1. PAINPOINT DRIVEN OPENING

Are your iron ore processing margins being eroded by persistent, unplanned downtime? Commercial operators and plant managers face significant financial pressure from equipment that cannot withstand the abrasive reality of highvolume iron ore. Common challenges include:
Excessive Wear & Component Failure: Standard crushing chambers and liners degrade rapidly under continuous Taconite or Hematite load, leading to frequent shutdowns for maintenance and high parts replacement costs.
Inconsistent Throughput & Product Gradation: Fluctuations in feed size or hardness result in poor control over final product sizing, causing bottlenecks in downstream grinding circuits and reducing pellet or sinter plant efficiency.
High Energy Consumption per Ton: Older or improperly configured crushing stages consume disproportionate power, directly impacting operational expenditure and carbon footprint.
Rigid Plant Configuration: Fixed crushing circuits struggle to adapt to varying ore body characteristics or market demands for different product specifications, limiting operational flexibility.

Is your primary crushing station a source of cost or a driver of profit? The solution lies in precision engineering applied directly to the unique demands of iron ore.

2. PRODUCT OVERVIEW

This content details a fully customizable, heavyduty stationary crushing plant solution engineered explicitly for hightonnage iron ore processing. The system is designed as a primary or primary/secondary stage unit, built around a core gyratory or jaw crusher configured for maximum abrasion resistance and volumetric throughput.

Operational Workflow:
1. Managed Feed Intake: Runofmine ore is directed via heavyduty apron feeder to the primary crusher, ensuring a consistent, chokefed load for optimal crushing action.
2. Primary Size Reduction: The core crusher utilizes high inertia and optimized kinematics to reduce large lump ore (up to 1.5m) to a manageable conveyorable size.
3. Primary Scalping & Fines Removal: A downstream heavyduty scalper removes natural fines prior to secondary crushing, increasing circuit efficiency and reducing unnecessary wear.
4. Secondary Crushing & Closed Circuit Control (Optional): A cone crusher module in closed circuit with a sizing screen allows precise control of final product gradation, typically to 50mm or 75mm for downstream milling.
5. Integrated Material Handling: Plant design includes robust conveyor systems, transfer points with impact beds, and dust suppression integration for complete material flow management.

Application Scope: Designed for greenfield installations or major upgrades in magnetite (taconite) and hematite mining operations with annual capacity requirements from 5 to 25+ million tonnes.

Limitations: Not suitable for lowtonnage operations (< 1 Mtpa) or as a tertiary/quartzite crushing unit without significant specification review.

3. CORE FEATURES

Patented Liner Geometry | Technical Basis: Finite Element Analysis (FEA) & wear modeling | Operational Benefit: Achieves more consistent product gradation throughout the liner life cycle, with reduced risk of bridging | ROI Impact: Up to 15% longer liner life reduces direct parts cost and changeout downtime

Intelligent Load & Feed Control System | Technical Basis: Realtime motor power & hydraulic pressure monitoring with automated feeder response | Operational Benefit: Maintains optimal crusher cavity loading, preventing overload stalls and emptycavity wear | ROI Impact: Protects drive components from shock loads; field data shows a 712% reduction in specific energy consumption (kWh/tonne)

Modular Plant Subframe Design | Technical Basis: Bolttogether, heavygauge steel modules with precisionmachined interfaces | Operational Benefit: Enables faster onsite erection and future reconfiguration or relocation with minimal cutting/welding | ROI Impact: Can reduce civil works and installation time by an estimated 30%, accelerating timetoproduction

Centralized Greasing & Fluid Systems | Technical Basis: Singlepoint lubrication distribution blocks with monitoring points for all critical bearings | Operational Benefit: Ensures correct lubrication intervals are met reliably, extending bearing service life in highdust environments | ROI Impact: Lowers manual maintenance labor hours by ~25% per shift and decreases bearing failure risk

HeavyDuty Dust Containment Skirting | Technical Basis: Multistage rubber skirting with adjustable tensioning on all conveyor transfers | Operational Benefit: Dramatically reduces airborne dust at emission points, improving site safety and environmental compliance | ROI Impact: Lowers water consumption for suppression and reduces cleanup costs; minimizes risk of regulatory noncompliance penalties

Crusher Backing Material Integration | Technical Basis: Automated dispensing system for epoxy resin backing during liner installation | Operational Benefit: Ensures complete cavity fill without air pockets, maximizing liner stability and energy transfer | ROI Impact: Eliminates premature liner failure due to improper backing, protecting major crusher body components

WalkIn Maintenance Platforms | Technical Basis: Integrated, OSHAcompliant platforms with handrails around all major service points (crusher top shell, motor, sheaves) | Operational Benefit Provides safe, direct access for inspection and component handling during planned maintenance| ROI Impact Reduces servicerelated safety incidents; improves maintenance efficiency by providing stable work areas

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | Custom Iron Ore Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life (Primary Mantle/Bowl) | ~1.2 Million Tonnes
Varies by ore abrasiveness| ~1.5 Million Tonnes
Based on magnetite feed| +25% |
| Total Plant Availability (Scheduled Runtime) | 9294%
Includes minor stops| >96%
Design target| +34 Percentage Points |
| Specific Energy Consumption
(kWh per tonne crushed) Baseline Dependent
Varies by circuit design| Field data indicates reduction of
712% vs. nonoptimized equivalent systems.| Up to 12% |
| Mean Time Between Failure (MTBF)
for Major Components
~2，000 hours
Drive/motor/bearing assemblies| >2，500 hours
Design target based on load management| +25% |
| Planned Maintenance Downtime
(per major liner change event)
4872 hours
Crew dependent|<36 hours target
Via modular liners & platforms| 33% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 2，500 to over 8，000 tonnes per hour (tph)， depending on feed size， ore work index，and product size requirement.
Primary Crusher Options: Gyratory Crushers (54”75” feed opening) or Jaw Crushers (60”x80”+). Selection based on required throughput， feed topology，and fragmentation analysis.
Drive Power: Electric motor drives ranging from 450 kW to 1，200 kW，with Vbelt or direct drive configurations available。 Softstart systems standard。
Material Specifications：
Crusher Liners： Manganese steel alloy（14%18%）with optional chrome carbide overlay for extreme abrasion zones。
Structural Steel： Primary support structures use S355JR grade steel； highwear areas utilize AR400 abrasionresistant plate。
Conveyor Idlers： CEMA class E/F sealed bearings； impact idlers at loading zones。
Physical Dimensions （Modular）： Modules designed for standard shipping container dimensions。 Typical primary station footprint： ~30m L x 15m W x 20m H （variable）。
Environmental Operating Range：
Ambient Temperature： 30°C to +50°C （with appropriate lube oil/heater packages）。
Dust Emissions： Designed to achieve <10 mg/Nm³ at containment points with integrated suppression。
Noise Level： Compliant with <85 dB(A) at operator stations via acoustic enclosures。

6. APPLICATION SCENARIOS

Greenfield Magnetite Concentrator｜Challenge： A new mine required a primary crushing plant capable of processing highly abrasive taconite at 6，000 tph，with strict product sizing (250mm) for SAG mill feed。 The remote location demanded high reliability due to limited local maintenance support。｜Solution： A customized gyratory crusherbased plant featuring our intelligent load control system， extendedlife liner package，and fully walkin maintenance modules was installed。 All lubrication and electrical cabinets were housed in heated enclosures。｜Results： The plant achieved nameplate capacity within two weeks of commissioning。 Liner life exceeded projections by 8%， achieving over 1。6 million tonnes per set。 Availability has averaged 96。7% over the first three years of operation。

Hematite Processing Plant Upgrade｜Challenge An existing hematite operation experienced chronic bottlenecks due to an aging jaw crusher plant suffering from frequent bearing failures and poor throughput consistency (<2，200 tph)，limiting downstream beneficiation output。｜Solution We replaced the existing unit with a customized modular jaw plant featuring the centralized greasing system，heavyduty skirting，and an optimized feeder/crusher interface geometry tailored to the specific ore characteristics。｜Results Throughput increased consistently above design rate of 2，800 tph。 Bearingrelated unscheduled downtime was eliminated in the first year postinstallation。 Product size distribution became markedly more uniform (+/10%) improving downstream screening efficiency。

7． COMMERCIAL CONSIDERATIONS

Our approach is based on providing transparent value aligned with your production targets。

Pricing Tiers
• Base Plant Configuration Includes core crusher motor feeders basic discharge conveyor structural supports walkways ladders
• Enhanced Configuration Adds intelligent control system dust suppression package premium liner options automated lubrication
• Turnkey Project Package Full engineering procurement construction management EPC/M including foundations electrical reticulation commissioning spares package

Optional Features
• OnBoard Hydraulic Power Unit For setting adjustment/clearing
• Rock Breaker Boom System For oversize breaking at grizzly
• Advanced Predictive Monitoring Vibration temperature sensors linked to SCADA
• Modular Secondary/Tertiary Crushing Stage For future expansion

Service Packages
• Planned Maintenance Agreements Scheduled inspections parts supply labor rates defined upfront
• Performance Guarantee Contracts Uptime availability或throughput guarantees supported by remote monitoring
• Liner Service Programs Fixedcostpertonne agreements covering all wear parts

Financing Options
We work with accredited partners to offer equipment leasing capital loans以及operational expenditure OpEx models where payment is tied directlyto verified production tonnage。

8． FAQ

Q What level of site preparation is required prior delivery？
A Our modular plants require prepared concrete foundations designed specificallyfor your soil conditions We provide full foundation drawings anchor bolt locations as partof basic engineering Minimal field welding should be required。

Q How does this solution integrate into my existing control room SCADA system？
A The plant control panel can be supplied asa standalone PLCbased systemor configuredto communicate via industrystandard protocols Modbus TCP/IP Profibus etc allowing full visibilityand control fromyour central facility。

Q Are performance guarantees offered？
A Yes subjectto mutually agreedupon feed material specifications we can contractually guarantee rated throughput capacity final product P80 sizing以及specific energy consumption targets。

Q What isthe typical lead timefrom order placementto commissioning？
A For standard configurations lead times range between914 months dependingon current manufacturingload Complex customizations may extendthis timeframe Detailed project schedules are provided upon initial technical review。

Q How do you address ongoing technical supportfor remote sites？
A We offer tiered support including24/7 remote diagnostics access trained regional service technicians以及comprehensive documentation Parts are strategically warehousedin key mining regions globallyto expedite delivery。

Q Can this plant be relocatedin future？
A Yes themodular bolted subframe designis specifically engineeredfor disassembly relocation andreassembly Minimally destructive techniquesare used preserving structural integrity Relocation feasibility studiesare availableas separate consultancy service。

Q What trainingis providedfor our operationsand maintenance teams？
A Comprehensive trainingis included covering normal operation shutdown procedures routine maintenance tasks troubleshooting We provide both classroom sessionsat our facility handson training during commissioningat yours alongwith detailed operational manuals