1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing a midtolarge scale aggregate operation and facing the constant pressure to balance highvolume output with operational stability? Les défis d'une usine de concassage de pierre de 250 300 tph sont importants. Les temps d'arrêt imprévus dus à une panne d'équipement peuvent coûter des milliers de dollars par heure en perte de production et en main d'œuvre inutilisée.. Inconsistent feed material leads to fluctuating final product gradation, causing rejections and compromising contract compliance. La hausse des coûts énergétiques érode directement les marges bénéficiaires sur chaque tonne produite. En outre, meeting stringent environmental regulations on dust and noise adds complexity and capital expense. Are these issues impacting your bottom line? Comment obtenir une fiabilité, hightonnage production while controlling operational costs and ensuring plant longevity? The solution lies in a fundamentally robust and intelligently engineered crushing plant design.

2. APERÇU DU PRODUIT

This datasheet details a complete stationary 250300usine de concassage de pierre tph engineered for granite, basalte, calcaire, and other hard rock applications. It is a multistage processing system designed for continuous, highvolume production of highquality aggregates (05mm, 510mm, 1020mm, 2031.5mm).

Flux de travail opérationnel:
1. Concassage primaire: Dump trucks feed material into a largecapacity vibrating grizzly feeder which removes fines before directing oversize to a heavyduty jaw crusher for initial size reduction.
2. Secondaire & Concassage Tertiaire: The primary crushed material is conveyed to a cone crusher for secondary reduction. A subsequent cone crusher or impact crusher (depending on material abrasiveness and product shape requirements) performs tertiary crushing.
3. Dépistage & Classification: Material is routed through multipledeck vibrating screens to precisely separate it into specified product sizes.
4. Manutention des matériaux & Stockage: Onspec aggregates are conveyed to designated stockpiles via radial stackers or fixed conveyors, while oversize material is recirculated back to the appropriate crusher.

Champ d'application: Idéal pour les opérations de grandes carrières, accompagnement de grands projets d’infrastructures (autoroutes, chemins de fer), et alimentation commerciale pour centrales à béton/asphalte. Limites: Not suitable for portable or skidmounted applications; requires stable foundation and substantial upfront civil works.

3. CARACTÉRISTIQUES PRINCIPALES

Système de contrôle d'alimentation intelligent | Base technique: Entraînement à fréquence variable (VFD) on feeder with level sensors | Avantage opérationnel: Maintains optimal chokefeed condition for crushers, preventing empty running and cavity flooding | Impact sur le retour sur investissement: Jusqu'à 15% reduction in energy consumption per ton and ~10% increase in liner life.

Centralized Dust Suppression Envelope | Base technique: Points de transfert encapsulés avec canons à brouillard stratégiquement placés & filtres à manches | Avantage opérationnel: Contains dust at source across entire flow path, ensuring compliance and improving site visibility/worker health | Impact sur le retour sur investissement: Mitigates regulatory fines and reduces cleanup labor by an estimated 30%.

Conception de chambre de concassage à haute efficacité | Base technique: Laminated crushing principle with optimized kinematics in jaw and cone crushers | Avantage opérationnel: Generates more interparticle crushing for improved product shape (higher cubicity) and increased yield of premium fractions | Impact sur le retour sur investissement: Higher market value for crushed products and reduced waste.

Logique de processus automatisée basée sur un API | Base technique: Programmable Logic Controller with HMI touchscreen monitoring crusher load, vitesses du convoyeur, and screen efficiency | Avantage opérationnel: Allows singleoperator oversight of entire plant flow; automatic adjustments prevent overloads and blockages | Impact sur le retour sur investissement: Reduces operational staffing requirements by up to 2 FTE per shift while increasing system availability.

Conception d'accès de maintenance modulaire | Base technique: Réglage hydraulique & setting release systems on crushers; walkin platforms around all major components | Avantage opérationnel: Enables faster liner changes, routine inspections, and component replacement with standard tools | Impact sur le retour sur investissement: Réduit les temps d'arrêt pour maintenance planifiée jusqu'à 40%, augmentant directement les heures de production annuelles.

HeavyDuty Conveyor Specification | Base technique: CEMA Class IV idlers with impact beds at loading zones; épissures de ceinture vulcanisées | Avantage opérationnel: Eliminates premature belt wear at transfer points, drastically reducing belt failure risk—a leading cause of unplanned stoppage | Impact sur le retour sur investissement: Prolonge le temps moyen entre les pannes (MTBF) for conveying system by over 50%.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (250300Usine de tph) | This Sustainable Stone Crushing Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Overall System Availability | ~85% 88% (Seasonal) |> 92% (Objectif annuel) |> +5% à +8% |
| Consommation d'énergie par tonne broyée| ~1,8 2.1 kWh/t |> 1.6 1.7 kWh/t |> ~10% Reduction |
| Coût total de possession (5Année projetée)| Référence |> 1520% Inférieur |> Direct Cost Savings |
| Forme du produit (% Contenu cubique)| Varies Widely (~6575%) |> Cohérent > 78% |> Higher Premium Product Yield |
| Noise Emission at Property Line| Souvent >75 dB(UN) |> Contrôlé < 70 dB(UN) |> Easier Permitting & Relations communautaires |

_Based on field data from comparable installations using similar granite feed material._

5. SPÉCIFICATIONS TECHNIQUES

Capacité de débit conçue: 250 300 tonnes métriques par heure (tph), en fonction de la dureté du matériau alimenté (<180 MPa recommandé), répartition des tailles (<750mm), et la gradation de produit requise.
Total Connected Power: Environ 550 650 kW.
Spécifications des matériaux clés:
Primary Crusher Feed Size Max.: ≤750mm
Tailles du produit final: Configurable from 05mm sand up to 31.5mm aggregate.
Conveyor Belt Width/Speed: Main conveyors typically B1000mm width @1.6m/s.
Empreinte physique (Env.): Length ~120m x Width ~65m (excluding stockpile areas). Requires detailed civil foundation engineering.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C avec des systèmes de lubrification appropriés; standard dust suppression rated for conditions up to 85% humidité relative.

6. SCÉNARIOS D'APPLICATION

Large Quarry Expansion Project

Défi: A regional quarry needed to increase output from 200tph to over 280tph reliably to fulfill a new highway contract but faced space constraints and strict new county noise ordinances.
Solution: Implementation of this compactly designed multistage stone crushing plant featuring soundinsulated enclosures around key equipment like the secondary/tertiary crushers.
Résultats: Achieved consistent throughput of ≥290tph while passing compliance noise audits (<70dB at site boundary). The automated control system allowed management of the increased throughput without adding shift personnel.

Integrated Concrete Producer

Défi: A vertically integrated concrete company operating its own limestone quarry experienced high maintenance costs from abrasive wear on tertiary stage equipment and inconsistent sand yield affecting mix designs.
Solution: Installation of this plant configuration featuring a tertiary cone crusher specifically selected for abrasive rock with a specialized chamber profile.
Résultats: Tertiary crusher manganese liner life increased by approximately two weeks per set under identical conditions due to optimized feed from preceding stages combined with chamber design.The consistent gradation curve improved sand yield stability by ±3%, leading directly to more predictable concrete batch quality.

7.CONSIDÉRATIONS COMMERCIALES

A sustainable stone crushing plant represents a significant capital investment designed for longterm returns.

Niveaux de tarification des équipements:
Base Configuration includes primary jaw crusher feeder station secondary cone tertiary impactor basic screening structure conveyors electrical control panel
Enhanced Configuration adds automated grease systems centralized lubrication advanced PLC automation package upgraded dust suppression bag filter units
Turnkey Premium Configuration includes full civil works design support erection commissioning supervision training extended commissioning period

Optional Features include metal detection tramp iron relief systems automatic sampler units remote monitoring telematics packages water recycling systems

Service Packages are offered as annual preventative maintenance contracts including scheduled inspections parts discounts priority technical support

Financing Options available through partner institutions include traditional equipment leasing longterm loans or powerbythehour style performancebased agreements where service costs are bundled

FAQ

What type of electrical supply is required?
The complete plant typically requires a mediumvoltage connection (~10kV) feeding into a dedicated transformer substation due to the total connected load (~550650kW). Detailed power requirements are provided during the project engineering phase.

How does this setup handle wet or sticky feed material?
The vibrating grizzly feeder deck can be equipped with heating elements or special liners We also recommend screen deck heating systems as an option These features prevent material buildup ensuring consistent flow during cold or damp conditions

What is the expected timeframe from order placement to commissioning?
For a standard configuration lead time is typically months following detailed engineering For turnkey projects including civil works total project duration generally ranges from months subject to sitespecific conditions

Les pièces de rechange sont-elles facilement disponibles?
Yes Critical wear parts like mantles concaves jaw plates are standardized items held in regional inventory Standard mechanical electrical components use globally available bearings seals motors drives minimizing procurement delays

Can this plant be reconfigured later if my product requirements change?
Yes The modular design allows for future modifications such as adding an extra screen deck integrating a different tertiary crusher type or rerouting conveyors Engineering support is provided for such upgrade projects