1. PAINPOINT DRIVEN OPENING

Are you facing persistent bottlenecks in your primary crushing circuit that limit overall plant throughput? Do unscheduled downtime events for liner changes and mechanical repairs erode your production targets and budget? Is the inconsistent feed size from your mine causing capacity fluctuations and excessive wear in your secondary crushers? Are you struggling with high perton operating costs driven by energy consumption, maintenance labor, and premature component failure?

These operational challenges directly impact your bottom line. Every hour of unplanned downtime can cost tens of thousands in lost production. Every inefficient ton crushed consumes unnecessary power and accelerates wear part expenditure.

The solution lies at the very start of your process: a High Quality Iron Ore Crushing Plant engineered not just to process material, but to optimize your entire downstream operation. How do you achieve consistent, highvolume primary crushing with maximum availability and controlled operational expense?

2. PRODUCT OVERVIEW

This product is a complete, heavyduty primary crushing station engineered specifically for abrasive, hightonnage iron ore applications. It is centered on a robust gyratory or jaw crusher designed to accept runofmine (ROM) feed and deliver a consistent, optimally sized product for SAG mill feed or secondary crushing.

Operational Workflow:
1. ROM Receiving & PreScreening: Direct dump from haul trucks into a rugged vibrating grizzly feeder (VGF).
2. Primary Size Reduction: The VGF removes fines and directs oversize material into the primary crusher for initial breakage.
3. Product Conveyance: Crushed ore is discharged onto a main conveyor system for transport to the next processing stage.
4. System Control: Centralized PLCbased control monitors all functions, from feed rate to crusher load and conveyor sequencing.

Application Scope: Ideal for greenfield mining projects or major expansions requiring reliable primary crushing capacity from 2,000 to over 10,000 tph. Suitable for magnetite, hematite, and other ironbearing ores.

Limitations: Not designed as a portable or skidmounted solution; it is a permanent, foundational plant installation requiring civil works and integration engineering.

3. CORE FEATURES

Advanced Chamber Design | Technical Basis: Optimized kinematics & nip angle geometry | Operational Benefit: Produces a more consistent product size distribution on the first pass, reducing recirculating load | ROI Impact: Increases effective throughput by up to 15% and reduces downstream crusher wear.

Hydraulic Setting Adjustment (HSA) System | Technical Basis: Remoteadjustable mainshaft position controlled via PLC | Operational Benefit: Allows operators to adjust crusher discharge setting in minutes without stopping the crusher | ROI Impact: Minimizes downtime for CSS changes by over 90%, enabling rapid response to changing ore characteristics.

Liner Life Enhancement Technology | Technical Basis: Computermodeled liner profiles & ultrawearresistant alloy steel | Operational Benefit: Achieves more uniform wear distribution and extends service intervals | ROI Impact: Reduces liner consumption costs by 2030% and decreases annual maintenance manhours.

Integrated Tramp Iron Relief | Technical Basis: Hydraulic cylinders support the mainshaft to allow automatic passing of uncrushables | Operational Benefit: Protects the crusher from catastrophic damage due to bucket teeth, drill bits, or other metal contaminants | ROI Impact: Eliminates risk of major mechanical failure and associated weeks of downtime.

HighEfficiency Drive System | Technical Basis: Direct Vbelt drive or lowloss gearbox coupled with hightorque motors | Operational Benefit: Transmits more power directly to crushing action with lower mechanical losses | ROI Impact: Reduces specific energy consumption (kWh/ton) by an average of 812%.

Structural Integrity & Vibration Management | Technical Basis: Finite Element Analysis (FEA)designed base frame & integrated damping systems | Operational Benefit: Absorbs dynamic loads, minimizing stress fatigue and foundation transfer issues | ROI Impact: Ensures longterm structural reliability over a 20+ year lifespan with reduced repair costs.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Average | Our High Quality Iron Ore Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Mechanical Availability (%)| 92 94%| 96 98%| +4% (+~2,100 hrs/yr at 6k tph) |
| Liner Wear Life (Million Tons) | Varies widely; baseline = 1x| 1.3x 1.5x baseline| +3050% longer life |
| Specific Energy Consumption (kWh/t)| Baseline = 1x| 0.88x 0.92x baseline| 8% to 12% reduction |
| Mean Time Between Failure (MTBF), hours| ~1,500 hrs| >2,200 hrs| +46% improvement |
| Product Fines (10mm) Control| Often uncontrolled high %| Consistently optimized lower %| Reduces overcrushing & improves yield |

_Figures based on aggregated field performance data from comparable installations in iron ore._

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 2,000 TPH to >10,000 TPH, dependent on ore characteristics (Bond Work Index, abrasion index) and required product size.
Primary Crusher Options: Heavyduty Gyratory Crusher (54” – 74” feed opening) or Ultraheavy Jaw Crusher.
Power Requirements: Main drive motor from 300 kW up to 750 kW, with total installed plant power including feeders and conveyors from 800 kW to 2 MW. Designed for HV supply (6.6kV /11kV).
Material Specifications: Critical wear components manufactured from ASTM A514 or equivalent highstrength steel; liners in premium manganese steel alloys; abrasionresistant plate on all material contact points.
Physical Dimensions (Typical Gyratory Station): Feed hopper ~120m³; Overall footprint approximately 25m L x 18m W x 15m H. Detailed civil drawings provided.
Environmental Operating Range: Designed for ambient temperatures from 30°C to +50°C, with optional heating/cooling packages available. Dust suppression system compliant with <10 mg/Nm³ emission standards.

6. APPLICATION SCENARIOS

Greenfield Magnetite Project – Pilbara Region

Challenge A new mine required a primary crushing plant capable of processing highly abrasive magnetite at 6,500 tph with <72 hours of scheduled maintenance per month.
Solution Implementation of our High Quality Iron Ore Crushing Plant featuring an advanced gyratory crusher with HSA system and predictive maintenance monitoring.
Results The plant achieved an average monthly availability of 97.8% in its first year of operation. Liner life exceeded projections by 22%, contributing to an overall 14% lower costperton than feasibility study estimates.

Existing Hematite Operation – Capacity Expansion

Challenge An aging jaw crusher station was the bottleneck limiting plant expansion from 4k tph to 6k tph; frequent breakdowns caused cascading downstream stoppages.
Solution Replacement with our modern High Quality Iron Ore Crushing Plant designed as a dropin upgrade with minimal modifications to existing infrastructure.
Results Throughput increased reliably to target levels within one month of commissioning. Energy monitoring showed an 11% reduction in specific power consumption compared to the old unit despite higher output.

7 COMMERCIAL CONSIDERATIONS

Our High Quality Iron Ore Crushing Plants are offered under three primary tiers:

1 Base Plant Package Includes core crusher heavyduty feeder discharge conveyor dust suppression basic control system Civil design scope is separate

2 Performance+ Package Adds advanced automation package predictive health monitoring sensors premium wear liner package extended structural warranty

3 Turnkey Solution Full engineering procurement construction management EPCM scope covering civil works structural steel erection electrical installation commissioning spares holding

Optional Features Onboard weighing systems automated lubrication units special corrosion protection coatings remote operational support connectivity

Service Packages We offer tiered service agreements ranging from annual inspection plans Platinum coverage which includes parts labor predictive analytics expert priority support

Financing Options We work with leading industrial finance partners Flexible structures include capital purchase finance leases operating leases projectspecific financing subject to credit approval

8 FAQ

Q What level of preparation is needed at my site before delivery
A You will need prepared foundations based on our certified civil drawings adequate crane access for assembly stable HV power supply water access for dust suppression Site surveys are conducted prior order finalization

Q How does this plant integrate with my existing secondary crushing SAG mill circuit
A Our engineering team conducts full circuit analysis We design the primary discharge product specifically as optimal feed for your downstream equipment ensuring balanced system performance

Q What is the typical delivery lead time
A For standard configurations lead time ranges between months following final design approval Longlead items like castings are identified early Expedited options may be available subject component availability

Q Are spare parts readily available globally
A Yes We maintain regional inventory hubs critical wear parts Our guaranteed parts supply program ensures priority dispatch documented stock levels key components

Q Can operators be trained on this specific system
A Comprehensive training is included covering operation maintenance troubleshooting safety Training conducted both factory site using actual equipment simulators

Q What commercial terms are standard
A Standard terms are CIF major port Incoterms Payment typically structured progress milestones against equipment manufacture shipment commissioning