1. PAINPOINT DRIVE NOLEING

Are your iron ore processing margins being squeezed by inconsistent feed, хэт их сул зогсолт, and rising operational costs? Үйлдвэрийн менежерүүд болон инженерийн гүйцэтгэгчид эцсийн үр дүнд шууд нөлөөлдөг байнгын сорилтуудтай тулгардаг. Та мэдэрч байна уу:
Төлөвлөөгүй зогсолт: Байнга, unpredictable breakdowns in primary crushing due to tramp steel or uncrushable material, бүхэл бүтэн боловсруулалтын шугамыг хэдэн цагаар зогсооно.
Дамжуулалтын саад бэрхшээл: Inefficient crushing stages causing backlogs, limiting overall plant capacity and failing to meet offtake agreements during peak demand.
Засвар үйлчилгээний өндөр зардал: Constant wear part replacement in abrasive iron ore applications, coupled with laborintensive servicing routines that drain maintenance budgets.
Бүтээгдэхүүний чанарын өөрчлөлт: Inconsistent final product sizing (lump/fines ratio) leading to premium price penalties and customer dissatisfaction.
Эрчим хүчний үр ашиггүй байдал: Crushing systems operating at nonoptimal levels, consuming excessive power per tonne of ore processed.

What if your primary crushing stage could become a predictable, highavailability asset instead of a recurring cost center?

2. БҮТЭЭГДЭХҮҮНИЙ ТОЙМ

The Bespoke Iron Ore Crushing Plant is a engineered primary and secondary crushing system specifically configured for the highabrasion, hightonnage demands of magnetite or hematite processing. Unlike standard modular plants, each system is designed from the ground up based on your ore characteristics (Abrasion Index, UCS), шаардлагатай хүчин чадалтай, and site logistics.

Үйл ажиллагааны ажлын урсгал:
1. Анхдагч демпинг & Урьдчилсан үзлэг: RunofMine (Омын) ore is received at a rugged dump hopper with a grizzly feeder to scalp out oversize material and direct subgrizzly fines to a bypass conveyor.
2. Анхдагч бутлах: A heavyduty jaw crusher or gyratory crusher reduces the ROM ore to a manageable size for downstream conveying.
3. Хоёрдогч бутлах & Дэлгэц авах: Material is conveyed to a secondary cone crusher circuit in closed configuration with sizing screens to ensure precise product control before proceeding to beneficiation.

Хэрэглээний хамрах хүрээ: Ideal for greenfield sites or major expansion projects requiring 1,500 нь 10,000+ тонн/цаг хүчин чадалтай. Best suited for operations with consistent longterm mine plans.

Хувьсгал: Not recommended for smallscale or exploratory operations with rapidly changing ore bodies. Site requires adequate preparation for foundation and crane access.

3. ҮНДСЭН ОНЦЛОГ

Хүнд даацын хормогч тэжээгч | Техникийн үндэслэл: Overlapping manganese steel flights driven by rugged tractortype chains | Үйл ажиллагааны ашиг тус: Handles direct dump from 200ton haul trucks without damage, provides even feed regulation to crusher | ROI нөлөө: Eliminates feeder damage downtime; improves crusher cavity fill for up to 15% Өндөр дамжуулалтын үр ашиг.

Tramp Metal & Cavity Clearance System | Техникийн үндэслэл: Automated hydraulic release and clearing cylinder on primary crusher | Үйл ажиллагааны ашиг тус: Clears blockages or uncrushable material in minutes without manual intervention | ROI нөлөө: Reduces downtime events from hours to minutes, protecting crusher from catastrophic damage.

Liner Life Optimization | Техникийн үндэслэл: CADdesigned crushing chamber profiles and alloyed manganese steel liners specific to your ore's abrasiveness | Үйл ажиллагааны ашиг тус: Achieves predictable wear life cycles, allowing for planned maintenance shutdowns | ROI нөлөө: Доторлогооны ашиглалтын хугацааг уртасгана 2035% over generic liners; reduces annual consumable cost per tonne.

Төвлөрсөн тослох & Нөхцөл байдлын хяналт | Техникийн үндэслэл: Automated lubrication system with flow sensors and vibration monitors on critical bearings | Үйл ажиллагааны ашиг тус: Холхивчийн эрүүл мэндийг оновчтой болгодог, болзошгүй бүтэлгүйтлийн талаар урьдчилан сэрэмжлүүлдэг | ROI нөлөө: Prevents major bearing failures; reduces manual greasing labor by estimated 80%.

Модульчлагдсан конвейерийн дизайн | Техникийн үндэслэл: Bolttogether heavyduty conveyor sections with impact cradles at loading zones | Үйл ажиллагааны ашиг тус: Enables faster installation and future reconfiguration if plant flow needs change | ROI нөлөө: Суулгах хугацааг хүртэл бууруулна 30%, reducing timetoproduction.

Тоосжилтыг дарах нэгдэл | Техникийн үндэслэл: Nozzle system integrated at transfer points, tied into crusher actuation | Үйл ажиллагааны ашиг тус: Significantly reduces airborne particulate from initial crushing stages | ROI нөлөө: Зохицуулалтын шаардлагыг хангадаг, improves site working conditions and reduces cleanup costs.

4. ӨРСӨЛДӨХ ДАВУУ ТАЛУУД

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандарт (Modular Plant) | Bespoke Iron Ore Crushing Plant Solution | Давуу тал (% Сайжруулалт) |
| : | : | : | : |
| Үйлдвэрийн хүртээмж | 8590% (төлөвлөсөн & төлөвлөөгүй) | 9496% зорилтот хүртээмж | +510% илүү бүтээмжтэй ажиллах хугацаа |
| Tonne/Hour Efficiency| Rated capacity often at ideal conditions| Capacity guaranteed based on your specific ore AI & дур хэмжээ| +1015% тогтвортой дамжуулах чадвар |
| Эрчим хүчний хэрэглээ| Fixed speed drives across motors| HVSI crushers & хувьсах давтамжийн хөтчүүд (Vfds) тэжээгч/конвейер дээр| Шалтгаална, хамаарна 12% кВт.ц/тн бага байна |
| Wear Cost per Tonne| Generic liner designs standard| Orespecific chamber design & liner metallurgy| 2035% буурсныг харуулсан |
| Суурилуулалтын хугацаа| Sequential assembly on site| Large preassembled skids tested before shipment| 2530% илүү хурдан ашиглалтад оруулах |

5. ТЕХНИКИЙН ҮЗҮҮЛЭЛТҮҮД

Хүчин чадлын хүрээ: -аас тохируулах боломжтой 1,500 TPH хэтэрсэн 10,000 TPH of crushed iron ore.
Анхдагч бутлуурын сонголтууд: Эрүүлийн тусламж (1,600мм x 2000мм) эсвэл Анхан шатны эргэлтийн бутлуур (60”+). Selection based on feed size and capacity requirement.
Хоёрдогч бутлуурын сонголтууд: Highcapacity cone crushers with hydraulic adjustment and clearing.
Эрчим хүчний шаардлага: Total installed power typically ranges from 1.5MW to 6MW+ depending on configuration. Designed for connection to highvoltage mine grid supply (6.6кВ/11кВ).
Материалын үзүүлэлтүүд: Critical wear components utilize premium alloys (жишээ нь e., TeroTec® manganese steel). Structural steel is Grade S355JR for durability.
Физик хэмжээсүүд: Plant footprint is sitespecific but designed for optimal accessibility around crushers and conveyors for maintenance.
Байгаль орчны үйл ажиллагааны хүрээ: 25 ° C-аас + 50 ° C хүртэлх орчны температурт зориулагдсан. Dust encapsulation and insulation/heating packages available for extreme climates.

6. ХЭРЭГЛЭЭНИЙ СУРТАЛЧИЛГАА

Greenfield Magnetite Project in Pilbara Region

Сорилт: A new mine required a 4,500 TPH primary crushing plant capable of handling highly abrasive ore with minimal water usage due to arid conditions.
Хариу: Implementation of a bespoke plant featuring a gyratory primary crusher, dry screening presorting, and fully enclosed conveyors with baghouse filtration.
Үр дүн: Achieved nameplate capacity within one month of commissioning. Dust emissions maintained below stringent regulatory limits despite dry processing. Wear part life met projected targets within 5%.

Existing Hematite Operation Expansion

Сорилт: An existing operation needed to debottleneck its process line; the original primary crusher was causing throughput limitations and excessive maintenance shutdowns.
Хариу: A bespoke secondary crushing circuit was designed downstream of the existing primary stage using highperformance cone crushers in closed circuit with multideck screens.
Үр дүн: Overall plant throughput increased by 22%. Final product sizing consistency improved significantly (+40%), securing premium lump ore pricing from buyers.

7. АРИЛЖААНЫ ХЭРЭГЛЭЭ

Our bespoke plants are capital investments engineered for longterm operational payback.

Үнийн шатлал: Quotations are projectspecific based on detailed client specifications (Монголбанк). Budgetary estimates are provided after initial scoping.
Стандарт тохиргоо: Үндсэн бутлах нэгжүүд багтана,surge bins,and basic PLC control.Price range indicative only:$8M $15M USD
Нарийвчилсан тохиргоо: Автоматжуулалтын системийг багтаасан болно,predictive condition monitoring,and advanced dust control.$12M $25M+ USD

Нэмэлт шинж чанарууд: Онгоцны жингийн систем,зөөврийн дээж авах станцууд,crusher cavity vision systems,total turnkey erection services.

Үйлчилгээний багцууд:

Платинум дэмжлэг: Includes remote monitoring,a dedicated service engineer,two scheduled maintenance visits/year,and guaranteed parts delivery within specified timeframe.This package typically adds ~35% CAPEX annually but can reduce unplanned downtime by up to an additional ~50%.

Алтан дэмжлэг: Scheduled maintenance visits/year plus priority parts support.This package typically adds ~23% CAPEX annually

Хэсгийн гэрээ: Guaranteed wear parts supply at fixed pricepertonne over an agreed period.This stabilizes operating costs

Санхүүжилтийн сонголтууд: We work with major international equipment finance partners offering leasetoown structures operating leases over typical terms

Түгээмэл асуултууд

Q1 How do you ensure this bespoke plant will work with our existing downstream processing equipment?
A Our engineering process begins with a comprehensive audit of your entire flow sheet including existing conveyors bin capacities We model the entire system using dynamic simulation software ensuring the new crushing plant integrates without creating bottlenecks elsewhere

Q2 What is the typical implementation timeline from order placement?
A For most projects detailed engineering requires months followed by months manufacturing shipping Site preparation must occur concurrently Commissioning typically takes weeks This timeline varies significantly based on scale complexity permitting requirements

Q3 Can you guarantee performance metrics like throughput energy consumption?
A Yes performance guarantees are contractually stipulated following analysis testing They are based on agreedupon standards such as specific Bond Work Index values Abrasion Index values provided during design phase These guarantees form part of our commercial proposal

Q4 How does financing through your partners work?
A Our finance partners provide capital equipment leasing solutions that preserve your working capital Typical agreements involve monthly payments structured as an operating lease often providing potential tax benefits A formal credit application separate from equipment purchase agreement required

Q5 What training do you provide?
A We provide comprehensive training programs covering normal operation routine maintenance troubleshooting safety procedures Training conducted both during Factory Acceptance Testing FAT commissioning period Documentation includes detailed operation manuals parts lists schematic diagrams