Industrial Stone Quarry Crushing Plant: Engineered for Maximum Tonnage and Minimum Downtime

1. PAINPOINT DRIVE NOLEING

Managing a stone quarry’s primary crushing stage is a critical bottleneck. Тогтворгүй тэжээл, зүлгүүрийн материал, and relentless operational demands directly impact your entire downstream process and profitability. Та эдгээр тоон сорилтуудтай тулгарч байна уу??

Төлөвлөөгүй сул зогсолтын зардал: A primary crusher failure can halt your entire operation, алдагдсан үйлдвэрлэл нь цагт хэдэн арван мянган зардал, сул хөдөлмөр, and missed shipments.
High Wear Part Expenditure: The extreme abrasion of granite, сагссах, or limestone leads to frequent and costly mantle, liner, and jaw replacements, cutting deeply into your margin per ton.
Тогтворгүй дамжуулалт & Бүтээгдэхүүний хэлбэр: Fluctuating feed size or poorly calibrated crushing chambers result in low yield of premium aggregate fractions and excessive recirculating load, straining secondary crushers.
Өсөн нэмэгдэж буй эрчим хүчний зардал: Inefficient crushing action with poor nip angles or excessive stroke consumes disproportionate power without maximizing throughput.
Аюулгүй байдал & Засвар үйлчилгээний нарийн төвөгтэй байдал: Урт, manual setting adjustments and unsafe maintenance procedures for worn parts increase risk and extend repair windows.

Үйлдвэрийн менежерүүдийн гол асуулт бол энэ юм: How can you achieve predictable, highvolume primary reduction while controlling operational costs and protecting your downstream circuit?

2. БҮТЭЭГДЭХҮҮНИЙ ТОЙМ

This product line encompasses stationary and semistationary primary crushing plants engineered for the initial reduction of blasted quarry rock. These plants are centered on highperformance jaw crushers or gyratory crushers designed for maximum intake size and durability.

Үйл ажиллагааны ажлын урсгал:
1. Тэжээлийн хэрэглээ: Dump trucks or wheel loaders deposit shot rock into a rugged vibrating grizzly feeder.
2. Урьдчилсан үзлэг & Тойрох: The grizzly scalps out natural fines and subfeedsize material, directing it to a bypass conveyor to optimize crusher efficiency.
3. Анхдагч бууралт: Oversize material is conveyed into the crusher where immense compressive force breaks it down to a manageable size.
4. Primary Discharge: Crushed material is discharged onto a main product conveyor for transport to secondary processing or stockpiling.

Хэрэглээний хамрах хүрээ & Хувьсгал:
Саад тохолтол тарз: Хатуу хаданд тохиромжтой (боржин чулуу, урхи чулуу, сагссах) and abrasive applications in hightonnage (>500 цагдаа) quarrying operations. Configurations support feed sizes up to 60 инчвэйм.
Хувьсгал: Not designed for very soft or lowabrasion materials like chalk or clay where alternative crusher types may be more economical. Requires significant capital investment and foundational civil works.

3. ҮНДСЭН ОНЦЛОГ

Patented Cavity Design | Техникийн үндэслэл: Компьютерийн оновчтой кинематик & хазах өнцөг | Үйл ажиллагааны ашиг тус: Ensures continuous compression crushing with minimal slippage, reducing wear energy consumption | ROI нөлөө: Талбайн өгөгдөл хүртэл харагдана 12% lower cost per ton in abrasive stone applications.

Гидравлик тохиргооны тохируулга | Техникийн үндэслэл: Integrated hydraulic cylinders for CSS control | Үйл ажиллагааны ашиг тус: Allows operators to adjust product gradation in under 5 minutes without manual shims | ROI нөлөө: Reduces downtime for product changeovers by over 90%, increasing plant flexibility.

Хүнд даацын холхивчийн угсралт | Техникийн үндэслэл: Forged alloy steel main shaft with oversized spherical roller bearings | Үйл ажиллагааны ашиг тус: Supports extreme radial and axial loads from irregular feed | ROI нөлөө: Холхивчийн ашиглалтын хугацааг дунджаар 30%, preventing catastrophic drivetrain failures.

Modular Liner Retention System | Техникийн үндэслэл: Mechanically locked liner wedges | Үйл ажиллагааны ашиг тус: Eliminates backing material use and enables faster, safer liner changes | ROI нөлөө: Доторлогоо солих хугацааг ойролцоогоор багасгадаг 40%, lowering labor costs and exposure risk.

Ухаалаг хөтөч & Protection System | Техникийн үндэслэл: VFD compatibility with torquesensing automation | Үйл ажиллагааны ашиг тус: Prevents stall conditions under tramp metal or overload scenarios | ROI нөлөө: Protects motor and crusher from damage; documented case studies show a reduction in related electrical failures by over 60%.

Reinforced Fabricated Main Frame | Техникийн үндэслэл: Төгсгөлийн элементүүдийн шинжилгээ (FEA) optimized steel plate construction with stressrelieving welds | Үйл ажиллагааны ашиг тус: Циклийн ачааллын дор урт хугацааны бүтцийн бүрэн бүтэн байдлыг хангана | ROI нөлөө: Mitigates frame fatigue cracking risk, safeguarding the longterm asset value of the plant.

4. ӨРСӨЛДӨХ ДАВУУ ТАЛУУД

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандарт жишиг | Our Quarry Crushing Plant Solution | Баримтжуулсан давуу тал |
| : | : | : | : |
| Бэлэн байдал (Үргэлж ажиллах) | 8892% in primary applications| >95% achievable availability| +47% жил бүр илүү бүтээмжтэй цаг |
| Манганы Wear Life (Зүлгүүрийн боржин чулуу) | Нэг багцад ~600,000 тонн| 850,000+ tons per set demonstrated| ~40% improvement in wear part utilization |
| Эрчим хүчний тусгай хэрэглээ (кВт.ц/тн)| Өргөн хүрээтэй; суурь = X кВт.ц/т| Consistently measures at X0.15 kWh/t| Шалтгаална, хамаарна 8% reduction in direct energy cost |
| Дамжуулагчийн тууштай байдал (Tonnage Std Dev.)| High variance with feed fluctuation| Low variance via optimized feed control| Шалтгаална, хамаарна 25% more consistent feed to secondary stage |

5. ТЕХНИКИЙН ҮЗҮҮЛЭЛТҮҮД

Хүчин чадлын хүрээ: -аас тохируулах боломжтой 500 нь 2,500 метр тонн/цаг (цагдаа), загвар болон тэжээлийн материалаас хамаарна.
Crusher Type Options: Хүнд хэлбэрийн хацарт бутлуур (900x1200mm to 1500x2000mm) or primary gyratory crushers (4265 inch feed opening).
Эрчим хүчний шаардлага: -аас үндсэн бутлуурын хөтөч 200 кВт хүртэл 600 kw. Total plant installed power typically ranges from 400 кВт 1.2 МВт.
Материалын үзүүлэлтүүд: Crusher liners manufactured from ASTM A128 manganese steel (Grade B3/B4). Main frame constructed from hightensile strength S355J2 steel plate.
Физик хэмжээсүүд (Typical Stationary Plant Footprint): Approximately 30m (Дээд) х 15м (Үнэр) х 12м (Х). Semistationary skidmounted options available with reduced footprint.
Байгаль орчны үйл ажиллагааны хүрээ: 20°С-аас +45°С хүртэлх орчны температурт зориулагдсан. Dust suppression system standard; full enclosure options available.

6. ХЭРЭГЛЭЭНИЙ СУРТАЛЧИЛГАА

Боржингийн карьерыг өргөтгөх төсөл

Сорилт: A southeastern US quarry needed to increase primary throughput by 50% without expanding their truck fleet or shot rock sizing. Their existing crusher created a bottleneck with excessive downtime for liner changes.
Хариу: Implementation of a semistationary primary jaw crushing plant with hydraulic setting adjustment and modular liners was integrated upstream of the existing circuit.
Үр дүн: Primary throughput increased by 58%. Liner change time reduced from 36 цаг хүртэл 20 цаг. The project paid back through increased sales volume in under 22 сар.

Basalt Aggregate Producer Facing High Wear Costs

Сорилт: A producer in volcanic rock was experiencing wear part costs that eroded 30% of their operating margin on base course material.
Хариу: Replacement of an older impactstyle primary unit with a configured gyratory crushing plant featuring our patented cavity design.
Үр дүн: Wear metal consumption decreased by 35% yearoveryear while maintaining the required product shape for asphalt chips. Нэг тонн эрчим хүчний хэрэглээ буурчээ 9%.

7. АРИЛЖААНЫ ХЭРЭГЛЭЭ

Our quarry crushing plants are offered under three primary tiers:

1. Стандарт үүргийн үйлдвэр ($2M $4M CAPEX): For consistent feed <1000mm, includes base crusher, тэжээгч, гадагшлуулах конвейер, явган хүний ​​зам, шат, and basic dust control.
2. Хүнд даацын үйлдвэр ($4M $7M CAPEX): For severeduty applications with maximum feed size >1200mm includes reinforced structures automated lubrication system advanced condition monitoring sensors
3

Optional features include automated rock breaker systems metal detection tramp iron relief advanced PLC control integration remote monitoring telematics packages

Service packages range from basic commissioning extended warranty plans comprehensive multiyear maintenance agreements including planned wear part changes

Financing options are available including equipment leasing longterm rentaltoown structures project financing support tailored capital expenditure planning

Түгээмэл асуултууд

What level of foundation work is required?
These plants require significant engineered concrete foundations designed specific model load data we provide Civil drawings anchor bolt templates are supplied as part purchase agreement

Can this plant integrate with our existing PLC SCADA system?
Yes most models offer standard communication protocols Modbus TCP/IP OPC UA Integration support provided during commissioning ensure data exchange production rates motor amperes CSS settings

Ердийн хүргэлтийн хугацаа гэж юу вэ?
For standard configurations lead time ranges from months following design approval Custom designs may require additional engineering fabrication time Detailed schedule provided upon project initiation

Операторын сургалт санал болгож байна уу?
Yes comprehensive onsite training included standard commissioning package covers safe operation routine maintenance procedures troubleshooting guides provided digital hard copy formats

How are wear parts priced supplied?
We offer transparent tiered pricing wear parts based projected annual consumption recommend maintaining strategic inventory critical items ensure uptime Local regional warehouse support available many territories

What happens if we encounter capacity issue after installation?
Our engineering team will perform audit identify constraint often related feed arrangement secondary screening recirculation load We provide actionable report potential upgrade paths optimize system performance

Гүйцэтгэлийн баталгааг санал болгож байна?
Yes we provide guaranteed minimum throughput capacity based agreed upon material characteristics feed size distribution written performance guarantee forms part commercial contract