1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing a highvolume aggregate production site and facing persistent bottlenecks that erode profitability? Pour les directeurs d’usine et les entrepreneurs en ingénierie, un 250300 tph stone crushing plant is a critical asset, pourtant, les configurations standard introduisent souvent des inefficacités coûteuses. Les défis courants incluent:
Temps d'arrêt imprévus: Component failures in harsh environments lead to production halts, coûtant des milliers de dollars par heure en perte de production et en main d'œuvre inutilisée.
Débit incohérent: Fluctuations in feed material hardness or size cause choke points, preventing the plant from consistently achieving its rated 250300 capacité tph.
Coûts opérationnels élevés: Excessive energy consumption from inefficient drives and frequent, costly wear part replacements directly impact your costperton metric.
Réglementaire & Supply Chain Friction: Sourcing components that are not uniformly RoHS compliant can lead to procurement delays, project specification noncompliance, and potential reputational risk.

La question centrale est: how do you specify a crushing plant that delivers reliable, rated throughput while controlling total operational expenditure and ensuring modern environmental compliance?

2. APERÇU DU PRODUIT

Ce produit est un complet, preengineered RoHS Compliant 250300tph Stationary Stone Crushing Plant. It is designed as a turnkey solution for highvolume production of aggregates for road base, béton, et applications d'asphalte.

Flux de travail opérationnel:
1. Concassage primaire: Matière première de grande taille (≤750mm) est réduit par un concasseur à mâchoires robuste ou un impacteur primaire.
2. Secondaire & Concassage Tertiaire: Material is conveyed to cone crushers and/or secondary impactors for further size reduction and shaping.
3. Dépistage & Classification: Vibrating screens separate material into specified product sizes; les surdimensionnés sont recyclés.
4. Manutention des matériaux: A network of RoHScompliant conveyors with energyefficient drives transfers material between stages.
5. Suppression de la poussière: Les systèmes de pulvérisation intégrés contrôlent les émissions de particules aux points de transfert.

Champ d'application: Idéal pour le granit, calcaire, basalte, and river gravel processing in quarrying, exploitation minière, and largescale construction projects requiring consistent, highquality spec aggregates.

Limites: This plant configuration is designed for stationary or semistationary installation. For projects requiring frequent relocation, a mobile or skidmounted solution should be considered.

3. CARACTÉRISTIQUES PRINCIPALES

RoHSCompliant Component Ecosystem | Base technique: EU Directive 2011/65/EU | Avantage opérationnel: Guaranteed supply chain of hazardous substancefree electrical components, câblage, and PLC systems | Impact sur le retour sur investissement: Eliminates procurement delays for regulated markets and futureproofs your asset against tightening global environmental standards.

Intelligent LoadSensing Hydraulic System | Base technique: Variable displacement pumps paired with pressurecompensated valves | Avantage opérationnel: Hydraulic power on demand for crusher adjustment and clearing functions reduces parasitic energy loss | Impact sur le retour sur investissement: Les données de terrain s'affichent jusqu'à un 18% reduction in hydraulic system energy consumption compared to fixedflow systems.

Contrôle API unifié & Monitoring Platform | Base technique: Centralized Siemens/AllenBradley controller with HMI interface | Avantage opérationnel: Your operators can monitor motor loads, températures des roulements, and production totals from a single station for proactive management | Impact sur le retour sur investissement: Reduces fault diagnosis time by an estimated 30% and enables datadriven maintenance scheduling.

Modular Crusher Cavity & Liner Designs | Base technique: Interchangeable liner profiles and mantle/bowl designs for jaw and cone crushers | Avantage opérationnel: Enables quick reconfiguration of the crushing circuit to adapt to changes in feed material or final product specification | Impact sur le retour sur investissement: Extends wear part life cycle by optimizing crush profiles; increases plant utilization for varied contracts.

HeavyDuty Vibrating Screen with Polyurethane Media | Base technique: HighGforce exciters coupled with abrasionresistant PU screen panels | Avantage opérationnel: Provides consistent screening efficiency with reduced blinding and lower noise generation | Impact sur le retour sur investissement: Longer panel life reduces changeout frequency; improved accuracy minimizes recrush of onspec material.

Graissage centralisé & Système de lubrification | Base technique: Automated singleline progressive system for all major crusher bearings | Avantage opérationnel: Ensures correct lubrication intervals without manual intervention at multiple hardtoaccess points | Avantage opérationnel: Atténue le risque de défaillance des roulements; documented to extend bearing service life by approximately 25%.

Structural DynamicsOptimized Support Fabrication | Base technique: FEA (Analyse par éléments finis) designed supports and platforms to mitigate resonant vibration | Avantage opérationnel: Reduces structural fatigue stress on conveyors, écrans, and chute work during fullload operation| ROI Impact Lowers longterm structural maintenance costs; minimizes vibrationinduced fastener failures.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (250300Usine de tph) | This RoHS Compliant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Efficacité énergétique (kWh/tonne) | ~0,85 1.0 kWh/tonne (estimé) VFDs optional| ≤0.75 kWh/tonne VFDs standard on all major drives| Jusqu'à 15% réduction |
| Wear Part Cost Index (Relative) Ligne de base = 100| Index of 100 (Manganese steel standard) Index of ~8590 (Hybrid/alloy options)| Index of ~80 Conception de cavité optimisée + optional ceramic composites| Jusqu'à 20% potentiel de réduction |
| Temps moyen entre les pannes (MTBF) Electrical Components| Varies widely based on component sourcing.| Increased MTBF Guaranteed RoHS compliance ensures highergrade industrial components| Documented ~40% improvement in component reliability |
| Cohérence du débit (% of time at rated capacity)| ~8085% due to feed variation & blocages.| ~9092% Intelligent load management & cavity optimization| ~7% increase in operational availability |

5. SPÉCIFICATIONS TECHNIQUES

Capacité conçue: 250 300 tonnes par heure (tph), en fonction de la dureté du matériau alimenté (<200 Mpa recommandé) et la taille du produit final.
Options du concasseur primaire: Curseur de mâchoire (PE900×1200) or HeavyDuty Primary Impact Crusher.
Stade secondaire/tertiaire: Combination of MultiCylinder Hydraulic Cone Crushers (par ex., HPC315) and/or Secondary Impact Crushers.
Étape de sélection: Crible vibrant robuste à trois étages (3YK3072).
Exigence de puissance: Puissance totale installée environ 800 950 kW. Requires stable threephase industrial supply.
Spécifications des matériaux clés: Tous les composants électriques (câblage, PLCs relays sensors switches etc.) comply with EU RoHS Directive Restriction of Hazardous Substances). Major steel structures utilize S355JR grade steel; wear liners use highmanganese steel or optional ceramic composites.
Empreinte approximative: ~75m (L) x 45m (W), sous réserve de la configuration finale de la disposition.
Plage de fonctionnement environnementale: Designed for 10°C to +45°C ambient temperature Dust suppression system maintains operation within local particulate emission standards

6. SCÉNARIOS D'APPLICATION

Granite Quarry Expansion Project Challenge A quarry needed to expand output but faced strict new environmental regulations requiring RoHScompliant equipment for the entire site upgrade Their existing plant suffered from low electrical reliability Solution Installation of this RoHS compliant tph stone crushing plant as the new primary production line Results The project met the tender's environmental specification exactly achieving consistent tph output Postinstallation analysis showed a % reduction in electrical component failures compared to the older line

LargeScale Infrastructure Contractor Challenge A contractor securing multiple projects with varying aggregate specifications required flexible highvolume production without constant reinvestment Frequent changeovers were causing significant downtime Solution Implementation of the modular crushing plant featuring quickly reconfigurable crusher cavities liner sets Results The crew can now reconfigure the circuit from producing road base to concrete aggregate in under hours Plant utilization increased by enabling fulfillment of diverse contracts

Aggregate Producer Focused on TCO Total Cost Ownership Challenge Rising energy costs unpredictable wear part expenses were making costperton projections unreliable Management needed predictable operational expenditure Solution Adoption of the complete solution featuring loadsensing hydraulics standard VFDs optimized wear parts Results Achieved a documented kWh tonne saving stabilized monthly consumables spend leading to a predictable costperton model that improved bidding accuracy

7 CONSIDÉRATIONS COMMERCIALES

Les niveaux de tarification des équipements sont structurés autour de choix de configuration de base:

Tier Basic Configuration Includes primary jaw crusher secondary cone crusher tripledeck screen basic conveyors central control panel
Tier Enhanced Configuration Adds tertiary crushing stage VFDs on all major drives upgraded polyurethane screen media automated greasing system
Tier Turnkey Premium Includes full dust suppression enclosure advanced rockbreaker at feed hopper comprehensive spare parts package extended commissioning support

Optional Features Onboard power generation package advanced particle size monitoring system remote telematics connectivity extra set of wear parts
Service Packages Available Annual inspection maintenance contracts operator training programs guaranteed critical parts availability within hours
Financing Options Flexible leasing structures operating lease finance lease available through partnered institutions can be tailored to match project cash flow timelines

8 FAQ

What does 'RoHS Compliant' mean specifically for this crushing plant It means all electrical electronic components within the plant from motors wiring control cabinets PLCs sensors lighting are manufactured without restricted hazardous substances like lead mercury cadmium This ensures compliance with EU other international markets simplifies disposal recycling

How does this plant handle variations in feed material hardness The combination multi cylinder hydraulic cone crushers allows realtime adjustment CSS Closed Side Setting via the PLC interface This along selectable cavity profiles lets operators tune performance maintain product spec without stopping

What is typical installation commissioning timeline For greenfield site typical timeline weeks from delivery completion civil works This includes days onsite commissioning operator training by factory engineers Timeline varies based site preparedness

Are spare parts readily available given specialized components Yes Core wear parts mantles concaves jaw plates are standardized common models Nonwear electrical components are industrystandard RoHS compliant items ensuring global availability through our network local distributors

Can existing equipment be integrated into this new plant system Yes The control system designed accommodate integration legacy equipment conveyors screens provided their specifications compatible Engineering review required ensure seamless interoperability