1. PEMBUKAAN PAINPOINT DRIVEN

Adakah anda menguruskan operasi pengeluaran agregat berskala midtolarge dan menghadapi kesesakan berterusan yang menghakis keuntungan? Untuk pengurus loji dan kontraktor kejuruteraan, loji penghancur batu 250300tph adalah aset kritikal, namun cabaran operasi biasa memberi kesan langsung kepada keuntungan anda. Pertimbangkan isu-isu yang kerap ini:
Inconsistent Throughput & Downtime: Unplanned stoppages due to feeder blockages, crusher overloads, or conveyor misalignment can cost thousands per hour in lost production and idle labor.
Beroperasi Tinggi & Kos penyelenggaraan: Frequent wear part replacement, high energy consumption per ton of output, and the need for specialized maintenance crews steadily increase your cost per aggregate ton.
Bentuk produk yang lemah & Kawalan penggredan: Inconsistent output leads to excess fines or outofspec material, reducing the market value of your end product and causing rejections.
Susun Atur Loji Tegar & Had Kebolehskalaan: Fixed designs struggle to adapt to changing feed material hardness or required product mixes, forcing costly retrofits or operating below optimal capacity.

How do you achieve stable, highyield production while controlling costs and ensuring final product quality? The solution lies in a robustly engineered 250300tph stationary crushing plant designed for predictable performance.

2. GAMBARAN KESELURUHAN PRODUK

This solution is a complete stationary stone crushing and screening plant engineered for a nominal output of 250 ke 300 Ton metrik sejam (tph) daripada agregat siap. It is designed as a primarytotertiary processing system for mediumhard to hard stones like granite, basalt, dan batu kapur.

Aliran Kerja Operasi:
1. Penghancuran utama: Bahan suapan besar (≤750mm) is reduced by a heavyduty jaw crusher or gyratory crusher.
2. Sekunder & Penghancuran tertiari: The primary crushed material is further processed by cone crushers for size reduction and improved particle shape.
3. Pemeriksaan & Pengelasan: Vibrating screens separate material into precise size fractions, routing oversize back to crushers and directing onspec product to final stockpiles.

Skop Permohonan: Ideal for large quarry operations, major infrastructure project support (lebuh raya, Keretapi), and commercial aggregate supply yards requiring highvolume, consistent output.

Had Utama: Feed material hardness must be within specified limits (mis., hingga 300 Kekuatan mampatan MPa). Plant requires stable foundation preparation and gridbased power connection. Not designed for mobile or frequent relocation.

3. CIRI TERAS

Sistem Kawalan Suapan Pintar | Asas Teknikal: Pemacu Frekuensi Boleh Ubah (VFD) on primary feeder with level sensors | Faedah Operasi: Prevents crusher cavity overload and minimizes bridging, memastikan aliran bahan yang lancar | Kesan ROI: Mengurangkan masa henti yang tidak dirancang sehingga 15% and improves crusher liner life

Laminated Crushing Chamber Design | Asas Teknikal: Multilayer crushing cavity geometry in cone crushers | Faedah Operasi: Produces superior particle shape with lower flakiness index and controlled fines generation | Kesan ROI: Increases premium product yield by 812%, enhancing sales revenue

Centralized Greasing & Sistem hidraulik | Asas Teknikal: Singlepoint lubrication stations with automated timers and pressure monitoring | Faedah Operasi: Ensures critical bearing points are serviced consistently, reducing failure risk | Kesan ROI: Lowers bearingrelated breakdowns by an estimated 25% and extends service intervals

HighStrength Modular Conveyor Framework | Asas Teknikal: CADoptimized truss design using hightensile steel | Faedah Operasi: Memberikan kestabilan luar biasa di bawah beban, reducing vibration and misalignment issues | Kesan ROI: Decreases conveyor maintenance time by approximately 20% over the plant lifecycle

PLCBased Automated Process Logic | Asas Teknikal: Pengawal Logik Boleh Aturcara dengan antara muka mesin manusia (HMI) for sequence control and interlocking | Faedah Operasi: Allows singleoperator oversight of startup/shutdown sequences and provides fault diagnostics | Kesan ROI: Optimizes power use during operation cycles and reduces labor requirements for plant control

HeavyDuty Vibrating Screen with QuickChange Decks | Asas Teknikal: Rubber shear mounts and sidetensioned screen media attachment system | Faedah Operasi: Provides efficient sizing with reduced noise/vibration transmission; enables faster screen cloth replacement | Kesan ROI: Cuts screen maintenance downtime by up to 40% setiap acara pertukaran

Sistem Penindasan Habuk Bersepadu | Asas Teknikal: Nozzle arrays at transfer points connected to a highpressure pump system | Faedah Operasi: Effectively controls airborne particulate at primary dust generation sources | Kesan ROI: Memastikan pematuhan peraturan alam sekitar, avoiding potential fines and improving site working conditions

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (250300tph Loji) | This 250300tph Stone Crushing Plant Solution | Kelebihan (% penambahbaikan) |
|||||
| Overall Equipment Effectiveness (OEE) | ~76% | Target ≥84% | +10.5% |
| Penggunaan kuasa (kWj/tan diproses) | Berbeza secara meluas; baseline = X | Optimized system design reduces baseline |7% ke 12% |
| Crusher Wear Part Life (Pelapik Mangan)| Based on abrasive feed | Improved chamber design & alloy selection |15% Kos Setiap Tan |
| Masa Min Antara Kegagalan (MTBF) Key Conveyors ~1,200 hours ~1,650 hours +37.5% |
| Indeks Bentuk Produk (Flakiness) Biasanya >20% Mengekalkan <15% 25% Improvement in Cubicity |

5. SPESIFIKASI TEKNIKAL

Julat kapasiti nominal: 250 – 300 tph (varies based on feed material hardness & required product gradation).
Pilihan Penghancur Utama: Kursus rahang (PE900 × 1200) atau Gyratory Crusher; Feed Opening up to 750mm.
Penghancur sekunder/tertiari: Multicylinder Hydraulic Cone Crushers.
Peralatan pemeriksaan: Tripledeck heavyduty circular motion vibrating screens; Total screening area ≥20m².
Jumlah Kuasa yang Dipasang: Kira -kira 550 – 650 kw (bergantung kepada konfigurasi).
Spesifikasi Bahan Utama: Primary frame construction Q345B steel; Highwear components use Mn18Cr2 or equivalent alloys; Conveyor belts rated for minimum PIW 800.
Jejak Tumbuhan Keseluruhan (LxW): Approximately 85m x 65m (bergantung susun atur). Height restrictions apply (~25m max).
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C; Dust emission control achieves ≤20mg/m³ at key points.

6. SENARIO APLIKASI

Projek Pembesaran Kuari Granit

Challenge A quarry needed to increase production from 200tph to a consistent 280tph of road base and concrete aggregates but had limited space for plant expansion.
Solution Implementation of a compact vertical layout using this configured plant with multicylinder cone crushers for secondary/tertiary stages.
Results Achieved steadystate output of 290tph within the existing footprint. Product cubicity met the highest local specification standards.

LargeScale Highway Construction Support

Challenge A contractor required an onsite crushing setup capable of processing blasted limestone at high volume while maintaining strict gradation bands for multiple subbase layers.
Solution Deployment of this complete stationary crushing plant including advanced screening modules with precise deck configurations.
Results The plant supplied over 1.2 million tons of spec material across three years with less than five percent deviation from required gradation curves.

7. PERTIMBANGAN KOMERSIL

Our solutions are offered in tiered configurations:
Tahap Konfigurasi Standard: Termasuk modul penghancuran teras,screening units,and basic PLC control.Priced as a turnkey package.
Peringkat Kecekapan Tinggi: Adds intelligent feed systems,crusher automation settings,and premium wear materials.Initial investment yields lower longterm operating costs.
Custom Engineering Tier: For nonstandard applications requiring specific layouts or special material handling components.Priced upon project engineering review.

Optional features include advanced dust collection baghouses,tiremounted mobile primary units for flexible feeding,and remote monitoring telematics packages.Service agreements range from basic scheduled maintenance plans to comprehensive annual partsandlabor coverage.Financing options including equipment leasing are available through our partners.

8. Soalan Lazim

What are the primary power requirements?
A stable threephase industrial power supply is required.Total connected load typically ranges from550to650kW.Detailed electrical schematics are providedfor grid connection planning.

Can this plant process river gravel or very abrasive materials?
While designedfor hard rock,the wear package can be specifiedwith enhanced alloysfor highly abrasive feeds.Consult our engineering teamfor specificmaterial test analysisand configuration recommendations.

What is the typical installationand commissioning timeline?
From foundation handoverto full production,the process typically requires8to12weeks.This includes mechanical erection,electrical connection,system calibration,and operator training conductedby our engineers.

Do you provide spare parts support globally?
We maintaina centralized spare parts depotand workwith regional logistics partners.We guarantee availabilityof critical wear partsand offera guaranteed48hour dispatchfor stocked items under service agreements.

How does thisplant handle variationsin feed sizeor hardness?
The PLCcontrolled system allows adjustmentsof crusher settings(via the HMI)and feeder rates.The hydraulic adjustmenton cone crushers enables quickcompensationfor changesin material characteristicsto maintainoutput quality