1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

L’augmentation des coûts opérationnels et les temps d’arrêt imprévisibles érodent vos marges de production globales? Pour les directeurs d’usine et les entrepreneurs en ingénierie, the core challenges in primary crushing often stem from the initial reduction stage. Inefficient or unreliable primary crusher performance creates cascading bottlenecks throughout your entire processing circuit.

Les défis opérationnels courants comprennent:
Temps d'arrêt élevés pour la maintenance: Frequent liner changes and unplanned stops for jam clearing can consume over 15% of available production time annually.
Gestion incohérente des aliments: Fluctuating feed size, humidité, and hardness lead to chokefeeding, wear imbalances, and suboptimal throughput.
Consommation d'énergie excessive: An inefficient crushing chamber design or misapplied technology can increase power costs by 2030% per ton of material processed.
Coûts élevés des pièces d’usure: Rapid abrasion of jaws, manteaux, and concaves in abrasive formations results in unsustainable consumables expenditure.
Flexibilité de configuration limitée: Les usines fixes ont du mal à s'adapter aux profils changeants des gisements ou aux nouvelles spécifications du projet, vous enfermer dans un seul mode opérationnel.

Is your primary crushing station a source of constant adjustment and cost, or a reliable foundation for your plant’s profitability?

2. APERÇU DU PRODUIT: Primary Jaw Crusher Station

A Primary Jaw Crusher Station is a fixed or modular assembly designed for the first stage of size reduction in hard rock quarries, opérations minières, et des projets de construction à grande échelle. Its function is to accept runofmine (ROM) material directly from the quarry face and reduce it to a manageable size for secondary crushing and conveying.

Flux de travail opérationnel:
1. Consommation alimentaire: Les camions à benne basculante ou les chargeurs déposent de gros (jusqu'à 1,5 m) ROM material into a rugged vibrating grizzly feeder (VGFF VGF).
2. Présélection & By-pass: La VGF sépare les amendes (< CSS) contourner le concasseur, reducing wear and improving overall efficiency.
3. Concassage primaire: Oversize material is directed into the jaw crusher’s cavity, where a reciprocating jaw exerts immense compressive force against a fixed jaw, breaking rock along its natural fracture lines.
4. Décharge & Transport: Crushed product is discharged onto a main conveyor at a controlled rate for transport to the next stage.

Champ d'application & Limites:
Portée: Ideal for hightonnage processing of hard, matériaux abrasifs comme le granit, basalte, et minerai de fer. Suited for stationary plants with longlife quarries.
Limites: Pas optimal pour le soft, nonabrasive rock or highly laminated/cleaved material where impact crushing may be more efficient. Requires substantial foundational support and is less mobile than some alternatives.

3. CARACTÉRISTIQUES PRINCIPALES

Chambre de concassage profonde & Angle de pincement agressif | Base technique: Optimized kinematics for increased compressive force | Avantage opérationnel: Handles larger feed sizes with fewer bridging incidents; produces a consistent, wellgraded output on the first pass | Impact sur le retour sur investissement: Reduces need for prebreaking or secondary hammering; lowers costperton in the primary stage.

Cadre en acier robuste | Base technique: Analyse par éléments finis (FEA)designed stress distribution | Avantage opérationnel: Provides unwavering stability under peak loads, minimiser la fatigue du cadre et les problèmes d'alignement sur une 20+ ans de durée de vie | Impact sur le retour sur investissement: Élimine les réparations structurelles coûteuses; protects major capital investment.

Réglage hydraulique & Système de compensation | Base technique: Vérins hydrauliques à double effet intégrés | Avantage opérationnel: Permet aux opérateurs d'ajuster le réglage du côté fermé (CSS) remotely for product size changes and safely clear blockages in minutes without manual intervention | Impact sur le retour sur investissement: Cuts nonproductive downtime by up to 80% during routine adjustments and stall recovery.

Doublures d'usure BoltOn & Modular Cheek Plates | Base technique: Highstrength alloy steel castings with reversible design | Avantage opérationnel: Enables fast replacement with standard tools; extends service intervals through multiple rotation cycles | Impact sur le retour sur investissement: Reduces liner changeout time by over 50%; lowers inventory costs through part commonality.

Système de graissage automatisé centralisé | Base technique: Programmable lubrication pump with feed lines to all critical bearings | Avantage opérationnel: Ensures optimal bearing health with precise grease volume control, independent of operator routine | Impact sur le retour sur investissement: Prevents premature bearing failure—a leading cause of major crusher repair—extending component life by an average of 40%.

Système de sécurité à plaque à bascule | Base technique: Mechanically sacrificial cast iron toggle plate | Avantage opérationnel: Agit comme un fusible mécanique; fractures under uncrushable overload (par ex., clochard métal), protecting the crusher from catastrophic damage | Impact sur le retour sur investissement: Avoids weeks of downtime and sixfigure repair bills associated with frame or shaft damage.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | Solution de concasseur à mâchoires primaire | Avantage (% amélioration) |
| : | : | : | : |
| Disponibilité (Temps de disponibilité) | ~8588% due to maintenance & jams| >92% with hydraulic adjustment & clairière| +57% des heures plus productives |
| Porter la vie (Roche Abrasive) | 120,000 150,000 tonnes par ensemble| 180,000 220,000 tonnes par ensemble| +40% intervalles d'entretien plus longs |
| Efficacité énergétique (kWh/tonne)~| Varie considérablement; baseline = X kWh/ton~| Field data shows X15% kWh/ton~| Jusqu'à 15% lower power consumption |
| Capacité de débit (tph)~| Rated at ideal conditions~| Sustained throughput at rated capacity in realworld feed conditions~| +1012% higher effective yield |

_Based on comparative field studies in granite quarries._~
_~Specific values depend on model selection and material characteristics._

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: 500 1,600 Tonnes métriques par heure (MTPH), selon le modèle et la granulométrie.
Ouverture d'alimentation: De 1 000 mm x 650 mm à 1 500 mm x 1 200 mm.
Exigences d'alimentation: Moteur du concasseur principal de 90 kW jusqu'à 300 kW. Total station power including VGF and conveyors typically ranges from 200 kW à 450 kW.
Spécifications matérielles: Main frame constructed from hightensile strength steel plate (Min. limite d'élasticité 355 MPa). Wear parts available in several manganese steel grades (14%,18%,22%) for optimal cost/performance matching.
Dimensions physiques (Gare typique): Length ~25m; Largeur ~8m; Hauteur ~7m (hors convoyeur de déchargement).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C. Système de suppression de poussière prêt. Noise emissions compliant with <85 dB(UN) aux postes opérateurs.

6. SCÉNARIOS D'APPLICATION

Agrandissement de la carrière de granit

Défi: Une grande carrière de granit nécessaire pour augmenter le débit du circuit primaire de 25% without expanding its footprint or changing feed size from new blasting patterns.
Solution: Implementation of a highcapacity singletoggle jaw crusher station with an optimized grizzly feeder section to improve feed distribution.
Résultats: Nous avons obtenu une augmentation soutenue du débit de 28%. Wear part consumption per million tons decreased by an estimated18%, meeting expansion goals within the existing layout.

Modernisation d'une usine de traitement de minerai de fer

Défi: Chronic downtime due to tramp steel causing catastrophic damage in the existing primary crusher,
averaging12 days of lost production annually.
Solution:
Retrofit installation featuring an enhanced tramp release system using energyabsorbing hydraulic cylinders
and an automatic reset function.
Résultats:
Eliminated major damage events.Recovery from uncrushable objects now takes less than
30 minutes.Incidentrelated downtime reduced by over95%.

7.CONSIDÉRATIONS COMMERCIALES

Equipment pricing tiers are primarily determined by capacity size
and customization level:

• Niveau I(Service standard):Pour une cohérence,friable material.Highest cost efficiency
for defined applications.

• Niveau II(Robuste):Our most common selection
for hard rock quarries.Includes standard hydraulic adjustment
and heavier components.Balances performance
with durability

• Niveau III(Modular/SkidMounted):Designed
for faster installation
or semimobile requirements.Priced accordingly

Fonctionnalités facultatives:

• Automated wear monitoring systems

• Advanced motor starters(VSD)

• Integrated dust suppression packages

Forfaits de services:

• Mise en service & Formation des opérateurs

• Planned Maintenance Agreements(with guaranteed parts availability)

• Remote Performance Monitoring Subscription

Options de financement:

Capital expenditure can be structured through equipment leasing programs,
contrats de location-vente à long terme,
or project financing partnerships tailored
for largescale infrastructure development

8.FAQ

T1:
How do I determine if this type is suitable versus gyratory crusher?
UN:Gyratory crushers excel at very high tonnage(>1，500 tph)
in mining.Jaw stations offer lower capital cost，
simpler maintenance，
and better handling
of slabby material，
making them preferred
for most quarry applications up
to ~1，200 tph

T2:
What infrastructure is required?
UN:A substantial reinforced concrete foundation capable
of supporting dynamic loads，
adequate crane access
for wear part replacement，
and integration points
for raw feed supply
and crushed product conveyors are essential

T3:
Can it handle wet，sticky material?
UN：While capable，
excessive clay or moisture significantly increases risk
of packing/choking.A robust vibrating grizzly feeder(scalpeur)
est critique，
and alternative primary crushing types may be recommended

T4：
What is typical installation timeline？
UN：For complete station including foundation，
allow8–14 weeks from delivery depending on site readiness.Modular skid versions can reduce this timeline significantly

Q5：
How are wear parts priced？
UN：Parts are offered under transparent pricing models—either fixedprice per operating hour agreements（cost certainty）or direct purchase.Consumables cost per ton processed should be calculated during application review