1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks that cap profitability? Untuk pengurus loji dan kontraktor kejuruteraan, loji penghancur batu 250300tph mewakili peringkat pengeluaran kritikal di mana ketidakcekapan diterjemahkan kepada kesan kewangan yang ketara. Cabaran biasa termasuk:
Inconsistent Throughput: Unplanned downtime from feeder to crusher mismatches or conveyor bottlenecks, losing hundreds of tons per shift.
Kos Operasi yang Tinggi: Spiking wear part consumption in secondary/tertiary stages and excessive energy use per ton of finished aggregate.
Varian Kualiti Produk: Ketidakupayaan untuk memenuhi pelbagai produk spesifikasi secara konsisten (mis., 3/4" agregat, 1/2" cip, pasir yang dihasilkan) from variable feed material.
Excessive Footprint & Masa persediaan: Modular plants that require extensive civil works and complex interconnection, delaying commissioning and ROI.

Persoalan utama ialah: how do you achieve reliable 250300tph output with lower costperton, penyelenggaraan yang dipermudahkan, and the flexibility to adapt to changing project demands?

2. GAMBARAN KESELURUHAN PRODUK

Loji penghancur batu pegun 250300tph ini adalah lengkap, engineered solution designed for continuous, highvolume production of aggregates for road base, konkrit, and asphalt applications. Ia dikonfigurasikan untuk utama, sekunder, and tertiary crushing stages to produce precisely graded end products.

Aliran Kerja Operasi:
1. Pengurangan utama: Large quarryrun rock (up to 750mm) is fed into a primary jaw crusher for initial size reduction.
2. Menghancurkan sekunder & Pemeriksaan: Keluaran dihantar ke penghancur kon sekunder. A primary screen separates sized material, routing oversize back for further crushing.
3. Pembentukan Tertiari & Saiz Akhir: Material requiring additional shaping is processed through a tertiary cone or impact crusher. Final screening decks separate the output into 35 specified product stockpiles.

Skop Permohonan: Sesuai untuk kuari agregat khusus, large infrastructure project support bases, and highdemand commercial concrete operations.
Batasan: This plant configuration requires stable, suapan batu keras (granit, basalt, batu kapur). For very abrasive or highsilica content materials, specific liner metallurgy is recommended. It is not a portable solution and requires planned foundation work.

3. CIRI TERAS

Perhimpunan Modular | Asas Teknikal: Skidmounted major component assemblies | Faedah Operasi: Mengurangkan masa pemasangan di tapak sehingga 40% berbanding binaan componentbycomponent | Kesan ROI: Faster commissioning allows revenue generation to begin weeks earlier.

Reka Bentuk Ruang Penghancur Pintar | Asas Teknikal: Optimized cavity geometry and kinematics | Faedah Operasi: Increases yield of inspec product on first pass by an estimated 1520%, mengurangkan beban peredaran semula | Kesan ROI: Directly lowers energy consumption and wear on crushers per ton of final product.

Sistem Automasi PLC Berpusat | Asas Teknikal: Pengawal Logik Boleh Aturcara dengan skrin sentuh HMI | Faedah Operasi: Membolehkan kawalan tunggal pengendali bagi keseluruhan aliran, monitors motor loads, and provides fault diagnostics | Kesan ROI: Reduces labor requirements for routine operation and minimizes downtime through predictive alerts.

Penyumpan Grizzly Bergetar Tugas Berat | Asas Teknikal: Robust sectionalized grizzly bars & high Gforce vibration | Faedah Operasi: Effectively scalps fines ahead of the primary crusher and ensures consistent, makanan terkawal | Kesan ROI: Protects primary crusher from unnecessary wear caused by fines packing and prevents chokefeeding.

Unified Walkway & Maintenance Access | Asas Teknikal: Integrated platform design around all major service points | Faedah Operasi: Menyediakan selamat, akses mudah untuk pemeriksaan harian, Perubahan pelapik, and belt maintenance | Kesan ROI: Cuts scheduled maintenance time significantly improves technician safety compliance.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri untuk Loji 250300tph | Penyelesaian Tumbuhan Ini | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Konsistensi Tan (Monthly Availability) | 9294% ketersediaan operasi | >96% ketersediaan operasi (sasaran reka bentuk) | +24% ketersediaan |
| Penggunaan tenaga (kWj/tan) Berbeza mengikut jenis batu. Baseline set at industry average. Industry Average Baseline = X kWh/ton Estimated X 0.88 kWh/ton Estimated reduction of ~12% |
| Kos Pakai ($/ton) Secondary Stage Secondary Crusher Wear Cost Secondary Crusher Wear Cost Focus on chamber design & material flow reduces abrasive wear Estimated reduction of ~1015% |
| Masa Pentauliahan Di Tapak (minggu) Componentbycomponent build Modular skid assembly Field data shows reduction of ~3040% |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti Direka: 250 300 Ton metrik sejam (275 330 AS tph), bergantung kepada kekerasan bahan suapan dan taburan saiz.
Penghancur utama: Model Jaw Crusher [mis., JC5460], Feed Opening suitable for up to 750mm rock.
Penghancur sekunder: Cone Crusher Model [mis., MC350], with hydraulic adjustment and clearing.
Penghancur Tertiari: Cone or Vertical Shaft Impact (Semua orang) Model Penghancur [mis., TC260 or VSI2800] for shaping/fine production.
Unit Saringan: Multideck vibrating screens (biasanya 23 unit), sizes tailored to final product specifications.
Keperluan kuasa: Jumlah kuasa terpasang lebih kurang 800 1000 kw. Requires dedicated highvoltage connection as per local grid.
Spesifikasi Bahan Utama: Struktur rangka utama; Heavyduty steel plate. Conveyor idlers; CEMA C/D rated bearings. Screen meshes; Hightensile wire or polyurethane panels.
Anggaran Jejak (L x W): ~85m x 45m (280' x 150'), tertakluk kepada konfigurasi susun atur akhir.
Julat Operasi Persekitaran: Designed for 20°C to +45°C ambient temperature with appropriate lubrication systems.

6. SENARIO APLIKASI

[Regional Granite Quarry] Cabaran: An established quarry needed to upgrade from a 200tph system to meet new highway contract demands without expanding its operational footprint or significantly increasing crew size.

[Large Infrastructure Project Dam Construction] Cabaran: A remote dam construction site required consistent production of multiple aggregate specifications (from riprap to fine aggregates) with limited technical personnel available onsite.

[Commercial Asphalt Producer] Cabaran: A producer aimed to increase yield of highvalue manufactured sand from their limestone feed while maintaining strict gradation control for asphalt mixes.

[Penyelesaian]: Implementation of this modulardesigned plant allowed the existing footprint to be utilized efficiently. The centralized PLC system enabled management of the higher throughput with the same operator team.

[Penyelesaian]: A ruggedized version was supplied with preassembled modules. The design prioritized reliability over ultimate flexibility.

[Penyelesaian]: Integration included a tertiary stage VSI crusher. The automation system was programmed with specific recipes for different sand products.

[Keputusan]: Mencapai output berterusan sebanyak 280tph. Plant availability increased from under 95%, meeting supply obligations on schedule without added labor costs.

[Keputusan]: Plant commissioned in months typical timeline). Achieved reliable >260tph output in harsh conditions with minimal specialist intervention required.

[Keputusan]: Increased saleable sand yield by >22%. Konsistensi produk bertambah baik secara mendadak. Allowed entry into new markets requiring precise filler material.

7. PERTIMBANGAN KOMERSIL

Our solutions are offered in clear pricing tiers based on core configuration:

Tier A – Base Plant Configuration includes primary jaw crusher secondary cone crushers primary screen core conveyors central control cabin
Tier B – Enhanced Configuration adds tertiary crushing stage additional final screening decks dust suppression system
Tier C – Turnkey Premium Configuration includes all above plus full electrical switchgear package advanced automation with production reporting preassembly services

Optional features include automated lubrication systems metal detection tramp iron relief systems sound enclosures

Service packages are available separately ranging from basic commissioning supervision through comprehensive multiyear maintenance agreements including parts kits

Financing options can be discussed including equipment leasing structures tailored for capital expenditure cycles typical in the aggregates industry

8.Soalan Lazim

Q1 Is this plant compatible with our existing primary feeding system or stacker conveyor?
A1 Yes provided your existing feeder or stacker can handle the required steadystate tonnage up to Our engineering team can review interface points like hopper dimensions discharge heights transfer chute designs

Q2 What is the expected operational impact during liner changes on the secondary cone crushers?
A2 With standard tooling field data indicates a trained twoperson crew can complete mantle concave replacement in Downtime can be further reduced with optional hydraulic assist kits

Q3 How does this plant manage variations in feed material hardness which we commonly experience?
A3 The PLC system monitors motor loads adjusting feeder rates accordingly Secondary tertiary crushers feature hydraulic adjustment allowing closedside setting changes under load within limits adapting quickly without stopping production

Q4 Are spare parts packages included in the initial purchase price?
A4 No spare parts are quoted separately We recommend an initial wear parts kit based on projected This ensures critical components are on hand minimizing potential downtime due to logistics delays

S5 Apakah tahap latihan pengendali yang disediakan?
A5 Comprehensive training is included covering normal operation startup shutdown sequences basic troubleshooting safety procedures Training occurs during commissioning both classroom style handson at controls Typically spans

Q6 Can this plant be reconfigured later if our product focus shifts e.g more emphasis on manufactured sand?
A6 The modular design allows reconfiguration Adding a VSI crusher as an additional tertiary stage or modifying screen decks are common future modifications Civil foundation planning initially considers such potential expansions

Q7 What are standard payment terms delivery lead times?
A7 Standard commercial terms involve progress payments tied milestones like order confirmation completion factory testing shipment Lead times typically range order confirmation depending current manufacturing schedule complexity chosen options