1. PEMBUKAAN PAINPOINT DRIVEN

Adakah anda menghadapi kesesakan yang berterusan dalam litar penghancuran utama anda yang mengehadkan keseluruhan pemprosesan loji? Do unscheduled downtime events for liner changes and mechanical repairs erode your production targets and budget? Is the inconsistent feed size from your mine causing capacity fluctuations and excessive wear in your secondary crushers? Are you struggling with high perton operating costs driven by energy consumption, buruh penyelenggaraan, dan kegagalan komponen pramatang?

Cabaran operasi ini secara langsung memberi kesan kepada keuntungan anda. Every hour of unplanned downtime can cost tens of thousands in lost production. Every inefficient ton crushed consumes unnecessary power and accelerates wear part expenditure.

The solution lies at the very start of your process: a Loji Penghancur Bijih Besi Berkualiti Tinggi engineered not just to process material, but to optimize your entire downstream operation. Bagaimana anda mencapai konsisten, highvolume primary crushing with maximum availability and controlled operational expense?

2. GAMBARAN KESELURUHAN PRODUK

Produk ini adalah lengkap, heavyduty primary crushing station engineered specifically for abrasive, hightonnage iron ore applications. It is centered on a robust gyratory or jaw crusher designed to accept runofmine (ROM) feed and deliver a consistent, optimally sized product for SAG mill feed or secondary crushing.

Aliran Kerja Operasi:
1. Penerimaan ROM & PraSkrining: Direct dump from haul trucks into a rugged vibrating grizzly feeder (VGFF VGF).
2. Pengurangan saiz utama: The VGF removes fines and directs oversize material into the primary crusher for initial breakage.
3. Pengangkutan Produk: Crushed ore is discharged onto a main conveyor system for transport to the next processing stage.
4. Kawalan Sistem: Centralized PLCbased control monitors all functions, from feed rate to crusher load and conveyor sequencing.

Skop Permohonan: Ideal for greenfield mining projects or major expansions requiring reliable primary crushing capacity from 2,000 ke atas 10,000 tph. Suitable for magnetite, hematit, dan bijih besi lain.

Batasan: Not designed as a portable or skidmounted solution; it is a permanent, foundational plant installation requiring civil works and integration engineering.

3. CIRI TERAS

Reka Bentuk Dewan Lanjutan | Asas Teknikal: Kinematik yang dioptimumkan & nip angle geometry | Faedah Operasi: Produces a more consistent product size distribution on the first pass, mengurangkan beban peredaran semula | Kesan ROI: Increases effective throughput by up to 15% and reduces downstream crusher wear.

Pelarasan Tetapan Hidraulik (HSA) Sistem | Asas Teknikal: Remoteadjustable mainshaft position controlled via PLC | Faedah Operasi: Allows operators to adjust crusher discharge setting in minutes without stopping the crusher | Kesan ROI: Meminimumkan masa henti untuk perubahan CSS lebih 90%, enabling rapid response to changing ore characteristics.

Teknologi Peningkatan Kehidupan Pelapik | Asas Teknikal: Computermodeled liner profiles & ultrawearresistant alloy steel | Faedah Operasi: Achieves more uniform wear distribution and extends service intervals | Kesan ROI: Reduces liner consumption costs by 2030% and decreases annual maintenance manhours.

Bantuan Besi Tramp Bersepadu | Asas Teknikal: Hydraulic cylinders support the mainshaft to allow automatic passing of uncrushables | Faedah Operasi: Protects the crusher from catastrophic damage due to bucket teeth, bit gerudi, or other metal contaminants | Kesan ROI: Eliminates risk of major mechanical failure and associated weeks of downtime.

Sistem Pemacu Kecekapan Tinggi | Asas Teknikal: Direct Vbelt drive or lowloss gearbox coupled with hightorque motors | Faedah Operasi: Transmits more power directly to crushing action with lower mechanical losses | Kesan ROI: Mengurangkan penggunaan tenaga tertentu (kWj/tan) dengan purata 812%.

Integriti struktur & Vibration Management | Asas Teknikal: Analisis Unsur Terhingga (FEA)designed base frame & integrated damping systems | Faedah Operasi: Menyerap beban dinamik, minimizing stress fatigue and foundation transfer issues | Kesan ROI: Ensures longterm structural reliability over a 20+ year lifespan with reduced repair costs.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Purata Piawaian Industri | Penyelesaian Loji Penghancur Bijih Besi Berkualiti Tinggi Kami | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Ketersediaan Mekanikal (%)| 92 94%| 96 98%| +4% (+~2,100 hrs/yr at 6k tph) |
| Kehidupan Pakai Pelapik (Juta Tan) | Berbeza secara meluas; baseline = 1x| 1.3x 1.5x baseline| +3050% hayat lebih panjang |
| Penggunaan Tenaga Khusus (kWj/t)| Baseline = 1x| 0.88x 0.92x baseline| 8% ke 12% pengurangan |
| Masa Min Antara Kegagalan (MTBF), jam| ~1,500 hrs| >2,200 jam| +46% penambahbaikan |
| Product Fines (10mm) Kawalan| Often uncontrolled high %| Consistently optimized lower %| Reduces overcrushing & improves yield |

_Figures based on aggregated field performance data from comparable installations in iron ore._

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 2,000 TPH kepada >10,000 Tph, dependent on ore characteristics (Indeks Kerja Bon, indeks lelasan) and required product size.
Pilihan Penghancur Utama: Heavyduty Gyratory Crusher (54” – 74” feed opening) or Ultraheavy Jaw Crusher.
Keperluan kuasa: Motor pemacu utama dari 300 kW sehingga 750 kw, with total installed plant power including feeders and conveyors from 800 kW kepada 2 MW. Direka untuk bekalan HV (6.6kV /11kV).
Spesifikasi Bahan: Critical wear components manufactured from ASTM A514 or equivalent highstrength steel; liners in premium manganese steel alloys; abrasionresistant plate on all material contact points.
Dimensi Fizikal (Typical Gyratory Station): Feed hopper ~120m³; Overall footprint approximately 25m L x 18m W x 15m H. Detailed civil drawings provided.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 30°C hingga +50°C, with optional heating/cooling packages available. Dust suppression system compliant with <10 mg/Nm³ emission standards.

6. SENARIO APLIKASI

Greenfield Magnetite Project – Pilbara Region

Challenge A new mine required a primary crushing plant capable of processing highly abrasive magnetite at 6,500 tph dengan <72 hours of scheduled maintenance per month.
Solution Implementation of our High Quality Iron Ore Crushing Plant featuring an advanced gyratory crusher with HSA system and predictive maintenance monitoring.
Results The plant achieved an average monthly availability of 97.8% in its first year of operation. Hayat pelapik melebihi unjuran oleh 22%, contributing to an overall 14% lower costperton than feasibility study estimates.

Existing Hematite Operation – Capacity Expansion

Challenge An aging jaw crusher station was the bottleneck limiting plant expansion from 4k tph to 6k tph; frequent breakdowns caused cascading downstream stoppages.
Solution Replacement with our modern High Quality Iron Ore Crushing Plant designed as a dropin upgrade with minimal modifications to existing infrastructure.
Results Throughput increased reliably to target levels within one month of commissioning. Pemantauan tenaga menunjukkan an 11% reduction in specific power consumption compared to the old unit despite higher output.

7 PERTIMBANGAN KOMERSIL

Our High Quality Iron Ore Crushing Plants are offered under three primary tiers:

1 Base Plant Package Includes core crusher heavyduty feeder discharge conveyor dust suppression basic control system Civil design scope is separate

2 Performance+ Package Adds advanced automation package predictive health monitoring sensors premium wear liner package extended structural warranty

3 Turnkey Solution Full engineering procurement construction management EPCM scope covering civil works structural steel erection electrical installation commissioning spares holding

Optional Features Onboard weighing systems automated lubrication units special corrosion protection coatings remote operational support connectivity

Service Packages We offer tiered service agreements ranging from annual inspection plans Platinum coverage which includes parts labor predictive analytics expert priority support

Financing Options We work with leading industrial finance partners Flexible structures include capital purchase finance leases operating leases projectspecific financing subject to credit approval

8 Soalan Lazim

Q What level of preparation is needed at my site before delivery
A You will need prepared foundations based on our certified civil drawings adequate crane access for assembly stable HV power supply water access for dust suppression Site surveys are conducted prior order finalization

Q How does this plant integrate with my existing secondary crushing SAG mill circuit
A Our engineering team conducts full circuit analysis We design the primary discharge product specifically as optimal feed for your downstream equipment ensuring balanced system performance

Q Apakah masa utama penghantaran biasa
A For standard configurations lead time ranges between months following final design approval Longlead items like castings are identified early Expedited options may be available subject component availability

Q Adakah alat ganti tersedia secara global
A Yes We maintain regional inventory hubs critical wear parts Our guaranteed parts supply program ensures priority dispatch documented stock levels key components

Q Can operators be trained on this specific system
A Comprehensive training is included covering operation maintenance troubleshooting safety Training conducted both factory site using actual equipment simulators

Q Apakah istilah komersial yang standard
A Standard terms are CIF major port Incoterms Payment typically structured progress milestones against equipment manufacture shipment commissioning