1. PEMBUKAAN PAINPOINT DRIVEN

Are your bulk limestone mining operations constrained by escalating costs and unpredictable throughput? Key operational challenges directly impact your bottom line:
High Cost per Ton: Inefficient extraction and primary crushing cycles lead to excessive fuel, buruh, and bit wear costs.
Masa Henti Tidak Berjadual: Equipment not engineered for abrasive limestone applications suffers premature failure, causing costly production halts.
Saiz Suapan Tidak Konsisten: Poorly fragmented shot rock creates bridging and chokefeeding at the primary crusher, reducing overall plant capacity by 1530%.
Rising Overburden Removal Costs: Inefficient stripping methods add nonproductive time before profitable limestone seams are exposed.

Bagaimana anda meningkatkan hasil setiap letupan, ensure reliable feeding of your processing plant, and reduce your total cost of ownership on the hardestworking equipment in your flow? The solution begins at the primary extraction and reduction stage.

2. GAMBARAN KESELURUHAN PRODUK

This content details highcapacity, tugas berat bulk limestone mining equipment, specifically focused on primary mobile crushing and screening solutions (MC&S) for quarry face applications. These systems are engineered to replace or augment traditional truckandshovel cycles directly at the pit.

Aliran Kerja Operasi:
1. An excavator or wheel loader feeds shot limestone directly into the mobile primary crusher’s hopper at the quarry face.
2. The heavyduty jaw or impact crusher reduces the rock to a conveyable size, typically below 250mm.
3. An integrated or separate mobile conveyor system transports the crushed material directly to a longdistance overland conveyor or a fixed secondary plant, eliminating dozens of truck cycles.

Skop Permohonan: Sesuai untuk operasi kuari berskala besar dengan pengeluaran tahunan melebihi 1 juta tan. Suited for medium to hard limestone formations.

Batasan: Not designed for selective mining of thin, multiple seams without significant operational adjustment. Initial capital investment requires analysis against longterm haulage savings.

3. CIRI TERAS

Pemberian Muka Langsung | Asas Teknikal: Pitside material integration | Faedah Operasi: Eliminates primary haul trucks between the face and stationary crusher | Kesan ROI: Reduces fuel, tire, and labor costs associated with truck fleets by up to 40% on this cycle

Ruang Penghancur Tahan Lelasan | Asas Teknikal: Pelapik keluli martensit krom tinggi & Plat rahang | Faedah Operasi: Withstands continuous abrasion from silica content in limestone | Kesan ROI: Memanjangkan sebahagian hayat pakai dengan 3050%, menurunkan costperton untuk bahan habis pakai

Pelarasan Tetapan Hidraulik | Asas Teknikal: Centralized hydraulic cylinders for crusher gap control | Faedah Operasi: Allows operators to adjust product size in under 2 minutes for different product stockpiles | Kesan ROI: Increases plant flexibility and reduces downtime for size changes

Intelligent Feeder Control | Asas Teknikal: Frequencycontrolled vibratory or apron feeder with loadsensing | Faedah Operasi: Prevents crusher overload and optimizes feed rate for maximum throughput | Kesan ROI: Protects drive components from shock loads and ensures rated capacity is consistently achieved

Sistem Penindasan Habuk Bersepadu | Asas Teknikal: Nozzle arrays at transfer points with programmable logic controller (Plc) timing | Faedah Operasi: Actively manages particulate emissions during crushing and conveying | Kesan ROI: Maintains regulatory compliance and improves site working conditions without manual intervention

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Truck & Shovel to Fixed Crusher) | Bulk Limestone Mining Solution (Mobile Primary Crushing) | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Fuel Cost per Ton | tinggi (Multiple truck cycles) | rendah (Direct conveying from face) | Hingga 60% pengurangan |
| Primary Reduction Downtime| Scheduled maintenance + unplanned haul delays <5% availability loss| Centralized maintenance on single system <10% availability gain |
| Intensiti Buruh| Requires multiple equipment operators (latih tubi, shovels, trak)| Reduced fleet simplifies logistics ~25% reduction in operators |
| Feed Size Consistency| Variable due to shot rock segregation| Controlled via active feeder & grizzly ~40% reduction in crusher stalls |

5. SPESIFIKASI TEKNIKAL

Kapasiti/Penilaian: 400 1,500 tan sejam (Tph), depending on model and feed size distribution.
Keperluan kuasa: Primary unit typically requires a 300500 kVA external power pack or onboard dieselelectric generator set.
Spesifikasi Bahan: Crusher wear parts manufactured from TENSAMANG® or equivalent highgrade steel; chassis constructed from welded Q345B steel plate.
Dimensi Fizikal (Contoh): Operating length approx. 22m; width approx. 3.5m; height approx. 4.2m. Transport configurations available.
Julat Operasi Persekitaran: Direka untuk suhu ambien 20°C hingga +45°C. Dust protection to IP65 standards on electrical components.

6. SENARIO APLIKASI

Large Aggregate Producer Challenge Specific problem needed consistent feed to new secondary plant located 2km from expanding pit face Solution Implementation of a trackmounted primary jaw crusher with a mobile field conveyor Results Direct diesel fuel savings of approximately $180 per operating hour; achieved required plant feed rate of $800 TPH within three months of commissioning

Cement Plant Raw Material Extraction Challenge High maintenance costs on aging haul truck fleet moving limestone to primary crusher Solution Deployment of a semimobile gyratory crusher station at a strategic pit location Results Reduced operating cost per ton by $22%; haul truck fleet requirements cut from twelve units to four

7 PERTIMBANGAN KOMERSIL

Equipment pricing is tiered based on capacity robustness and level of automation:
Peringkat Standard: Highcapacity jaw plant with basic controls Capable of $800$1000 Tph
Peringkat Premium: Integrated gyratory crusher with advanced automation telemetry remote monitoring Capable of $1200+ Tph
Optional features include hybrid dieselelectric drive systems secondary screening modules onboard weighing systems extended warranties Service packages range from scheduled maintenance only to full comprehensive coverage including wear parts Financing options include capital lease operating lease leasetoown structures tailored to cash flow requirements

8 Soalan Lazim

What is the typical setup time required when relocating this equipment within the quarry?
With selfpropelled track systems relocation between prepared platforms can be completed in under one hour by a single operator

How does this solution integrate with our existing secondary crushing circuit?
The system is designed as a direct feed source Conveyor discharge heights are adjustable ensuring compatibility with most existing surge piles or secondary crusher feeders

What are the expected maintenance intervals compared to stationary primary plant?
Maintenance schedules are similar but centralized Field data shows that accessibility can reduce service time by up to % due to improved component layout

Can you provide a detailed analysis of projected ROI specific parameters?
Yes commercial proposals include a proprietary costmodeling tool that inputs your current fuel labor maintenance consumable costs generates sitespecific payback period projection

Latihan apa yang disediakan oleh kakitangan penyelenggaraan operasi kami?
We offer comprehensive onsite training programs covering safe operation routine maintenance troubleshooting procedures ensure minimal disruption during implementation