1. PEMBUKAAN PAINPOINT DRIVEN

Adakah anda menguruskan operasi agregat komersial dengan konsisten, pengeluaran volum tinggi adalah penting untuk keuntungan? Anda 250300 tph stone crushing plant faces significant operational pressures. Inconsistent feed material causes unexpected wear and crusher stalls, leading to costly, masa henti yang tidak dirancang. Energy consumption per ton remains stubbornly high, terhakis margin. Meeting strict, dualgrade specifications for base and chip products often requires inefficient, multistage recrushing. Tambahan pula, the total cost of ownership—from liner replacements to conveyor maintenance—accumulates faster than projected.

How do you increase plant availability beyond 92%? Can you reduce your cost per ton while maintaining precise product shaping? Is your current setup flexible enough to handle varying rock hardness without sacrificing throughput? The solution requires a system engineered not just for capacity, tetapi untuk diramal, efficient commercial production.

2. GAMBARAN KESELURUHAN PRODUK

ini 250300tph Turnkey Stone Crushing and Screening Plant is a stationary, hardrock processing solution designed for highvolume production of aggregates (05mm, 510mm, 1020mm, 2031.5mm) and other specification materials. Ia mengintegrasikan penghancuran utama, menghancurkan sekunder/tertiari, pemeriksaan, and material handling into a coordinated system.

Aliran Kerja Operasi:
1. Pengurangan utama: Dump trucks feed <750mm rock into a vibrating grizzly feeder which bypasses sub100mm fines and directs oversize to a robust primary jaw crusher.
2. Sekunder & Penghancuran tertiari: Primary crushed material is conveyed to a cone crusher for intermediate reduction. A second cone crusher or impact crusher in closed circuit performs final shaping and size refinement.
3. Saiz & Pengelasan: Material is routed to a multideck vibrating screen where it is precisely separated into finished product stockpiles.
4. Recirculation: Oversize from the screens is automatically returned via closedcircuit conveyors to the appropriate crusher for further processing.
5. Penindasan Debu: Sistem semburan bersepadu di titik pemindahan mengawal pelepasan zarah.

Skop Permohonan: Ideal for granite, basalt, river pebble, batu kapur, and other abrasive materials with compressive strength up to 350 MPa. Suitable for large quarry operations, sokongan projek infrastruktur utama (lebuh raya, Keretapi), and dedicated commercial aggregate supply yards.

Batasan: Not designed for mobile or semimobile applications requiring frequent relocation. Site requires stable foundation preparation and adequate space for plant layout and stockpiling.

3. CIRI TERAS

Sistem Kawalan Suapan Pintar | Asas Teknikal: Pemacu Frekuensi Boleh Ubah (VFD) on feeder & level sensors | Faedah Operasi: Maintains optimal chokefeed condition for cone crushers automatically | Kesan ROI: Meningkatkan daya pengeluaran sebanyak 812% and reduces liner wear by up to 15%
Konfigurasi Penghancur Tugas Berat | Asas Teknikal: Pelarasan hidraulik & clearing on all crushers | Faedah Operasi: Enables rapid CSS changes for product sizing and safe clearing of tramp metal/stalling | Kesan ROI: Reduces downtime for chamber clearing from hours to minutes
Kawalan Proses Berpusat | Asas Teknikal: Automasi berasaskan PLC dengan HMI skrin sentuh | Faedah Operasi: Allows singleoperator monitoring of entire flow from a control room; logs production data | Kesan ROI: Lowers labor costs and provides data for production optimization
Modular Electrical & Hydraulic Design | Asas Teknikal: Preassembled skids with quickdisconnect couplings | Faedah Operasi: Memudahkan pemasangan, pentauliahan, and future maintenance access | Kesan ROI: Reduces installation time by ~30% and lowers service costs
MultiStage Dust Suppression | Asas Teknikal: Pressurized spray nozzles at key transfer points with moisture sensors | Faedah Operasi: Effectively controls dust without overwetting material | Kesan ROI: Ensures environmental compliance and protects downstream equipment

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (250300tph Loji) | This 250300tph Plant Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Ketersediaan Loji | 88 91% | 92 95%| +4% (Downtime Downtime) |
| Penggunaan kuasa (kWj/tan)| 1.8 2.2 kWj/t | 1.65 1.85 kWj/t| Hingga 12% (Penjimatan Tenaga) |
| Kehidupan Pelapik Penghancur (Batu Abrasive)| ~450 waktu operasi| 520+ waktu operasi| +15% (Reduced Wear Cost) |
| Indeks Bentuk Produk (Kegelapan)| >18% in chip products| <15% in chip products| Nilai Produk Lebih Tinggi |
| Masa Konfigurasi Semula (Perubahan CSS)| Pelarasan shim manual (~4 hrs)| Pelarasan hidraulik (~30 min)| 87% (Fleksibiliti operasi) |

5.SPESIFIKASI TEKNIKAL

Kapasiti Throughput Direka: 250 300 Ton metrik sejam (berdasarkan kepadatan bahan ~1.6 t/m³)
Penghancur utama: Jaw Crusher Model JC1303 / Pembukaan suapan:1300x300mm / Saiz suapan maksimum: ≤750mm
Penghancur sekunder/tertiari: Two units of Cone Crushers Model CC300 / Each with hydraulic adjustment & pembersihan
Unit Saringan: Tripledeck Vibrating Screen Model VS2460 / Kawasan Skrin: ~14 sqm
Keperluan Kuasa: Jumlah kuasa terpasang lebih kurang 650 kw; Mains connection recommended at400V/50Hz or480V/60Hz.
Spesifikasi Bahan Utama: Main frame construction Q345B steel; Conveyor belts EP630/4; Crusher liners Mn18Cr2 high manganese steel.
Dimensi Fizikal (lebih kurang): Overall layout length ~85m; width ~25m; max height ~12m.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C; dust emission concentration at outlet ≤20mg/m³.

6\. SENARIO APLIKASI

Pengeluaran Kursus Pangkalan Lebuhraya | Cabaran:A national contractor required consistent,sustained production of Class A base course(031\.5mm)and chip sealing aggregates(510mm)from hard granite for a toll highway project.Plant stoppages directly threatened project timelines.| Penyelesaian:A turnkey250\300tph plant was installed featuring twostage cone crushing in closed circuit with precise screening.The automated control system allowed quick switching between product specifications.| Keputusan:The plant achieved an average output of280tph over22months.Availability averaged94\.2%.The consistent cubical shape of the chip product reduced bitumen consumption by an estimated7%,noted by the paving contractor.

Commercial Quarry Expansion Challenge:A regional quarry operator needed to upgrade from150tph to meet new supply contracts but had limited space for expansion and needed to maintain production during phased commissioning.| Penyelesaian:The modular design of the250\300tph plant allowed it to be constructed parallel to the old line.Critical preassembled skids reduced onsite assembly time.The old line was decommissioned only after the new plant was fully operational.| Keputusan:The expansion was completed with only48hours of total production stoppage.The new plant's energy efficiency reduced power costs by$0\.11per ton produced,increasing annual gross margin significantly.

Limestone Processing for Concrete Aggregates Challenge:A readymix concrete supplier's own aggregate plant struggled with excessive fines generation(<0\.075mm)and poor shape in the critical10\20mm fraction,increasing cement demand in their mixes.| Penyelesaian:The plant configuration prioritized lowwear,cubicalproduct crushing stages.An impact crusher was selected as the tertiary unit,and screen deck configurations were optimized to remove excess fines early.| Keputusan:Fines generation was reduced by22%.The improved particle shape increased the workability of the concrete mix.Field data showed a potential3\5%reduction in cement usage while maintaining slump specifications.

PERTIMBANGAN KOMERSIL

Pricing is structured around core configuration levels:

• Tier1(Konfigurasi Pangkalan):Termasuk penghancur rahang utama,penghancur kon tunggal,tripledeck screen,penghantar asas,and central control panel.Priced as acapital investmentfor standard materials like limestone.
• Tier2(Konfigurasi Dipertingkat):Adds secondary cone crusherfor full closedcircuit operation,intelligent VFD feed control,and enhanced dust suppression.Recommendedfor abrasive materials(granit,basalt).
• Tier3(Konfigurasi Tersuai):Incorporates specific options such as washing systemsfor manufactured sand,finer screening decksfor specialized products,and extended weather protection enclosures.

Ciri pilihan termasuk telematik pemantauan jarak jauh,mobile generator hookups,and automated lubrication systems.Service packages range from basic commissioningand operator trainingto comprehensive annual maintenance contracts with guaranteed parts availability.Financing options including equipment leasingand term loans are available through partnered financial institutions,making capital expenditure manageable against longterm supply contracts.

Soalan Lazim

Q:What if my feed material size or hardness varies frequently?
A:The hydraulic adjustment on the crushers allows operators to change the Closed Side Setting(CSS)in minutes via the control panel.This adapts the crushing chamberto different conditions without stopping production,a key featureof this commercial stone crushing plantsolution.

Q.How many operators are requiredto run this plant?
A.The centralized PLC automationis designedfor singlestation control.One trained operatorin the control room can manage the entirecrushingandscreening process.Routine ground inspectionsare still recommended,but direct machinelevel operationis not required.

Q.Can this system integratewith our existing primary feedingor downstream equipment?
A.YES.The design includes standardized feedand discharge heights.Conveyor lengthsand transfer pointscan be modifiedduring engineering.We will review your site layoutto ensure compatibilitywith your current stockpile feedersor existing tertiary processing lines.

Q.What isthe typical installationand commissioning timeline?
A.For aprepared foundation site,the modular skidded components allow erectionin approximately8\10weeks.Commissioningand performance testingtypically takes an additional1\2weeks.This timeframe assumes all civil worksare complete prior todelivery.

S. Adakah alat ganti sedia ada,and what arethe lead times?
A.We maintaina strategic inventoryof highwear parts(Plat rahang,mantel,jerat skrin).For standard wear parts,the commitmentis shipmentwithin72hours.For major components,a stocklistwith guaranteed lead timesis providedwith themaintenance contract.

Q.What kindof trainingis providedfor our maintenance team?
A.Comprehensive trainingincludes both classroom instructionon system principlesand handson field training.It covers daily checks,troubleshooting usingthe HMI diagnostics,prosedur penyelenggaraan rutin,and safe liner changeout protocols.Training documentationis supplied digitallyandin print