Professionnel 250 300producteur d usine de concassage de pierre tph
1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR
Gérez-vous une opération de granulats à volume élevé et êtes-vous confronté à des goulots d'étranglement persistants qui érodent la rentabilité ?? Pour les directeurs d’usine et les entrepreneurs en ingénierie, a 250300tph stone crushing plant is a critical production asset, Pourtant, des défis opérationnels courants peuvent nuire considérablement à son retour sur investissement.. Consider these frequent issues:
Temps d'arrêt imprévus: Component failures in key crushers or screens halt your entire line, costing thousands per hour in lost production and idle labor.
Inconsistent Final Product Quality: Fluctuations in grain size and shape result from poorly synchronized or overloaded crushing stages, leading to product rejection and reduced market value.
Haut opérationnel & Coûts d'entretien: Excessive wear part consumption, high energy consumption per ton processed, and laborintensive routine maintenance steadily increase your cost of ownership.
Inflexible Configuration: Can your plant efficiently adapt to changing feed material hardness or produce different product gradations for various contracts without major reconfiguration?
La question centrale est: comment pouvez-vous obtenir un, hightonnage output with predictable operating costs and superior product control? The solution lies in a professionally engineered 250300tph stone crushing plant designed for industrial durability and operational efficiency.
2. APERÇU DU PRODUIT
This solution is a stationary 250300 tonperhour (tph) usine de concassage et de criblage de roches dures. It is engineered for primary contractors and aggregate producers requiring consistent, highvolume output of specification aggregates from materials like granite, basalte, and limestone.
Flux de travail opérationnel:
1. Concassage primaire: Matière première de grande taille (≤750mm) is reduced to ≤200mm by a robust primary jaw crusher.
2. Secondaire & Concassage Tertiaire: Material is conveyed to secondary cone crushers for further reduction, with optional tertiary cone or impact crushers for precise shaping and final size reduction.
3. Dépistage & Classification: Multipledeck vibrating screens accurately separate crushed material into required finished product sizes (par ex., 05mm, 510mm, 1020mm).
4. Manutention des matériaux & Stockage: Closedcircuit conveyors recirculate oversize material while radial stackers build controlled stockpiles of finished products.
Champ d'application & Limites:
Portée: Ideal for largescale quarry operations, grands projets d'infrastructures (highway, rail), and commercial aggregate supply yards requiring sustained high output.
Limites: Non conçu pour les applications portables ou mobiles. Feed material compressive strength should typically not exceed 350 MPa without specific configuration adjustments. Requires stable foundation and gridbased power supply.
3. CARACTÉRISTIQUES PRINCIPALES
HeavyDuty Primary Station | Base technique: Reinforced hopper/feeder structure with abrasionresistant liners | Avantage opérationnel: Handles direct dump from large loaders (par ex., CAT 980+), minimizes bridging, ensures consistent feed to primary crusher | Impact sur le retour sur investissement: Reduces loader cycle time delays and eliminates costly downtime from feed blockages.
Intelligent Crushing Chamber Design | Base technique: Optimized cavity geometry based on feed material analysis | Avantage opérationnel: Maintains target throughput while improving product shape (cubique) and reducing wear part stress | Impact sur le retour sur investissement: Extends manganese liner life by up to 20%, lowering costperton for wear parts.
Centralized Process Control System | Base technique: PLCbased automation with touchscreen HMI | Avantage opérationnel: Allows singleoperator monitoring and control of entire plant flow; provides realtime data on production rates, consommation d'énergie, et alarmes de panne | Impact sur le retour sur investissement: Reduces labor requirements for plant operation by approximately 40% versus manual controls.
Advanced Vibration Screening Decks | Base technique: HighGforce multifrequency screens with quickchange tensioning systems | Avantage opérationnel: Achieves precise particle separation even with damp or sticky feed material; increases screening efficiency to >95% | Impact sur le retour sur investissement: Minimizes product contamination and recrushing of finished sizes, directly boosting salable tonnage.
Système de convoyeur modulaire | Base technique: Standardized bolttogether sections with impactresistant idlers | Avantage opérationnel: Simplifies site layout adaptation and future plant expansion; facilitates easier maintenance access | Impact sur le retour sur investissement: Cuts installation time by an estimated 30% compared to custombuilt systems.
Système de suppression de poussière intégré | Base technique: Strategically placed nozzles with solenoid control tied to crusher operation | Avantage opérationnel: Effectively controls dust at transfer points without oversaturating material | Impact sur le retour sur investissement: Assure le respect de la réglementation environnementale, avoiding fines and reducing cleanup labor.
4. AVANTAGES CONCURRENTIELS
| Mesure de performances | Norme industrielle pour les usines de 250 300 tph | This Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité globale (Exécution planifiée) | ~85% 88% due to mechanical delays| ≥92% through component derating & redundancy design| +5% à +8% more productive hours |
| Consommation d'énergie par tonne traitée| ~1,8 2.1 kWh/t average| ≤1.65 kWh/t via optimized drive systems & gestion des charges| Jusqu'à 15% reduction in power costs |
| Wear Part Cost per Ton (Primary Stage)| Varie considérablement; baseline = $0.45/t| Target ≤$0.36/t via chamber optimization & sélection des matériaux| Jusqu'à 20% lower consumable cost |
| Product Shape Index (Cubicité %)| Typically ~6575% cubical content| Constamment >78% cubical content across product range| Highervalue aggregate commanding premium price |
| Reconfiguration Time for New Product Specs| Often requires halfday shutdowns|<4 hours through adjustable crusher settings & screen deck changes| Faster response to market demands |
5. SPÉCIFICATIONS TECHNIQUES
Plage de capacité conçue: 250 300 tonnes métriques par heure (tph), en fonction de la dureté du matériau alimenté (<200 Résistance à la compression MPa).
Concasseur primaire: Jaw Crusher Model Equivalent CJ412 or similar; Feed Opening 1200mm x 800mm; Max Feed Size ≤750mm.
Concasseurs secondaires/tertiaires: Two x Cone Crusher Model Equivalent CH440/CS440; equipped with ASRi automated control system.
Screening Units: Two x TripleDeck Vibrating Screens; Deck Size 2400mm x 6000mm.
Exigence de puissance: Total Installed Power ~550 kW; Exigence de tension primaire: 400V/50Hz ou personnalisé.
Spécifications des matériaux clés: Main frame construction S355JR steel; Conveyor belt rating ≥800 PIW; Wear liners highgrade manganese steel (18% Mn).
Empreinte approximative (Lxl): ~85m x 45m for full closedcircuit layout.
Plage de fonctionnement environnementale: Designed for ambient temperatures 20°C to +45°C; dust emission levels compliant with <10 mg/Nm³ standards when using integrated suppression.
6. SCÉNARIOS D'APPLICATION
Projet d'agrandissement de la carrière de granit
Défi: A regional quarry needed to increase annual production by over 800,000 tons to fulfill a new highway contract but was constrained by an aging plant with low availability (<80%) and poor product shape consistency.
Solution: Implementation of this turnkey configured hard rock stone crushing plant featuring advanced cone crushers for tertiary shaping.
Résultats: Plant availability increased to an average of >93%. The improved cubicity (>80%) of the base course aggregate met strict DOT specifications without reprocessing. The project achieved the required tonnage within the first year.
Integrated Mining & Aggregate Operation
Défi: A mining operation sought to monetize waste rock from overburden removal by producing construction aggregates but faced highly variable feed hardness that caused frequent chokeups in their existing system.
Solution: Deployment of this robust stone crushing plant configured with heavyduty feeders capable of handling variablesized boulders up to the maximum design limit of ≤750 mm diameter as well as variable rock hardness upto the maximum design limit of ≤350 MPa compressive strength..
Résultats: The system processed highly variable waste rock into certified aggregates at a steady rate of ~280 tph without significant downtime events dueto chokeups.. This created a new revenue stream while reducing waste disposal costs..
Commercial Aggregate Supplier
Défi:: A supplier needed flexibilityto quickly switch between producing different aggregate blendsfor concrete asphaltand drainage applicationsfor various clientsoften within the same week..
Solution:: Installationof this modular stone crushing plantwith quickadjust conecrushersand interchangeable screenmeshes..
Résultats:: Changeover timebetween different product specificationswas reducedfrom an averageof eighthoursto under threehours.. This operational agility allowedthe companyto accept smaller more profitable custom orderswithout disrupting core production..
Commercial Aggregate Supplier
Défi:: A supplier needed flexibilityto quickly switch between producing different aggregate blendsfor concrete asphaltand drainage applicationsfor various clientsoften within the same week..
Solution:: Installationof this modular stone crushing plantwith quickadjust conecrushersand interchangeable screenmeshes..
Résultats:: Changeover timebetween different product specificationswas reducedfrom an averageof eighthoursto under threehours.. This operational agility allowedthe companyto accept smaller more profitable custom orderswithout disrupting core production..
Commercial Aggregate Supplier
Défi:: A supplier needed flexibilityto quickly switch between producing different aggregate blendsfor concrete asphaltand drainage applicationsfor various clientsoften within the same week..
Solution:: Installationof this modular stone crushing plantwith quickadjust conecrushersand interchangeable screenmeshes..
Résultats:: Changeover timebetween different product specificationswas reducedfrom an averageof eighthoursto under threehours.. This operational agility allowedthe companyto accept smaller more profitable custom orderswithout disrupting core production..
Commercial Aggregate Supplier
Défi:: A supplier needed flexibilityto quickly switch between producing different aggregate blendsfor concrete asphaltand drainage applicationsfor various clientsoften within the same week..
Solution:: Installationof this modular stone crushing plantwith quickadjust conecrushersand interchangeable screenmeshes..
Résultats:: Changeover timebetween different product specificationswas reducedfrom an averageof eighthoursto under threehours.. This operational agility allowedthe companyto accept smaller more profitable custom orderswithout disrupting core production..
Commercial Aggregate Supplier
Défi:: A supplier needed flexibilityto quickly switch between producing different aggregate blendsfor concrete asphaltand drainage applicationsfor various clientsoften within the same week..
Solution:: Installationof this modular stone crushing plantwith quickadjust conecrushersand interchangeable screenmeshes..
Résultats:: Changeover timebetween different product specificationswas reducedfrom an averageof eighthoursto under threehours.. This operational agility allowedthe companyto accept smaller more profitable custom orderswithout disrupting core production..
Commercial Aggregate Supplier
Défi:: A supplier needed flexibilityto quickly switch between producing different aggregate blendsfor concrete asphaltand drainage applicationsfor various clientsoften within the same week..
Solution:: Installationof this modular stone crushing plantwith quickadjust conecrushersand interchangeable screenmeshes..
Résultats:: Changeover timebetween different product specificationswas reducedfrom an averageof eighthoursto under threehours.. This operational agility allowedthe companyto accept smaller more profitable custom orderswithout disrupting core production..
Commercial Aggregate Supplier
Défi:: A supplier needed flexibilityto quickly switch between producing different aggregate blendsfor concrete asphaltand drainage applicationsfor various clientsoften within the same week..
Solution:: Installationof this modular stone crushing plantwith quickadjust conecrushersand interchangeable screenmeshes..
Résultats:: Changeover timebetween different product specificationswas reducedfrom an averageof eighthoursto under threehours.. This operational agility allowedthe companyto accept smaller more profitable custom orderswithout disrupting core production..
Commercial Aggregate Supplier
Défi:: A supplier needed flexibility