes réglementaires et réduit les coûts de nettoyage

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Plante générique) | Private Label Iron Ore Crushing Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Durée de vie du revêtement (Acier au manganèse)| 450,000 550,000 tonnes| 600,000 750,000 tonnes| +25% à +35% |
| Temps moyen entre les pannes (MTBF)| ~720 heures| ~1,100 hours| +53% |
| Tonnage Throughput Consistency| ±15% variance from target| ±7% variance from target| >50% improvement in stability |
| Durée de l'installation sur site| 1216 semaines| 810 semaines| ~33% reduction |
| Consommation d'énergie spécifique| Référence = 100%| Réalise 9295% of benchmark| 58% amélioration de l'efficacité énergétique |

5. SPÉCIFICATIONS TECHNIQUES

Capacité nominale: Configurable à partir de 1,200 à plus 3,500 tonnes par heure (TPH), based on crusher selection.
Options du concasseur primaire: Concasseur à mâchoires à bascule unique (1.2m x 1.5m up to 1.6m x 2.0m) ou concasseur giratoire primaire (4265 gamme).
Exigences d'alimentation: Total installed power typically between 450kW 900kW depending on configuration; supplied at either 6.6kV or medium voltage.
Spécifications matérielles: Structure primaire Acier au carbone ASTM A36; wear surfaces Hardox® 450/500; crusher liners ASTM A128 Manganese Steel.
Dimensions physiques (Typique): Footprint approximately 25m L x 18m W x 15m H (excluding feed ramp and discharge stockpile).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dust protection rating of IP65 for electrical enclosures.

6. SCÉNARIOS D'APPLICATION

Direct Feed Hematite Operation

Défi: An existing hematite operation used a legacy crusher located far from the new pit face, requiring doublehandling by loaders and incurring high hourly equipment rental costs.
Solution: Implementation of a private label iron ore crushing plant with a deeppit receiving hopper adjacent to the new pit rim.
Résultats: Elimination of loader rehandling reduced operating costs by approximately $0.85 per tonne hauled. The plant achieved design throughput within two weeks of commissioning.

Expansion du concentrateur de magnétite

Défi: A magnetite concentrator needed to increase primary crushed tonnage by over onethird but had limited space within the existing fixed infrastructure footprint.
Solution: Deployment of a modular private label crushing plant designed with vertical stacking conveyors to fit the constrained site layout.
Résultats:The modular design reduced civil works by an estimated $300k USD compared to traditional construction.The expansion was completed during a planned twoweek shutdown with no further production delays.

HighAbrasion Banded Iron Formation

Défi:A new BIF deposit exhibited higherthanaverage abrasiveness index values,causing premature failure of conveyor belts,revêtements de concasseur,and chutes in test runs using standard equipment.
Solution:A bespoke private label solution featuring enhanced wear packages,a slowerspeed jaw crusher configuration,and specialized impact beds on all transfer points.
Résultats:Liner life improved by over onethird against initial projections.Conveyor belt replacement intervals extended from six months back toward standard ninemonth cycles,saving $120k annually in belt costs alone.

7.CONSIDÉRATIONS COMMERCIALES

Equipment pricing tiers are structured around core crusher selection:

Niveau I(HighCapacity Jaw Crusher Based):For midrange tonnage requirements.Capital cost range:$2M$4M USD depending on options.
Niveau II(Primary Gyratory Crusher Based):Pour un débit maximal (>2，500 TPH)et dur，abrasive ores.Capital cost range:$4M$7M USD depending on options.

Fonctionnalités facultatives:
OnBoard Power Generation Package
Surveillance avancée de la taille des particules(PSM)Système
Systèmes de graissage automatisés
Full Perimeter Dust Containment Skirting

Forfaits de services:
Mise en service & Formation des opérateurs(Standard)
Inspection annuelle & Parts Kitting Agreement
FullService Maintenance Contract with guaranteed uptime SLA

Options de financement:
Available through partner financial institutions including operating lease structures，capital leasetoown plans，or projectbased financing tailored for mining developments.This allows preservation of capital while securing critical production infrastructure.

8.FAQ

Q:What level of customization is possible with a private label plant versus an OEM standard model?
UN：Significant customization is core to the value proposition.You can specify crusher manufacturer，drive motor suppliers，conveyor belt grade，control system brand（e.g.,Siemens，AllenBradley），and structural details like access stair placement.This ensures compatibility with your existing spares inventory和maintenance practices。

Q：How does this solution integrate with my existing secondary crushing circuit和downstream processing？
UN：The plants are engineered based on your required final product size（typically 250mm）for optimal secondary circuit feed.Design parameters include discharge height，conveyor speed和transfer point geometryto match your existing receiving hoppers或stockpile conveyors seamlessly。

Q：What are the lead times from order placementto commissioning？
UN：Lead times vary but typically range from32to48weeksfor complete plants.This includes detailed engineering，fabrication，shop assembly testing，dismantlementfor shipment和reassemblyon your site。Expedited options may be available。

Q：Pouvez-vous fournir des garanties de performance ?
UN：Oui。Performance guaranteesfor throughput capacity based on agreed feed material specificationsand product sizeare standardin contracts。Wear rate guaranteesfor key components like linerscan also be structuredbased on agreed abrasiveness indices。

Q：Who holds responsibilityfor equipment warranties？
UN：The private label dealer holds ultimate responsibilityfor warranty administration。Components are coveredby their original manufacturer's warranties（e.g.,crusher,roulements,motors），while structuraland assembly workmanshipis warranted directlyby the fabricator under our singlepoint accountability。

Q：What trainingand documentationare provided？
UN：Comprehensive documentation包括asbuilt drawings,P.&identifiants，electrical schematics，parts manuals和lubrication schedules。Onsite trainingfor operationsand maintenance crews is conductedduring commissioningwith both classroomand handson modules。

Q：Are these plants suitablefor remote locationswith limited service support？
UN：Oui。They are designedwith serviceabilityas apriority。Common component standardization,easy access platformsand designedin service tool clearances reduce required skill levelsfor routine tasks。Remote monitoring capabilityallows our support teamsto assistwith diagnosticsoffsite。