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, les principaux défis du concassage primaire se concentrent souvent sur trois domaines critiques:

Temps d'arrêt imprévus: Pannes de roulements, unexpected wear part changes, and mechanical breakdowns halt your entire downstream process. Every hour of lost production can represent thousands in lost revenue and idle labor costs.
Débit incohérent & Forme du produit: La dureté et la taille fluctuantes du matériau d'alimentation peuvent provoquer un étranglement ou une cavitation., leading to suboptimal tonnage and poor particle shape that affects secondary crushing efficiency and final product value.
SkyHigh Maintenance Complexity & Frais: Traditional designs require extensive manual adjustment, frequent lubrication interventions, and lengthy procedures for wear part replacement, demanding significant skilled labor hours.

How do you select a primary stone crusher plant that delivers not just raw power, but predictable performance, simplified maintenance, and a demonstrable return on investment? The solution requires a focus on engineered reliability and operational intelligence.

2. APERÇU DU PRODUIT: PRIMARY JAW CRUSHER STATION

This product description details our heavyduty mobile primary jaw crusher plant, engineered for the first stage of rock reduction in quarrying, exploitation minière, et applications de recyclage par démolition. The plant is designed as a selfcontained crushing station for processing hard abrasive materials like granite, basalte, et béton recyclé.

Flux de travail opérationnel:
1. Alimentation: Dump trucks or wheel loaders deposit runofquarry material (jusqu'à la taille d'alimentation spécifiée) into the vibrating grizzly feeder (VGFF VGF).
2. Pré-écran & Écraser: The VGF removes fines from the feed stream via a bypass chute while directing oversize material evenly into the robust jaw crusher cavity.
3. Réduction primaire: The jaw crusher utilizes compressive force to break large rocks into smaller fragments (typically 150mm 200mm).
4. Décharge: Crushed material is discharged onto the main product conveyor for transport to the next stage or a stockpile.

Champ d'application & Limites:
Portée: Idéal pour le concassage primaire de roche dure (Résistance à la compression > 250 MPa), pierre de carrière dynamitée, déchets de démolition de construction, et gravier de rivière.
Limites: Ne convient pas aux collants, matériaux riches en argile sans prétraitement. Maximum feed size is fixed by crusher inlet dimensions; oversize rock requires preblasting or breaking.

3. CARACTÉRISTIQUES PRINCIPALES

Conception de mâchoire à chambre profonde | Base technique: Optimized nip angle and longer crushing zone | Avantage opérationnel: Augmente la capacité jusqu'à 10% versus standard chambers and produces a more consistent product gradation with less slabby output. | Impact sur le retour sur investissement: Higher throughput per fuel/power unit consumed improves costperton metrics.

Bascule hydraulique & Système de réglage | Base technique: Remplace les plaques à bascule mécaniques traditionnelles par un vérin hydraulique à double effet. | Avantage opérationnel: Enables remote clearing of chamber blockages in minutes instead of hours and allows quick CSS adjustment under load for product size changes. | Impact sur le retour sur investissement: Reduces downtime from tramp metal events by over 80% and minimizes noncrushing time during product changeovers.

Integrated HeavyDuty Grizzly Feeder | Base technique: Stepped grizzly bars with high stroke amplitude. | Avantage opérationnel: Effectively scalps fines to reduce crusher cavity packing while handling severe impact from direct truck dumping. | Impact sur le retour sur investissement: Improves overall plant efficiency by up to 15% by optimizing crusher load and protecting belts from fines spillage.

PLCBased Plant Control System | Base technique: Centralized control panel with CANBUS communication monitoring key parameters (consommation d'énergie, pression, température). | Avantage opérationnel: Provides operators with realtime diagnostics, historical trend data for predictive maintenance, and automated startup/shutdown sequences. | Impact sur le retour sur investissement: Lowers risk of catastrophic failure through early warning alerts and standardizes operation to reduce human error.

Unified Greasing System & Plateformes de services | Base technique: Centralized lube points routed to groundlevel access with automated timerbased greasing options. | Avantage opérationnel: Cuts routine service time by half by eliminating the need to access multiple highpoint bearings individually during daily checks. | Impact sur le retour sur investissement: Reduces scheduled maintenance labor costs and enhances technician safety.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | Notre solution de concasseur à mâchoires primaire | Avantage (% amélioration) |
| : | : | : | : |
| Durée de vie des pièces d'usure (Mn18/22 Jaws) | ~120,000 MTon (Granit abrasif) | ~150,000 MTon (Granit abrasif) | +25% Durée de vie prolongée |
| Chamber Clearance Time (Blockage)| Manuel / Mécanique; 24 hours average| Bascule hydraulique; <15 minutes typical| 90% Downtime Reduction |
| Average Power Consumption per Tonne| Baseline Reference| Jusqu'à 8% lower due to optimized kinematics & conception de la chambre| 8% Efficacité énergétique|
| Daily WalkAround Inspection Time| ~45 minutes (multiple access points)| ~25 minutes (centralized systems & plates-formes)| 44% Labor Time |

5. SPÉCIFICATIONS TECHNIQUES

Modèle de concasseur: JC145 HeavyDuty Jaw Crusher
Ouverture d'alimentation: 1400mm x 1100mm
Taille maximale d'alimentation: 1000mm longueur du bord
Réglage du côté fermé (CSS) Gamme: 150mm 250mm (réglable hydrauliquement)
Plage de capacité: Jusqu'à 750 MTPH, dépend du matériel d'alimentation et du CSS.
Power Plant Options: Étage 4 Final / Stage V dieselelectric hybrid or direct electric drive (400V/50Hz ou personnalisable).
Puissance totale installée: ~440 kW
Convoyeur principal: Largeur de bande 1400mm; discharge height adjustable up to 5m.
Construction du cadre: Hightensile steel plate with reinforced stress zones; abrasionresistant liners at impact points.
Plage de température de fonctionnement: 25°C to +45°C with standard fluid packages.
Capacity based on crushed granite with bulk density 1.6 t/m³.

6. SCÉNARIOS D'APPLICATION

Extraction de roches dures – Production de granulats de granit

Défi: A granite quarry faced excessive downtime from uncrushable material causing shearpin failures on their old jaw crusher. Replacement procedures took a full shift each occurrence.
Solution: Implementation of our mobile primary jaw crusher plant featuring the hydraulic toggle system for automatic uncrushable material release.
Résultats: Elimination of shearpin related stoppages. Chamber clearing events now resolved in under 20 minutes versus 8+ hours previously, increasing annual available production time by an estimated ~300 hours.

Large Infrastructure Project – OnSite Basalt Processing

Défi: A major highway project required consistent highvolume production of base materials across multiple work fronts within a tight schedule.
Solution: Deployment of two identical primary jaw crusher plants with PLC control systems for consistent operation by different crews.
Résultats: A atteint un débit soutenu de >700 MTPH per plant with matched product gradation from both sites due to precise hydraulic CSS control. Project completed aggregate production phase two weeks ahead of schedule.

7. CONSIDÉRATIONS COMMERCIALES

Our primary jaw crusher plants are offered in clear pricing tiers based on configuration:

1. Niveau d'usine de base: Includes core jaw crusher station with basic grizzly feeder, main conveyor, dieselelectric power pack, et plates-formes piétonnières.
2. Niveau de performances (Le plus courant): Adds hydraulic CSS adjustment & blockage clearing system, integrated metal detector on feeder belt PLC control system with advanced diagnostics.
3. Niveau Premium: Includes all Performance features plus extended service packages remote telematics gateway automated central greasing system upgraded heavyduty wear liners throughout

Optional features include dust suppression systems magnetic cross belt separator various side conveyor configurations

We offer comprehensive service packages ranging from annual inspection plans to fullsite operationandmaintenance contracts Financing options including equipment leasing rentaltoown agreements are available through our partners

FAQ

Q1 Is this stone crusher plant compatible with my existing secondary cone crushers screen decks?
Our plants are designed as modular units Standard discharge heights conveyor widths can be configured match most common downstream equipment layouts We provide detailed interface specifications facilitate integration

Q2 What is the expected impact on my operational labor requirements?
Field data shows these plants reduce daily inspection time simplify routine tasks However we recommend initial training focused on utilizing PLC data predictive maintenance rather than reactive repairs potentially reallocating labor resources

Q3 How does pricing compare traditional stationary primary crushing setup?
Initial capital outlay may be comparable highly engineered stationary foundations conveyors However total installed cost often lower due reduced civil works mobility offers significant value projects requiring relocation

Q4 What are standard commercial terms delivery lead times?
Standard terms involve progress payment against manufacturing milestones Lead times typically range from weeks depending model complexity current order backlog confirmed upon project specification

Q5 What level site preparation required before installation?
A stable compacted level working platform sufficient bearing capacity support total plant weight required Unlike stationary plants extensive concrete foundations not necessary reducing site preparation time cost

Q6 Can you provide performance guarantees?
Yes we offer guaranteed capacity wear part life metrics based specific agreedupon feed material laboratory analysis These form part commercial agreement ensure performance meets your production targets