1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang meningkat dan masa henti yang tidak menentu menghakis margin projek anda? Untuk pengurus loji dan kontraktor kejuruteraan, litar penghancuran dan saringan sering menjadi punca kesesakan kritikal. Cabaran biasa termasuk:
Kos Penyelenggaraan Tinggi: Kegagalan galas yang kerap, perubahan kain skrin, and conveyor belt wear from improper material flow can consume 1520% of your annual operating budget.
Masa Henti Tidak Berjadual: A primary crusher failure or screen box structural issue can halt an entire site, costing tens of thousands per hour in lost production and labor.
Inefficient Material Flow: Poorly matched equipment leading to recirculating loads, chokefeeding, or underutilization reduces overall system capacity by up to 30%.
Penggredan Produk Tidak Konsisten: Offspec aggregate or mineral product results in costly recrushing, stockpile segregation issues, and rejected loads.
Peningkatan Penggunaan Tenaga: Older, mechanically inefficient drives and components directly increase your kWhperton cost, a key metric under constant pressure.

Is your operation equipped to minimize these risks while maximizing throughput and product quality? The foundation lies in selecting robust, intelligently engineered peralatan penghancuran dan penyaringan.

2. GAMBARAN KESELURUHAN PRODUK

This content outlines the critical considerations for stationary and trackmounted peralatan penghancuran dan penyaringan, the core machinery for reducing raw feed material (mis., batu kuari, konkrit kitar semula, mineral ore) ke dalam saiz agregat yang ditentukan. Aliran kerja operasi adalah proses yang berterusan:
1. Pengurangan saiz utama: Large feed material is reduced by jaw or gyratory crushers.
2. Material Transport & Scalping: Conveyors move material to vibrating screens that remove undersize material prior to secondary crushing.
3. Penghancuran Menengah/Tertiari: Cone or impact crushers further reduce material to required dimensions.
4. Saringan Akhir & Menyusun: Multideck screens accurately separate crushed material into precise product fractions (mis., ¾” chip, pasir yang dihasilkan).
5. Stok & ReCirculation: Onspec product is conveyed to stockpiles; oversize material is recirculated back into the circuit.

Skop permohonan termasuk kuari, perlombongan, pembinaan & Kitar semula perobohan, dan pengeluaran agregat. Key limitations involve feed material abrasiveness (impacting wear life) dan spesifikasi produk akhir yang diperlukan (dictating circuit design).

3. CIRI TERAS

Geometri Dewan Dipatenkan | Asas Teknikal: Computermodeled kinematics and cavity profiles | Faedah Operasi: Optimized nip angle and crushing stroke for higher reduction ratios with less wear on manganese surfaces | Kesan ROI: Hingga 12% lower costperton in abrasive applications due to extended liner life.

Modular Screen Media System | Asas Teknikal: Quicktensioning wedgelock design with polyurethane damping | Faedah Operasi: Screen deck changes completed in under 2 hours versus a typical 68 hour shift, with consistent tension for longer cloth life | Kesan ROI: Reduces labor hours for maintenance by ~70% per changeout, meningkatkan ketersediaan tumbuhan.

Centralized Greasing & Pemantauan Keadaan | Asas Teknikal: Automated lube points with flow sensors feeding a central PLC | Faedah Operasi: Ensures critical crusher and screen bearings receive precise lubrication without manual intervention; alerts operators to blockages | Kesan ROI: Prevents an estimated 85% of bearingrelated failures, avoiding associated downtime costs.

Hybrid Power Drive System | Asas Teknikal: Dieselelectric configuration with onboard genset or external grid connection capability | Faedah Operasi: Operators can select the most costeffective power source; electric mode reduces fuel consumption by 100% when grid power is available | Kesan ROI: Field data shows average energy cost savings of 2540% in hybrid mode versus dieselonly operation.

HeavyDuty Feeder with PreScreening Section | Asas Teknikal: Grizzly feeder with integrated stepped grizzly bars or punch plate section | Faedah Operasi: Removes natural fines and subproduct size material before the primary crusher, reducing chamber volume usage and wear | Kesan ROI: Increases effective primary crusher throughput by up to 15% by eliminating precrushed material.

Reinforced Structural Frame Design | Asas Teknikal: Analisis Unsur Terhingga (FEA) optimized steel fabrication with highstress zone reinforcements | Faedah Operasi: Withstands continuous highcycle loading without frame fatigue or cracking common in highproduction environments | Kesan ROI: Eliminates unplanned structural repairs, protecting asset lifespan over a 15+ year service period.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | Penghancuran Kami & Screening Solution Documented Performance | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Crusher Liner Wear Life (Batu Abrasive) | ~450,000 tons per set (Cone Crusher Mn18) | ~520,000 tons per set (Proprietary Mn22 Alloy) | +15% Lebih Panjang Umur |
| Screen Box Sideplate Vibration Fatigue Failure Mean Time Between Failure (MTBF) | ~8,000 operating hours before weld repair required| >14,000 operating hours before inspection advised| +75% Improved Durability |
| Penggunaan tenaga (kWh per Ton Processed) Baseline for a 300tph Circuit| ~0.85 kWh/Ton Average| ~0.72 kWh/Ton Documented Average| 15% Kos Tenaga yang Lebih Rendah |
| Jumlah Kos Pemilikan (Tco) berakhir 5 Years (Penyelenggaraan + Bahagian + Downtime)| Indexed at 100% untuk perbandingan| Estimated at 7882% of benchmark TCO| 18% ke 22% Lower TCO |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Tumbuhan pegun daripada 150 ke atas 1,200 tan sejam (Tph). Trackmounted mobile units from 200 ke 500 Tph.
Keperluan kuasa: Primary crushing units typically require 150400 kW drives. Full electric stationary plants may require a total connected load of 8002,500 kVA bergantung pada skala.
Spesifikasi Bahan: Dibuat daripada keluli struktur S355JR; highwear components utilize HB500 abrasionresistant steel liners; crusher jaws/cones in premium manganese steel (Mn18Cr2/Mn22Cr2).
Dimensi Fizikal (Example Mobile Unit): Transport length approx.16m; Operating length approx.19m; Max height approx.4m; Operating weight approx.45 tonnes.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 25°C hingga +45°C; galas terlindung habuk (IP65+); capable of operating at altitudes up to 3,000 meters with engine deration.

6. SENARIO APLIKASI

Projek Pembesaran Kuari Granit

Challenge A major quarry needed to increase production by 40% without expanding their permitted footprint or adding a second processing shift.
Solution Implementation of a new tertiary crushing stage featuring a highspeed cone crusher paired with a tripledeck fine screen in closed circuit.
Results Achieved target throughput increase within existing footprint. The closedcircuit design reduced recirculating load by over half compared to the old layout while improving cubicity of the chip products.

Bandar C&D Recycling Operation

Challenge Processing highly variable construction demolition waste led to frequent jamming in the primary impact crusher from uncrushable rebar matts and excessive fines clogging screens.
Solution Deployment of a heavyduty jaw crusher as primary stage for better tramp metal tolerance and an aggressive linear stroke screen ahead of secondary processing for fines removal.
Results Unplanned stoppages due to feeding issues decreased by approximately90%. The removal of fines early in the circuit significantly improved efficiency of downstream sorting equipment.

7 PERTIMBANGAN KOMERSIL

Equipment pricing tiers are structured around capacity capability:
Peringkat I (600 Tph): Customengineered stationary crushing and screening plants.

Optional features include advanced dust suppression systems automated metal detection/ ejection magnetic head pulleys extended conveyor systems

Service packages range from basic warranty support through comprehensive multiyear maintenance agreements including scheduled parts kits

Financing options are available including capital lease operating lease commercial loans tailored

8 Soalan Lazim

What level of ground preparation is required for installing this equipment?
Stationary plants require engineered concrete foundations Mobile track mounted units require stable compacted ground but minimal civil work enabling rapid redeployment

How does your equipment interface with our existing conveyors stackers?
Our engineering team provides detailed interface specifications for chute heights discharge trajectories belt widths ensuring compatibility

What is the typical lead time from order commissioning?
For standard mobile units lead time is typically weeks For large custom stationary plants detailed engineering procurement fabrication requires months

Adakah anda menyediakan jaminan prestasi?
Yes we offer guaranteed minimum capacity based on agreed feed material specifications Guarantees are backed by pre purchase material testing circuit simulation

What operator training technical support do you provide?
We include comprehensive onsite training for operations maintenance crews along with digital manuals Access remote diagnostic support via data link standard