1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

La gestion d'un circuit de concassage de minerai de fer présente des, des défis coûteux. Are you facing persistent bottlenecks that limit your plant’s rated throughput? Is unscheduled downtime for liner changes and component wear eroding your production schedule and maintenance budget? Do you struggle with inconsistent product sizing, leading to downstream processing inefficiencies in grinding or beneficiation? En outre, are rising energy costs per ton of processed material directly impacting your operational margins? Ces problèmes se traduisent par des pertes quantifiables: heures de production perdues, excessive spare parts inventories, and suboptimal resource yield.

La question centrale pour les directeurs d'usine est la suivante: comment pouvez-vous obtenir un, hightonnage reduction of abrasive iron ore while controlling capital and operational expenditure? La solution réside dans la spécification d'un objectif conçu private label iron ore crushing plant.

2. APERÇU DU PRODUIT

Ce produit est un complet, modular crushing system engineered for primary and secondary reduction of magnetite, hématite, et autres minerais de fer. It is supplied as a private label solution, allowing for branding alignment while leveraging proven, heavyduty componentry.

Flux de travail opérationnel:
1. Dump primaire & Grizzli: Runofmine ore is dumped onto a rugged grizzly feeder, scalping out fine material to bypass the primary crusher, améliorer l'efficacité globale.
2. Concassage primaire des mâchoires: Un concasseur à mâchoires robuste effectue une réduction initiale de la taille, delivering a consistent feed to the secondary stage.
3. Concassage secondaire à cône: Le cœur du système, a highcapacity cone crusher—configured for coarse or mediumfine output—provides the final cubical product sizing critical for downstream processing.
4. Dépistage & Contrôle en circuit fermé: Sized material is screened; oversize is recirculated back to the cone crusher in a closedloop system ensuring precise final product specification.

Champ d'application & Limites:
Portée: Ideal for greenfield installations or expansion projects requiring 500 à 2,500+ Capacité TPH. Suited for processing hard, abrasive iron ores with compressive strengths up to 350 MPa.
Limites: Not designed as a tertiary or quaternary stage for ultrafine grinding. Feed size must conform to crusher opening specifications. Optimal performance requires consistent feed gradation and controlled moisture content to prevent chamber packing.

3. CARACTÉRISTIQUES PRINCIPALES

HeavyDuty Liner Geometry | Base technique: Computermodeled cavity profiles and highchrome white iron metallurgy | Avantage opérationnel: Extended wear life by 3050% over standard manganese steel in abrasive service | Impact sur le retour sur investissement: Reduces liner change frequency and inventory costs, augmentation de la disponibilité des concasseurs.

Advanced Chamber Clearing System | Base technique: Hydraulic or gaspowered tramp release and clearing automation | Avantage opérationnel: Recovers from stall conditions in under 60 secondes sans intervention manuelle | Impact sur le retour sur investissement: Prevents cascading downtime from uncrushable material, protecting downstream conveyor systems.

Graissage centralisé & Contrôle API | Base technique: Automated lubrication intervals tied to bearing temperature and operating hours | Avantage opérationnel: Ensures optimal bearing health and eliminates manual greasing errors | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements majeurs jusqu'à 40%, réduire le risque de panne catastrophique.

Conception de patins modulaires | Base technique: Preassembled structural steel skids with integrated walkways and maintenance platforms | Avantage opérationnel: Reduces onsite civil works and installation time by an estimated 40% | Impact sur le retour sur investissement: Lowers total installed cost (TIC) and accelerates timetoproduction.

Entraînement à fréquence variable (VFD) Compatibilité | Base technique: Crusher motor integration with plantwide process control systems | Avantage opérationnel: Allows realtime adjustment of crusher speed/throw to match feed conditions for optimal power draw and product shape | Impact sur le retour sur investissement: Achieves energy savings of 1015% under variable load conditions versus fixedspeed operation.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (AggregateFocused Plant) | Private Label Iron Ore Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Durée de vie de la doublure (Minerai abrasif) | ~450 000 tonnes par ensemble (Manganèse) | ~650,000 tons per set (Special Alloy) | +44% |
| Disponibilité du système (Programmé) | ~92% (y compris. changements de doublure) | ~95 % (y compris. changements de doublure) | +3 Points de pourcentage |
| Consommation d'énergie par tonne traitée| Référence (100%)| Chambre optimisée & drive = ~90% of baseline |10% |
| Installation & Temps de mise en service| 810 semaines sur place| 56 semaines sur place (modulaire)| 30% |
| Amendes du produit (10mm) Contrôle| Typiquement 1822% de sortie| Chamber optimization yields 1518% de sortie| 20% reduction in unwanted fines |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 500 TPH à plus 2,500 TPH nominal throughput of taconite ore.
Exigences d'alimentation: Concasseur primaire: 150400 kW; Concasseur secondaire: 250600 kW; Total System Feeders/Conveyors/Screens: Additional 300800 kW en fonction de la configuration.
Spécifications matérielles: Primary wear liners in premium manganese steel; Secondary chamber liners in highchrome white iron (27% Cr). Structural steel is Grade S355JR with abrasionresistant plate in highwear zones.
Dimensions physiques (Dérapage typique): Secondary crushing module approx. L12m x W6m x H7m. Full plant footprint varies with configuration.
Plage de fonctionnement environnementale: Designed for ambient temperatures from 25°C to +45°C with optional heating/cooling packages. Dust suppression system integrated as standard.

6. SCÉNARIOS D'APPLICATION

Expansion du concentrateur de magnétite de Greenfield

Défi:
A major mining operator needed to expand concentrator throughput but was constrained by existing primary crushing capacity producing inconsistent feed size for new SAG mills.
Solution:
Implementation of a turnkey private label iron ore crushing plant as a parallel primary/secondary circuit specifically calibrated for their magnetite ore characteristics.
Résultats:
Nous avons obtenu une augmentation soutenue du débit de 1,800 TPH at a consistent 25mm product size. Mill feed stability improved grinding circuit efficiency by an estimated 8%, contributing directly to higher concentrate output.

Lifecycle Replacement in Hematite Operation

Défi:
An aging fleet of disparate crushers led to high maintenance costs (~20% of annual OPEX), poor availability (94%.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification: Offered across three standardized capacity tiers—Medium Duty (1,800 TPH)—with corresponding component specifications.
Fonctionnalités facultatives: Upgrades include advanced predictive monitoring sensors (vibrations/température), automated wear measurement systems, hybrid diesel/electric power modules for remote sites,
and enhanced dust encapsulation packages.
Forfaits de services: Tiered annual support agreements are available covering scheduled maintenance inspections,
examen de l'analyse prédictive,
and priority parts provisioning with guaranteed dispatch times.
Options de financement: Flexible capital expenditure solutions can be structured including equipment leasing models,
project financing linked to production milestones,
or traditional purchase agreements.

8.FAQ

T1:
Are these private label plants compatible with our existing conveying infrastructure?
A1:
Yes.The modular design allows engineering interfaces
(hauteurs de décharge,
feed chute orientations)
to be customized during the design phase
to integrate with your current stockpile conveyors
or downstream process feed points.Field surveys are conducted
to ensure dimensional compatibility prior
to fabrication

T2:
Quel est l’impact opérationnel attendu lors de la mise en service?
A2:
Our phased commissioning protocol minimizes disruption.Crushing modules are pretested at our facility.Onsite commissioning typically requires two weeks
of planned integration downtime followed by one week
of rampup under supervision until design capacity is met

T3:
How does the pricing compare
to sourcing major OEM equipment directly?
A3:
The private label model typically offers capital cost savings between fifteen percent without compromising critical component quality.We achieve this through optimized global supply chain logistics
for structural components while utilizing tierone suppliers
for all mechanical drive
and wear parts

T4:
What are the lead times from order placement
to delivery?
A4:
For standard capacity configurations lead time ranges from twentysix weeks depending on current manufacturing schedule.Complex customizations may extend this timeline which will be defined during project scoping

Q5:
Is training provided for our operations
et équipes de maintenance?
A5:
Comprehensive training is included covering safe operation routine maintenance procedures troubleshooting guides specific documentation review conducted both at your site during commissioning

Q6:
Quelles conditions de garantie s'appliquent?
A6:
The complete structure carries standard warranty.All major mechanical components including crusher main frames shafts bearings motors carry manufacturer warranties which we manage on your behalf providing singlepoint support

Q7:
Can this plant handle variations in ore hardness within our deposit?
A7：
The hydraulic adjustment systems on both jaw cone crushers allow operators adjust closed side settings compensate variations hardness maintain consistent product size PLC control system can automate adjustments based power draw maintaining optimal performance across different ore zones