1. PAINPOINT DRIVE NOLEING

Are your crushing and screening operations constrained by persistent bottlenecks, unpredictable maintenance costs, and suboptimal material yield? Inefficient plant design directly impacts your bottom line through excessive energy consumption, unscheduled downtime for liner changes and repairs, эцсийн бүтээгдэхүүний зэрэглэл тогтворгүй байх нь ачааллаас татгалзахад хүргэдэг. Эдгээр нийтлэг сорилтуудыг авч үзье:
Үйл ажиллагааны өндөр зардал: Are you facing escalating expenses from premature wear part failure, inefficient power use per ton processed, and high labor requirements for manual adjustments?
Үйлдвэрлэлийн гацаа: Is your current flow limited by mismatched equipment capacities, causing one stage to consistently idle or choke another, үйлдвэрийн нийт нэвтрүүлэх чадварыг бууруулах?
Бүтээгдэхүүний чанарын зөрүү: Are you struggling to consistently meet tight aggregate or mineral specifications due to inadequate screening efficiency or poor crushing chamber geometry, resulting in costly recrushing or lost premiums?
Adaptability Gaps: Does your fixed plant design lack the flexibility to efficiently process varying feed materials or adapt to new project requirements without major capital expenditure?

Addressing these issues requires a foundational solution: a professionally engineered crushing and screening equipment design service.

2. БҮТЭЭГДЭХҮҮНИЙ ТОЙМ

Бидний Crushing and Screening Plant Design Service provides a complete, engineered blueprint for your aggregate, олборлолт, or recycling operation. We move beyond simple equipment selection to deliver an integrated system optimized for your specific ore or material, Нягтлууд, and production goals.

Үйл ажиллагааны ажлын урсгал:
1. Site & Data Analysis: Our engineers conduct a thorough review of your feed material characteristics (ангис хуудас, ХӨДӨЛМӨР, чийг), Сайтын хязгаарлалт, болон үйлдвэрлэлийн зорилтууд.
2. Flow Sheet Development: We create a detailed process flow diagram (PFD), selecting and sizing primary crushers (jaw/gyratory), хоёрдогч/гуравдагч бутлуур (cone/impact), дэлгэц (чичиргээ/бөмбөр), and conveying systems to work in harmony.
3. Зохион байгуулалт & Integration Engineering: We produce 2D and 3D plant layouts that optimize material flow, ensure safe access for maintenance, minimize transfer points and dust generation.
4. Тоног төхөөрөмжийн тодорхойлолт & Sourcing Support: We provide detailed technical specifications for all major machinery and auxiliary systems (тоосны дарангуйлал, Эр зөвшөөрөх), assisting in vendor selection.
5. Хэрэгжүүлэх дэмжлэг: Our service includes documentation review and operational guidance during commissioning to ensure the built plant performs as designed.

Хэрэглээний хамрах хүрээ: Greenfield plant development, brownfield plant expansion or modernization, mobile/semimobile plant configuration for mining and quarrying.
Хувьсгал: Final performance is contingent on correct equipment manufacturing according to specs; detailed geotechnical surveys are required separately for foundation design.

3. ҮНДСЭН ОНЦЛОГ

Optimized Flow Sheet Design | Техникийн үндэслэл: Mass balance simulation & particle size distribution analysis | Үйл ажиллагааны ашиг тус: Eliminates interstage bottlenecks, ensures each component operates at its peak efficiency band | ROI нөлөө: Increases overall system throughput by 1525%, maximizing capital asset utilization

Lifecycle Cost Modeling | Техникийн үндэслэл: Wear rate calculations based on material abrasion indices & crusher chamber kinematics | Үйл ажиллагааны ашиг тус: Informs selection of crusher liners and screen media for longest service life at optimal cost point | ROI нөлөө: Reduces costperton for wear parts by an estimated 1030% over the equipment lifecycle

MaintenanceCentric Layout | Техникийн үндэслэл: Ergonomics study & spatial analysis for safe tool access | Үйл ажиллагааны ашиг тус: Provides clear access zones for jaw die replacement, cone crusher mantle changes, and screen deck maintenance | ROI нөлөө: Төлөвлөсөн засвар үйлчилгээний зогсолтыг хүртэл бууруулна 40%, enhancing asset availability

Чандруу & Noise Mitigation Planning | Техникийн үндэслэл: Airborne particulate modeling & acoustic analysis at transfer points | Үйл ажиллагааны ашиг тус: Integrates effective containment strategies at source (skirting systems, хамга) from the design phase | ROI нөлөө: Reduces environmental compliance risks and associated retrofit costs

Бүтцийн & Foundation Load Analysis | Техникийн үндэслэл: Төгсгөлийн элементүүдийн шинжилгээ (FEA) of support structures under dynamic loads | Үйл ажиллагааны ашиг тус: Ensures structural integrity under maximum load conditions with defined safety factors | ROI нөлөө: Prevents costly structural failures and foundation cracks that lead to extended unplanned shutdowns

Energy Efficiency Auditing | Техникийн үндэслэл: Power draw analysis per crushing stage vs. theoretical rock breakage energy (Bond's Law) | Үйл ажиллагааны ашиг тус: Identifies opportunities to rightsize motors and utilize variable frequency drives (Vfds) конвейер дээр | ROI нөлөө: Achieves measurable reductions in kWh per ton processed

Ихэмжиг & Flexibility Planning | Техникийн үндэслэл: Modular design principles with provision for future tiein points | Үйл ажиллагааны ашиг тус: Allows for phased capacity increases or circuit modifications with minimal disruption to existing operations | ROI нөлөө: Protects initial investment by deferring major capital outlay for future expansion

4. ӨРСӨЛДӨХ ДАВУУ ТАЛУУД

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандарт хандлага | Манай бутлах & Screening Design Solution | Давуу тал (% Сайжруулалт) |
| : | : | : | : |
| Системийн хүртээмж| Sequential equipment sizing; reactive maintenance access| Balanced circuit design with proactive maintenance zones| +2035% less downtime |
| Нэг тонн элэгдлийн зардал| Selection based on initial capital cost| Liner selection based on modeled wear life & cost analysis| +1030% lower lifecycle cost |
| Эрчим хүчний зардал| Motors sized for peak possible load only| Powermatched components with optimized idling control| +815% кВт.ц/тн бага байна |
| Layout Footprint Efficiency| Equipment placed based on sequential delivery| 3D spatial optimization for flow & засвар үйлчилгээний хүртээмж| +1525% more compact area use |
| DesigntoCommissioning Timeline| Linear process with potential redesign loops| Integrated digital prototyping clash detection| +30% faster project completion |

5. ТЕХНИКИЙН ҮЗҮҮЛЭЛТҮҮД

Our design service deliverables are tailored to client parameters. The following outlines the specification framework we engineer within:

Хүчин чадлын үнэлгээ: Designs developed for throughput ranges from 50 Цагдаа (small aggregate/recycling) нь 2,500+ Цагдаа (largescale mining).
Эрчим хүчний шаардлага: Complete electrical load list provided; designs accommodate voltages from 400V – 10kV based on plant size.
Материалын үзүүлэлтүүд: Equipment specs include requirements for abrasionresistant steel grades (жишээ нь e., AR400/500) at highwear points; recommendations for screen media composition (rubber/polyurethane/wire).
Физик хэмжээсүүд: Layout drawings provided in industrystandard formats (AutoCAD DWG, PDF). Overall footprint is minimized while adhering to safety clearances per MSHA/OSHA guidelines.
Байгаль орчны үйл ажиллагааны хүрээ: Designs account for ambient operating temperatures from 20°C to +50°C; include provisions for dust suppression water supply (~1.52 liters per ton of material processed).

6. ХЭРЭГЛЭЭНИЙ СУРТАЛЧИЛГАА

Боржингийн карьерыг өргөтгөх төсөл

Challenge A quarry operator needed to increase production by 40% but was constrained by space limitations and an outdated secondary/tertiary circuit causing inconsistent chip production.
Solution Our design service reconfigured the entire flow postprimary crushing using a multistage cone crusher layout with highfrequency screens in closed circuit.
Хүрсэн үр дүн a 42% throughput increase within the existing property boundary while improving chip product yield by 18%, meeting premium specification consistently.

Төмрийн хүдэр боловсруулах үйлдвэрийн шинэчлэл

Challenge An aging plant suffered from low availability due to frequent liner changes in secondary crushers and excessive spillage/dust at transfer points.
Solution We redesigned the secondary crushing chamber selections based on updated ore competency data and engineered new transfer chutes with impact beds and sealing systems.
Results Extended secondary crusher liner life by over 35%, reduced transfer point dust emissions by over 70%, increasing overall plant availability by an average of two days per month.

Со&D Recycling Facility Setup

Challenge A new recycling venture needed a flexible plant capable of handling highly variable construction demolition waste with high contamination rates without constant clogging.
Solution The service designed a robust prescreening circuit with a heavyduty trommel before crushing stages incorporated strategic magnetic separation points within conveyors.
Results The system achieved over 95% uptime processing highly variable feed reduced manual sorting labor costs by an estimated three positions per shift.

7. АРИЛЖААНЫ ХЭРЭГЛЭЭ

Our Crushing Screening Equipment Design Service is offered in tiered packages:

Инженерийн үндсэн багц: Includes core flow sheet development preliminary equipment sizing singleline layout drawing Ideal feasibility studies budget estimates Pricing typically projectscoped starting from a fixed fee basis

Detailed Design Package: Comprehensive offering including all Basic elements plus detailed P&IDs general arrangement drawings in D foundation loading data technical specifications procurement support Most common selection priced as percentage of total estimated project CAPEX

Premium Turnkey Support Package All Detailed Design elements plus construction drawing review commissioning supervision protocols operator training manuals Priced as fixed fee plus time materials basis during implementation phase

Optional Features Addon modules include discrete element modeling DEM simulation advanced dust collection system design full automation PLC control philosophy documentation

Service Packages Annual review contracts are available postdesign assess actual vs modeled performance recommend adjustments

Financing Options For projects where we also facilitate equipment procurement we can arrange financing solutions through partner institutions including leasetoown structures operational leases traditional loans subject to credit approval

Түгээмэл асуултуудын хэсэг

What specific input data do you require from us begin the design process?
We require representative samples of your feed material comprehensive test results Bond Work Index abrasion index particle size distribution moisture content along with survey data target production rates product gradation requirements any specific site constraints topography geotechnical reports available

How does this service integrate with our chosen equipment brands?
We provide performancebased technical specifications that are brandneutral This allows you solicit bids from multiple OEMs ensures competition Alternatively we can optimize designs around preferred vendor technology if specified early ensuring all interfaces are correctly engineered

Can you redesign only section our existing plant address bottleneck?
Yes Our service is modular often engaged specifically bottleneck analysis redesign individual circuits such as closedloop secondary tertiary screening section improve overall balance without requiring complete greenfield redesign

What measurable improvements should expect terms operational efficiency?
Based historical field data clients typically report quantifiable gains including reduction energy consumption per ton processed decrease unscheduled downtime related flow issues improved consistency final product gradation reducing waste reprocessing These typically translate direct reduction operating cost per ton metric you can track

What are typical timelines deliver completed design package?
For Detailed Design Package standard timeline ranges weeks depending complexity scope Basic Engineering packages can be delivered weeks Premium support extends through construction commissioning phase Key factor is speed client providing accurate complete input data commencement