1. PEMBUKAAN PAINPOINT DRIVEN

Managing a 250300tph stone crushing plant presents distinct operational and financial challenges. Adakah anda mengalami:
Masa Henti Tidak Berjadual: Unplanned stops due to feeder blockages, lebihan penghancur, or conveyor misalignment, menelan belanja ribuan sejam dalam pengeluaran yang hilang dan buruh terbiar.
Produk Akhir yang tidak konsisten: Fluctuations in aggregate size and shape, membawa kepada penolakan produk, reduced saleable yield, and compromised contract compliance.
Kos Operasi yang Tinggi: Spiking energy consumption from inefficient load distribution and excessive wear part replacement cycles that erode profit margins.
Bottlenecking & Inefficient Flow: Kapasiti tidak sepadan antara utama, sekunder, and tertiary stages causing one section to wait on another, preventing the plant from achieving its designed 300tph potential.
Kerumitan Penyelenggaraan: Timeconsuming inspections and component changes that require extended plant shutdowns.

Persoalan utama untuk pengurus loji ialah: bagaimana anda boleh mencapai boleh dipercayai, konsisten 250300 ton per hour output while controlling operational costs and maximizing equipment uptime? The answer lies in a holistically engineered crushing plant solution.

2. GAMBARAN KESELURUHAN PRODUK

Loji penghancur batu pegun 250300tph ialah sistem pemprosesan bahan lengkap yang direka untuk pengeluaran agregat volum tinggi untuk pembinaan, Pangkalan jalan, dan balast kereta api. It integrates multiple stages of size reduction and classification into a synchronized workflow.

Aliran Kerja Operasi:
1. Penghancuran utama: Bahan suapan besar (up to 750mm) dikurangkan oleh penghancur rahang yang teguh atau penghancur gyratory.
2. Sekunder & Penghancuran tertiari: Bahan dihantar kepada penghancur kon atau penghancur impak untuk pengurangan selanjutnya kepada saiz sederhana.
3. Pemeriksaan & Pengelasan: Skrin bergetar mengasingkan bahan hancur kepada pecahan saiz tertentu.
4. Pengendalian bahan: A network of belt conveyors transfers material between stages and to final stockpiles.
5. Kawalan & Pemantauan: A centralized control system manages startup sequences, load balancing, and operational parameters.

Skop Permohonan: Sesuai untuk operasi kuari berskala besar, major infrastructure projects requiring dedicated onsite aggregate production, and highcapacity commercial aggregate suppliers.

Batasan: This is a capitalintensive solution requiring significant site preparation, stable electrical supply (typically high voltage), and is designed for semipermanent or permanent installation. It is not suitable for highly mobile or smallscale operations.

3. CIRI TERAS

Sistem Pengurusan Beban Pintar | Asas Teknikal: PLCintegrated amp monitoring with variable frequency drives (VFDS) | Faedah Operasi: Prevents crusher overloads and feeder blockages by automatically adjusting feed rates | Kesan ROI: Mengurangkan masa henti yang tidak dirancang sehingga 30% and minimizes stressrelated component failures

Reka Bentuk Loji Modular | Asas Teknikal: Bolttogether sections with standardized interfaces | Faedah Operasi: Membolehkan pemasangan tapak yang lebih pantas (~25% less time) dan konfigurasi semula atau pengembangan masa hadapan | Kesan ROI: Lowers initial installation costs and protects longterm capital investment

Centralized Greasing & Pelinciran | Asas Teknikal: Automatik, programmable system delivering precise lubricant volumes to key bearing points | Faedah Operasi: Extends bearing life by ensuring consistent lubrication; reduces manual labor requirements | Kesan ROI: Cuts lubricationrelated bearing failures by an estimated 40% and associated maintenance manhours

Sistem Penghantar Tugas Berat | Asas Teknikal: Impact beds at loading points, abrasionresistant belts with proper tensioning | Faedah Operasi: Minimizes belt wear and spillage, ensuring consistent material flow between stages | Kesan ROI: Reduces belt replacement costs and cleanup labor, directly supporting sustained 300tph throughput

Penyepaduan Penindasan Debu Lanjutan | Asas Teknikal: Strategically placed nozzles with solenoid valves tied to crusher/screen operation | Faedah Operasi: Suppresses dust at source points only when needed, meningkatkan keterlihatan tapak dan pematuhan alam sekitar | Kesan ROI: Reduces water consumption versus constant spraying and avoids potential regulatory fines

Unified Control Cabin | Asas Teknikal: Sounddampened cabin with full visualization of process flow on SCADA monitors | Faedah Operasi: Provides operators with a safe, ergonomic environment to monitor the entire plant from a single point | Kesan ROI: Improves operational response time by 50% and enhances personnel safety

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri untuk Loji 250300tph | Our Engineered Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Keseluruhan Ketersediaan Loji (Bulanan) | 8892% (Lebih kurang. 3540 jam henti)| >95% (37% bertambah |
| Penggunaan Tenaga setiap Tan Diproses| Berbeza secara meluas; often suboptimal load sharing| Optimized via VFDs & efficient drive trains| Data lapangan menunjukkan 812% pengurangan |
| Pakai Bahagian Hayat dalam Penghancur Sekunder| Dependent on feed; inconsistent monitoring| Extended via load management & alloy options| Didokumenkan 1525% penambahbaikan |
| Pemasangan & Masa Pentauliahan| 810 weeks for full system integration| Streamlined modular design reduces this span| Kira -kira 25% penyebaran lebih cepat|
| Kecubisan Produk (Indeks Bentuk)| Can fluctuate with feed hardness/type| Maintained via crusher chamber optimization & settings control| More consistent output within spec |

5. SPESIFIKASI TEKNIKAL

Kapasiti Throughput Direka: 250 300 Ton metrik sejam (tph) daripada agregat batu yang dihancurkan.
Pilihan Penghancur Utama: Kursus rahang (900x1200mm) atau Gyratory Crusher (4265).
Peringkat Menengah/Tertiari: Two units of Cone Crushers (mis., HPC315 atau setara).
Peringkat Saringan: Skrin bergetar tugas berat berbilang dek (mis., 2 sets of 2400x6000mm).
Total Installed Power Requirement: Kira -kira 800 1000 kw; requires stable HV grid connection.
Spesifikasi Bahan Utama: Primary frame constructed from highstrength steel (Q345B); Liner plates from Mn18Cr2 or equivalent; Abrasionresistant conveyor belting (minimum ST1250).
Jejak Tumbuhan Biasa (L x W): ~120m x 85m (varies based on stockpile layout).
Julat Operasi Persekitaran: Direka untuk suhu ambien 20°C hingga +45°C; dust emission control to meet local standards below <20mg/m³.

6. SENARIO APLIKASI

Pembesaran Kuari Batu Kapur Besar | Cabaran: Existing plant capped at 200tph could not meet new contract demands for road base material; bottlenecks at secondary screening caused frequent slowdowns. Solution Implementation of a new modulardesigned crushing plant configured for consistent throughput across primary jaw crushing followed by twostage cone crushing with precise screening decks integrated into the existing flow where possible Results Achieved steadystate production of over tph of specificationcompliant product within two months of commissioning reducing reliance on subcontracting crushed material by

Major Highway Construction Corridor Challenge Required establishing multiple high volume temporary aggregate plants along the corridor with fast setup teardown times each needing reliable output Solution Deployment of semi stationary plants built on modular skid bases featuring unified control cabins pre wired connections Results Each site was operational within weeks achieving target production rates Project reporting indicated lower fuelpower costs per ton produced compared to mobile fleet alternatives meeting tight project timelines

7 PERTIMBANGAN KOMERSIL

Pricing tiers are structured around core configuration choices:

1 Standard Tier Includes primary jaw crusher secondary cone crushers basic screening conveyors central control panel Designed for consistent feed material Priced as a complete turnkey system
2 Enhanced Tier Adds tertiary crushing stage automated grease systems advanced dust suppression higher capacity stockpile conveyors Suited for producing more spec products or harder feed materials
3 Custom Tier Incorporates specific customer requirements such as specialized metal detection washing systems integration with existing equipment or unique layout constraints Priced upon engineering review

Optional Features High frequency fine screening decks remote monitoring diagnostics packages automated wear part measurement systems spare parts starter kits
Service Packages Comprehensive packages are available including scheduled preventive maintenance onsite technical support annual health inspections Extended warranty options can be negotiated
Financing Options Flexible commercial terms can be arranged including leasing structures milestone based project financing or traditional equipment loans through our partnered financial institutions

8 Soalan Lazim

What are the primary electrical requirements for this tph plant The system typically requires a high voltage connection kV range with total installed power draw between kW A detailed power distribution plan is part of our pre installation engineering assessment
Can this plant be configured to produce multiple aggregate specifications simultaneously Yes through strategic screen deck selection proper conveyor routing the standard design can produce up separate spec products concurrently such as base course chipsand manufactured sand
How does your solution manage variations in feed rock hardness The intelligent load management system adjusts feeder rates automatically protecting downstream crushers For extreme variations we recommend selecting specific liner profiles chamber options during the configuration phase
What is the expected timeline from order placement to full commissioning For standard tier configurations lead time is typically months followed by weeks onsite installationcommissioning subject to site readiness Custom configurations require additional engineering time
Are training services included for our operations team Yes comprehensive training covering daily operation routine maintenance safety procedures troubleshooting is provided onsite during commissioning Documentation includes detailed operating manuals parts lists schematics