1. PEMBUKAAN PAINPOINT DRIVEN

Adakah anda menguruskan operasi agregat volum tinggi dan menghadapi kesesakan berterusan yang menghadkan keuntungan anda? For plant managers and contractors running 250300tph stone crushing requirements, common challenges include:
Masa Henti Tidak Berjadual: Component failures in critical crushers or screens can halt your entire line, menelan belanja ribuan sejam dalam pengeluaran yang hilang dan buruh terbiar.
Penggredan Output Tidak Selaras: Fluctuations in final product size can lead to rejected loads, penalti kontrak, and wasted material, secara langsung memberi kesan kepada keuntungan anda.
Kos Operasi yang Tinggi: Penggunaan bahagian haus yang berlebihan, inefficient power use across multiple machines, and frequent manual adjustments erode your profit margins.
Had Kebolehskalaan: Inflexible plant layouts struggle to adapt to changing feed material or market demand for different aggregate specifications.

Bagaimana anda mencapai kebolehpercayaan, consistent 300tonperhour output while controlling operational expenses and maintaining product quality? The solution lies in a purposeengineered 250300tph stationary stone crushing plant designed as an integrated system, not just a collection of machines.

2. GAMBARAN KESELURUHAN PRODUK

This 250300tph Stone Crushing Plant is a complete, litar pemprosesan hardrock direka bentuk untuk berterusan, pengeluaran tinggi agregat. Ia dikonfigurasikan untuk utama, sekunder, and tertiary crushing stages to produce precisely graded stone products.

Aliran Kerja Operasi:
1. Pengurangan utama: Suapan besar (≤750mm) is introduced to a robust primary jaw crusher for initial size reduction.
2. Menghancurkan sekunder & Pemeriksaan: Crushed material is conveyed to a secondary cone crusher. A primary screen then separates the product stream; sized material is routed to final stockpiles, while oversize proceeds to tertiary crushing.
3. Pembentukan Tertiari & Saringan Akhir: Oversize material is processed through a tertiary cone crusher (or impact crusher for specific applications) for final shaping and reduction. A closedcircuit conveyor loop with final screening decks ensures precise gradation control.

Skop Permohonan: Ideal for granite, basalt, batu sungai, dan bahan pelelas lain dengan kekuatan mampatan sehingga 350 MPa. Sesuai untuk operasi kuari besar, projek infrastruktur utama yang memerlukan bekalan khusus di tapak, and highcapacity commercial aggregate production.

Batasan: Tidak direka untuk aplikasi mudah alih atau mudah alih. Memerlukan penyediaan asas yang stabil dan sambungan kuasa berasaskan grid. Initial capital investment is significant, justified by longterm operational ROI.

3. CIRI TERAS

Modular HeavyDuty Frame | Asas Teknikal: Pra-kejuruteraan, bolttogether structural steel sections with reinforced walkways and access platforms. | Faedah Operasi: Enables faster onsite installation compared to fieldwelded designs and provides safe, permanent maintenance access. | Kesan ROI: Mengurangkan masa pemasangan sehingga 30%, mengurangkan kos buruh dan mempercepatkan masa untuk pengeluaran.
Sistem Kawalan Proses Pintar | Asas Teknikal: PLC berpusat dengan beban motor pemantauan HMI skrin sentuh, kelajuan penghantar, paras tong sampah, and crusher parameters. | Faedah Operasi: Allows operators to optimize feed rates and detect anomalies early from a single control station, preventing cascading failures. | Kesan ROI: Improves overall plant efficiency by an estimated 812% through optimized throughput and reduced risk of major downtime events.
Reka Bentuk Ruang Penghancuran Kecekapan Tinggi | Asas Teknikal: Crushers equipped with latestgeneration chamber geometries and higher stroke/ speed combinations as applicable. | Faedah Operasi: Delivers a higher reduction ratio per stage and produces a more cubicle end product with less flaky material. | Faedah Operasi: Increases yield of inspec product while reducing recirculating load and wear on downstream equipment.
Penindasan Debu Lanjutan & pembendungan | Asas Teknikal: Strategically placed spray nozzles at transfer points paired with enclosed conveyor skirts and dust collection cyclones on screens. | Faedah Operasi: Significantly improves site environmental compliance and creates a safer working atmosphere for personnel.| Kesan ROI: Mitigates risk of regulatory fines and reduces cleanup costs while prolonging component life by limiting abrasive dust ingress.
Unified Greasing & Sistem hidraulik | Asas Teknikal: Centralized lubrication points for major bearings and integrated hydraulic power units for crusher adjustment & clearing.| Faedah Operasi: Streamlines routine maintenance checks from hours to minutes and allows safe remote clearing of stalled chambers.| Kesan ROI: Increases mechanical availability by reducing maintenance windows; protects major assets from catastrophic damage due to lubrication failure.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (250300tph Plants) | Penyelesaian Loji 250300tph kami | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Ketersediaan Mekanikal | 8590% (terancang & masa henti yang tidak dirancang) | 9295% (berdasarkan pemilihan komponen & reka bentuk sistem) | +5% ke +8% more uptime |
| Penggunaan Kuasa setiap Tan| Berbeza secara meluas; often suboptimal load sharing| Saiz motor yang dioptimumkan & conveyor drive selection| Hingga 10% pengurangan in kWh/ton processed |
| Kos Pakai setiap Tan (Batu Abrasive)| $0.45 $0.65/ton (crusher liners only) | $0.38 $0.52/ton (via premium alloys & pengoptimuman ruang)| ~15% lebih rendah consumable cost |
| Konsisten Penggredan Produk (± spesifikasi) | Reliant on frequent manual adjustment| Automated screen loading & crusher setting feedback loops| Deviation improved by up to 40%, mengurangkan sisa |

5.SPESIFIKASI TEKNIKAL

Kapasiti Throughput Direka: 250 300 Ton metrik sejam (275 330 AS tph), bergantung kepada kekerasan bahan suapan dan taburan saiz.
Penghancur utama: Model Jaw Crusher [mis., JC546], Feed Opening 1400x1100mm Max Feed Size ≤750mm
Penghancur sekunder: Model Penghancur Kon [mis., HPC400], Accepts feed ≤250mm
Penghancur Tertiari: Model Penghancur Kon [mis., HPT300] or Impact Crusher Model [mis., PFQ1520] based on product shape requirements.
Unit Saringan: Skrin bergetar berbilang dek (23 unit), jumlah kawasan saringan ≥25m².
Keperluan Kuasa: Total installed power ~750kW 900kW; primary voltage requirement: 400V/50Hz atau 480V/60Hz (boleh dikonfigurasikan).
Spesifikasi Bahan Utama: Primary conveyor belts ST3150/EP800; Wear liners in primary stage made of Mn18Cr2 alloy steel; Screen decks clad with replaceable polyurethane or rubber modulations.
Anggaran Jejak (L x W): ~85m x 45m (~280ft x150ft), depending on stockpile configuration.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C (4°F to113°F). Dust suppression system requires water supply (~50m³/day).

6\. SENARIO APLIKASI

Pengembangan Kuari Granit Berskala Besar

Cabaran: An existing quarry needed to double production capacity but had limited space for plant expansion while maintaining strict railway ballast specifications.
Penyelesaian: Implementation of this compactly designed threestage stationary crushing plant featuring highreductionratio cone crushers in closed circuit configuration.
Keputusan: Achieved sustained output of over280tph within the existing footprint.Ballast product cubicity exceeded national standards by22%, commanding apremium price.Recirculating load decreased by18%, mengurangkan kos tenaga.

Projek Pembinaan Lebuhraya Utama

Cabaran:A contractor required guaranteed onsite aggregate supply at270tphfora24month project,facing highly variable basalt feed hardness with zero tolerance forscheduling delays due top lant failure .
Penyelesaian:A ruggedized version oftheplant was deployed ,featuring enhanced tramp metal protectionand automated cavity clearing systems .
Keputusan:The plant maintained anaverage mechanical availabilityof94% throughouttheproject ,deliveringover1 .2million tons ofmaterial .Un scheduled stoppages were reducedto less than1 .5 %ofoperating hours ,keepingtheproject aheadofschedule .

Pengeluar Agregat Komersial

Cabaran:A producer supplying multiple concreteand asphalt plants struggledwithhighwear costsand inconsistent sand yieldfromtheir existing circuit .
Penyelesaian:Theplant was configuredwitha tertiary impactcrusherfor shaping anda fines recovery /washing module addedtothefinal screening stage .
Keputusan:Sand yield increasedby15 %,creatinganewrevenue stream .Wear costsontertiary components droppedby30 %due tot heoptimized rockonrockcrushing action .Product versatility allowedtheproducer tom eetdiversespecifications frommultiple clients .

Pengeluar Agregat Komersial

Cabaran:A producer supplying multiple concreteand asphalt plants struggledwithhighwear costsand inconsistent sand yieldfromtheir existing circuit .
Penyelesaian:Theplant was configuredwitha tertiary impactcrusherfor shaping anda fines recovery /washing module addedtothefinal screening stage .
Keputusan:Sand yield increasedby15 %,creatinganewrevenue stream .Wear costsontertiary components droppedby30 %due tot heoptimized rockonrockcrushing action .Product versatility allowedtheproducer tom eetdiversespecifications frommultiple clients .

Pengeluar Agregat Komersial

Cabaran:A producer supplying multiple concreteand asphalt plants struggledwithhighwear costsand inconsistent sand yieldfromtheir existing circuit .
Penyelesaian:Theplant was configuredwitha tertiary impactcrusherfor shaping anda fines recovery /washing module addedtothefinal screening stage .
Keputusan:Sand yield increasedby15 %,creatinganewrevenue stream .Wear costsontertiary components droppedby30 %due tot heoptimized rockonrockcrushing action .Product versatility allowedtheproducer tom eetdiversespecifications frommultiple clients .

Pengeluar Agregat Komersial

Cabaran:A producer supplying multiple concreteand asphalt plants struggledwithhighwear costsand inconsistent sand yieldfromtheir existing circuit .
Penyelesaian:Theplant was configuredwitha tertiary impactcrusherfor shaping anda fines recovery /washing module addedtothefinal screening stage .
Keputusan:Sand yield increasedby15 %,creatinganewrevenue stream .Wear costsontertiary components droppedby30 %due tot heoptimized rockonrockcrushing action .Product versatility allowedtheproducer tom eetdiversespecifications frommultiple clients .

Pengeluar Agregat Komersial

Cabaran:A producer supplying multiple concreteand asphalt plants struggledwithhighwear costsand inconsistent sand yieldfromtheir existing circuit .
Penyelesaian:Theplant was configuredwitha tertiary impactcrusherfor shaping anda fines recovery /washing module addedtothefinal screening stage .
Keputusan:Sand yield increasedby15 %,creatinganewrevenue stream .Wear costsontertiary components droppedby30 %due tot heoptimized rockonrockcrushing action .Product versatility allowedtheproducer tom eetdiversespecifications frommultiple clients .

Pengeluar Agregat Komersial

Cabaran:A producer supplying multiple concreteand asphalt plants struggledwithhighwear costsand inconsistent sand yieldfromtheir existing circuit .
Penyelesaian:Theplant was configuredwitha tertiary impactcrusherfor shaping anda fines recovery /washing module addedtothefinal screening stage .
Keputusan:Sand yield increasedby15 %,creatinganewrevenue stream .Wear costsontertiary components droppedby30 %due tot heoptimized rockonrockcrushing action .Product versatility allowedtheproducer tom eetdiversespecifications frommultiple clients .

Pengeluar Agregat Komersial

Cabaran:A producer supplying multiple concreteand asphalt plants struggledwithhighwear costsand inconsistent sand yieldfromtheir existing circuit .
Penyelesaian:Theplant was configuredwitha tertiary impactcrusherfor shaping anda fines recovery /washing module addedtothefinal screening stage .
Keputusan:Sand yield increasedby15 %,creatinganewrevenue stream .Wear costsontertiary components droppedby30 %due tot heoptimized rockonrockcrushing action .Product versatility allowedtheproducer tom eetdiversespecifications frommultiple clients .

Pengeluar Agregat Komersial

Cabaran:A producer supplying multiple concreteasphalt plants struggledw ithh ig hw ear cos tsandinconsistent sanyieldf romth eirexistingcircuit.Solution:T hep lantwasconfiguredw it ha t er ti aryi mpactcru sherforshapinganda fi nesrec overy/washingmoduleaddedtot h efina ls creeningstage.R esults:Sandyieldincreasedb y1s5%,cre ating anewrevenuestream.W earco stso nte rt i arycomponentsdroppedb y3s0%d ueto t h eo p timi zedrockonro ckcr ushingaction.P roductversatilityallowedth ep roducertom ee td iv ersesp ec ificationsf rommu ltipleclients.7\. PERTIMBANGAN KOMERSIL

Equipment pricing fort hisclassofstationarystone crushing plantis structured aroundcoreconfigurationands electedcomponents:

Peringkat Harga:
Peringkat1(BasePlant):Includesprimaryjaw ,kon sekunder ,skrin asas ,penghantar ,steelstructure ,andelectricalcontrol.C apacityratedfor250tp hinlimestone.Tier2(EnhancedPlant):UpgradedtoH Pseriesconec rushers ,largerscreeningarea ,premiumbelting ,andenhanceddustcontrol.Ratedforfull300tp hinabrasivegranite.Tier3(CustomCircuit):Includesadditionsliketer ti aryshapingstage ,automatedproductdiverters ,fineswashingsystem ,orcomprehensiveweighing/batchingsystems.Optional Features:DustCollectorCyclone/BaghouseSystemsOnBoardGeneratorHookupsForBackupPowerRemoteMonitoringTelematicsPackageAdvancedPredictiveMaintenanceSensorKitsExtendedWearPartKits(Initial2YearSupply)

Pakej Perkhidmatan:
StandardCommissioning&Latihan Operator( included )ExtendedWarrantyPlans(12–36months )AnnualPreventativeMaintenanceContractsOnSiteTechnicalSupportRetainerPartsConsignmentStockingAgreements

Pilihan Pembiayaan:
Capital equipment financing can be arranged through partners offering leasetoown structures commercial loans or projectbased financing typically requiring20–30%down payment with terms ranging36–72months

Soalan Lazim

Q:Whatistheleadtimeforsupplyandaverageinstallationduration?
A Fromorderconfirmationmajorcomponentmanufacturerequires4–6monthsSitefoundationworkshouldrunconcurrentlyMechanicalerectionandelectricalcommissioningtypicallyrequire8–10weeksonsitew ithaproperlypreparedfoundation

Q:Canyour250–300tp hstonecrushingplanthandlewetorstickyfeedmaterial?
A Thebas icdesignassumesmaterialwithmoderatesurfacemoistureForconsistentlywetorclayboundmaterialmodificationsarerequiredincludingfeederdesignprimaryscreenselectionandspecificchute liningsTheseoptionsshouldbediscussedduringengineeringreview

Q Howdoesthecontrolsystemintegratewithexistingquarryoperations?
A ThePLCsystemoffersstandardindustrialcommunicationprotocols(Profibus Ethernet/IP ModbusTCP) allowingintegrationintocentralSCADA systemsfordataaggregationItcanalsooperateasastandaloneunit

Q Whatistheexpectedlifespanof themainstructuralcomponents?
A Theheavy dutysteelsuperstructureisdesigned fora minimumservice lifeof20+yearswithpropermaintenanceCrushersandscreensframescarrysimilarlong termdesignlifeexpectanciesw ithperiodicrebuildsof internalmechanicalcomponents

Q Areprocessflowdiagrams(PFD)andpipinginstrumentationdiagrams(PIDs)provided?
A YesacompletebasicengineeringpackageincludinggeneralarrangementdrawingsPFDsPIDsandelectricalschematic sisprovidedaspartofthetechnicaldocumentationpackageto facilitatepermittingandsiteplanning

Q Whattrainingisprovidedforouroperators an dmaintenancestaff?
A Comprehensiveon sitetrainingisconductedduringcommissioningcoveringnormalstartup/shutdownproceduresroutineadjustmentsdailychecksbasictroubleshootingandsafetyprotocolsFormalclassroomtrainingatourfacilityisavailableasanoption