Export Jc5000 Jaw Crusher Makers
Export Jc5000 Jaw Crusher Makers: HighCapacity Primary Crushing for Global Mining Operations
Are Your Primary Crushing Operations Costing You $50,000+ Per Day in Downtime and Inefficiency?
Plant managers and engineering contractors face persistent challenges with primary jaw crushers: premature wear on toggle plates and bearings requiring replacement every 68 minggu, inconsistent product sizing that forces secondary crushers to work harder, and throughput bottlenecks that reduce overall plant capacity by 1525%. When a crusher fails midshift, the cost of lost production, emergency maintenance labor, and replacement parts can exceed $12,000 setiap jam. Your current setup may be delivering 180220 tons per hour when your plant requires 300+ tons per hour consistently. Are you still operating with a crusher that cannot handle the feed size and abrasiveness of your material?
Gambaran Keseluruhan Produk: The Jc5000 Jaw Crusher for HighVolume Primary Reduction
The Jc5000 jaw crusher is a heavyduty primary crushing machine designed for continuous operation in hard rock mining, Pengeluaran agregat, dan aplikasi pemprosesan mineral. It processes feed material up to 500mm in size, reducing it to a consistent 50150mm product in a single pass.
Aliran Kerja Operasi:
1. Pemuatan Suapan: Material enters the 500mm x 1200mm feed opening via excavator, pemuat roda, or conveyor system
2. Penghancuran mampatan: The fixed jaw and moving jaw create a Vshaped crushing chamber; the eccentric shaft drives the moving jaw through a 2025mm stroke at 300350 Rpm
3. Patah Bahan: Rock is compressed against the fixed jaw plate, fracturing along natural stress lines
4. Pelepasan Graviti: Crushed material falls through the adjustable closedside setting (CSS) of 50150mm
5. Edaran Semula Bersaiz Besar: Material exceeding CSS returns for additional crushing via conveyor or grizzly system
Skop Permohonan: Sesuai untuk granit, basalt, kuarzit, bijih besi, bijih tembaga, dan batu kapur dengan kekuatan mampatan sehingga 350 MPa. Tidak disyorkan untuk bahan tanah liat melekit melebihi 15% moisture content or materials with high silica content above 80% tanpa pelapik pakai khusus.
Ciri Teras
Perhimpunan Aci Sipi Tugas Berat | Asas Teknikal: Keluli aloi 40CrNiMo palsu dengan jurnal galas keras aruhan | Faedah Operasi: Transmits 30% more crushing force per stroke compared to cast shafts, reducing stall events in hard rock | Kesan ROI: Memanjangkan hayat galas dengan 2,500 waktu operasi, mengurangkan kos penggantian dengan $4,800 setiap tahun
Sistem Pelarasan CSS Hidraulik | Asas Teknikal: Dual hydraulic cylinders with integrated position sensors providing ±2mm adjustment accuracy | Faedah Operasi: Operators can change product size in 35 minit tanpa menghentikan penghancur, berbanding 4560 minutes with mechanical shims | Kesan ROI: Increases annual productive hours by 180220 jam, bernilai pada $36,000$44,000 at $200/hour plant operating cost
Reversible ToothShaped Jaw Plates | Asas Teknikal: Keluli mangan (Mn14Cr2) dengan 180200 Kekerasan HB, reversible design for double wear life | Faedah Operasi: Each set provides 14,00018,000 tons of crushing before replacement, dengan 50% longer life than standard straight plates | Kesan ROI: Mengurangkan kos bahagian haus tahunan sebanyak $6,200$8,500 setiap penghancur
Sistem Pelinciran Bersepadu | Asas Teknikal: Automatic grease lubrication with 8point distribution, programmable intervals of 1560 minit | Faedah Operasi: Eliminates manual greasing errors that cause 40% of bearing failures in field data | Kesan ROI: Mengurangkan masa henti yang tidak dirancang dengan 1215 jam setiap tahun, penjimatan $14,400$18,000 dalam pengeluaran yang hilang
Rangka Dasar Peredam Getaran | Asas Teknikal: Fabricated steel frame with rubber isolation mounts, natural frequency below 8 Hz | Faedah Operasi: Reduces foundation stress by 60% and transmitted vibration to surrounding equipment by 75% | Kesan ROI: Eliminates need for reinforced concrete foundations, penjimatan $15,000$25,000 in installation costs
Sistem Pelega Besi Tramp | Asas Teknikal: Hydraulic relief valve set at 110% tekanan operasi biasa, automatic reset within 2 saat | Faedah Operasi: Protects crusher from damage when uncrushable materials enter the chamber, preventing shaft and bearing failure | Kesan ROI: mengelak $18,000$35,000 in repair costs per tramp iron incident
Kelebihan Kompetitif
| Metrik Prestasi | Piawaian Industri (300400 kelas tph) | Penyelesaian Jc5000 | Kelebihan (% penambahbaikan) |
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| Throughput (tan/jam) | 220280 tph | 300380 tph | 36% kapasiti yang lebih tinggi |
| Penggunaan kuasa (kWj/tan) | 0.450.55 | 0.320.40 | 22% penggunaan tenaga yang lebih rendah |
| Masa pelarasan CSS (minit) | 4560 | 35 | 92% pelarasan yang lebih cepat |
| Kehidupan plat rahang (tan/set) | 8,00012,000 | 14,00018,000 | 50% hayat pakai lebih lama |
| Masa min antara kegagalan (jam) | 1,2001,800 | 2,4003,000 | 67% kebolehpercayaan yang lebih tinggi |
| Buruh penyelenggaraan (jam/bulan) | 2432 | 1216 | 50% lower maintenance |
Spesifikasi Teknikal
| Parameter | Spesifikasi |
|||
| Pembukaan suapan (width x depth) | 500mm x 1200mm (20" x 47") |
| Saiz suapan maksimum | 450500mm (1820") |
| Julat CSS | 50150mm (26") |
| Kapasiti throughput | 300380 tph (at 100mm CSS) |
| Kuasa motor | 110132 kw (150180 Hp) |
| Kelajuan aci sipi | 300350 Rpm |
| Strok | 2025mm |
| Bahan plat rahang | Mn14Cr2 (keluli mangan), 180200 HB |
| Bahan rangka utama | Keluli struktur ASTM A36, 20plat mm |
| Berat (penghancur sahaja) | 18,500 kg (40,800 lbs) |
| Berat (with base frame) | 22,300 kg (49,200 lbs) |
| Dimensi keseluruhan (L x W x H) | 3,200mm x 2,100mm x 2,800mm |
| Julat suhu operasi | 20°C hingga +50°C (4°F to 122°F) |
| Lubrication type | gris automatik, NLGI 2 |
| Tekanan sistem hidraulik | 16 MPa (2,320 psi) |
Senario Aplikasi
Lombong Emas Hard Rock, Australia Barat | Cabaran: Existing jaw crusher produced 180 tph dengan 45% kandungan denda, causing excessive wear on downstream cone crushers and reducing gold recovery by 8% due to overgrinding | Penyelesaian: Installed Jc5000 with 80mm CSS, replacing 15yearold singletoggle crusher | Keputusan: Throughput meningkat kepada 340 tph, kandungan denda dikurangkan kepada 28%, cone crusher liner life extended by 40%, gold recovery improved by 5.2%, annual production value increased by $1.8 juta
Kuari Batu Kapur, Vietnam | Cabaran: Tumbuhan diperlukan 500 tph of 100mm product for cement production, but two existing jaw crushers operating in parallel delivered only 420 tph dengan 18% oversize material requiring recrushing | Penyelesaian: Replaced both units with single Jc5000 operating at 70mm CSS | Keputusan: Singleunit throughput of 380 tph dengan 4% bersaiz besar, eliminated one crusher maintenance cost ($62,000/tahun), reduced energy consumption by 0.15 kWj/tan, mencapai bayaran balik dalam 14 bulan
Copper Mine, Chile | Cabaran: Highaltitude operation at 4,200 meters with 30% lower air density caused overheating in existing crusher motors, mengehadkan daya pengeluaran kepada 160 tph during summer months | Penyelesaian: Jc5000 with derated motor (132 kw) and forcedair cooling system | Keputusan: Terpelihara 310 tph yearround, motor temperature stayed below 85°C even at 35°C ambient, reduced annual downtime from 180 jam ke 24 jam, disimpan $216,000 dalam pengeluaran yang hilang
Pertimbangan Komersial
Peringkat Harga Peralatan:
- Base configuration (standard manganese plates, pelinciran manual): $185,000$215,000 FOB
- Konfigurasi yang dipertingkatkan (premium wear package, pelinciran automatik, CSS hidraulik): $235,000$275,000 FOB
- Complete system (penghancur, rangka asas, motor, panel pemula, conveyor interface): $310,000$365,000 FOB
- Sistem pemantauan jauh tanpa wayar: $8,500 (termasuk sensor getaran, kuar suhu, data logging)
- Plat rahang komposit seramik (untuk bahan highsilica): $4,200 premium per set
- Sistem semburan penindasan habuk: $3,800
- Portable chassis with wheels: $28,000
- Waranti standard: 12 bulan atau 4,000 waktu operasi
- Waranti lanjutan: 24 bulan atau 8,000 waktu operasi (menambah 8% kepada kos peralatan)
- Full maintenance contract: $18,000/tahun (termasuk pemeriksaan suku tahunan, pakai alat ganti, 24respons kecemasan jam)
- Pajakan peralatan: 3660 terma bulan, 4.57.5% APR based on credit rating
- Bayaran tertunda: 90day payment terms with 1.5% faedah bulanan
- Program Tradein: 1525% credit for qualifying used jaw crushers (200+ kapasiti tph, operational condition)
Ciri Pilihan:
Pakej Perkhidmatan:
Pilihan Pembiayaan:
Soalan Lazim
Q: Can the Jc5000 handle wet or sticky materials?
A: The crusher is designed for materials up to 15% kandungan kelembapan. Above this level, material buildup on jaw plates reduces throughput by 2030% and increases power consumption. For sticky applications, we recommend a vibrating grizzly feeder with 50mm spacing ahead of the crusher.
Q: What is the expected lifespan of the main bearings?
A: With proper lubrication and regular inspection, the spherical roller bearings typically last 8,00012,000 waktu operasi. Data medan daripada 47 installations shows average bearing replacement at 9,600 jam. The automatic lubrication system extends this by approximately 2,500 hours compared to manual greasing.
Q: How does the Jc5000 compare to cone crushers for secondary crushing?
A: The Jc5000 is a primary crusher and should not replace cone crushers in secondary applications. It produces a more elongated product shape (indeks kekeringan 1825%) berbanding dengan penghancur kon (1015%). For final aggregate specifications requiring cubic shapes, the Jc5000 output should feed a cone or impact crusher.
Q: What electrical infrastructure is required for installation?
A: The crusher requires a 400V/480V, 3phase power supply with 150175 amp capacity. A motor starter panel with softstart capability is recommended to reduce inrush current by 60%. Total connected load including conveyor drives is approximately 160185 kVA.
Q: Can the CSS be adjusted while the crusher is running?
A: ya, the hydraulic CSS system allows adjustment during operation. Walau bagaimanapun, we recommend making adjustments in 5mm increments and allowing 23 minutes for the system to stabilize between changes. Continuous adjustment during fullload operation may cause uneven wear on jaw plates.
Q: What is the typical delivery lead time for export orders?
A: Masa utama standard ialah 1216 minggu dari pengesahan pesanan, termasuk pembuatan, ujian kualiti, dan peti untuk pengangkutan laut. Penghantaran dipercepatkan (810 minggu) tersedia dengan a 12% premium. Spare parts orders ship within 57 hari perniagaan.
Q: How does the Jc5000 perform in cold climates?
A: The crusher operates effectively down to 20°C with standard lubricants. For temperatures below 20°C, we recommend synthetic grease (NLGI 1) and heated lubrication lines. The hydraulic system uses ISO 32 oil with coldweather additives for reliable operation at 30°C.