1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang meningkat dan masa henti yang tidak menentu menghakis margin projek anda? Dalam pengeluaran agregat, pemprosesan mineral, dan kitar semula, penghancuran dan penyaringan yang tidak cekap adalah kesesakan utama. Cabaran biasa termasuk:
Masa Henti Berlebihan untuk Penyelenggaraan: Perubahan pelapik yang kerap, kegagalan galas, and conveyor issues halt your entire production line.
Penggredan Produk Tidak Konsisten: Poor screening efficiency and improper crushing chamber dynamics lead to offspec material, causing product rejection and revenue loss.
Kos Operasi yang Tinggi: Penggunaan tenaga yang semakin meningkat setiap tan, coupled with high wear part replacement frequency, secara langsung memberi kesan kepada keuntungan anda.
Konfigurasi Loji Tegar: Sistem tetap tidak boleh menyesuaikan diri dengan menukar bahan suapan atau keperluan produk akhir, mengehadkan fleksibiliti operasi.

Adakah peralatan semasa anda menangani isu ini, atau adakah ia sumber mereka? The right primary crushing station is not just a purchase; it’s a strategic decision for longterm site profitability.

2. GAMBARAN KESELURUHAN PRODUK: PRIMARY CRUSHING AND SCREENING STATION

This primary crushing and screening station is a fullyintegrated, trackmounted or modular system designed for the initial size reduction of runofmine ore, batu kuari, or demolition concrete. Its workflow is engineered for continuous heavyduty operation:
1. Suapan: Material is deposited via excavator or wheel loader into a robust vibrating grizzly feeder.
2. PraSkrining & Menghancurkan: The grizzly bypasses fines directly to a conveyor while oversize material is directed into the highcapacity jaw crusher.
3. Penghancuran utama: The jaw crusher performs the first mechanical reduction using compressive force.
4. PostCrushing Screening: Crushed material is conveyed to an integrated screen for immediate separation into required product fractions.
5. Stockpiling or Secondary Conveyance: Sized fractions are stockpiled or conveyed to the next stage of processing.

Skop Permohonan: Sesuai untuk perlombongan batu keras, kuari agregat, projek pembinaan berskala besar, dan C&D recycling operations requiring highvolume primary reduction.
Batasan: Tidak direka untuk membentuk produk akhir (penghancuran tertier) or processing highly abrasive materials without specific liner configurations. Feed size must adhere to crusher opening specifications.

3. CIRI TERAS

Direct Drive Jaw Crusher | Asas Teknikal: Eliminates Vbelts and associated components | Faedah Operasi: Reduces power transmission losses and removes routine belt tensioning/maintenance | Kesan ROI: Data medan menunjukkan sehingga 10% penggunaan bahan api yang lebih rendah dan 15% less scheduled maintenance time.

Independent PreScreen Module | Asas Teknikal: Twodeck vibrating grid mounted ahead of the crusher | Faedah Operasi: Removes fines and natural sand from the crusher feed, reducing chamber wear and increasing throughput of valuable midsize material | Kesan ROI: Can extend manganese liner life by up to 30% and increase total station output.

Pelarasan Tetapan Hidraulik (HSA) | Asas Teknikal: Wedgebased chamber adjustment via hydraulic cylinders | Faedah Operasi: Allows operators to change the crusher closedside setting (CSS) di bawah 2 minutes for precise product size control without stopping the plant | Kesan ROI: Minimizes nonproductive time during product changeovers by over 90%.

HeavyDuty Feeder with Step Grizzly | Asas Teknikal: Reinforced feeder with stepped grizzly bars to prevent clogging | Faedah Operasi: Ensures consistent feed flow even with sticky or claybound materials, preventing bridging and feeder stall | Kesan ROI: Maintains target throughput rates in challenging conditions, avoiding costly flow interruptions.

Integrated Plant Automation System (IPAS) | Asas Teknikal: PLCbased control with touchscreen interface monitoring all critical functions | Faedah Operasi: Menyediakan data masa nyata tentang kadar pengeluaran, Cabutan kuasa, and operational status; enables singlepanel control for setup and troubleshooting | Kesan ROI: Meningkatkan keberkesanan keseluruhan peralatan (OEE) through better monitoring and reduces diagnostic time by an average of 50%.

Titik Greasing Berpusat | Asas Teknikal: Manifold system linking all major bearing points to a single station | Faedah Operasi: Membolehkan selamat, rapid daily lubrication checks without requiring access around moving components | Kesan ROI: Standardizes preventive maintenance routines, enhancing bearing life and reducing lubricationrelated failures.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penyelesaian Standard Industri | This Primary Crushing & Screening Station | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Tan sejam (Tph) Kecekapan| Reliant on optimal feed conditions only| Mengekalkan >90% of rated TPH with variable/ sticky feed due to step grizzly design| +1520% sustained output |
| Kos Bahagian Pakai setiap Tan| Based on standard manganese composition| Utilizes sitespecific alloy analysis for jaw liners in highabrasion applications| Hingga 25% kos setiap tan dihancurkan |
| Persediaan / Configuration Time| Multiple machine positioning & cable connections required| Singlelift modules with prerigged electrical connections between units| 70% relocation time |
| Penggunaan tenaga (kWj/tan)| Direct mechanical drive with fixed speed motors| Loadsensing hydraulics & direct electric crusher drive adjust power to demand| 8% penggunaan tenaga purata |

Based on comparative field trials in granite quarry applications.

5. SPESIFIKASI TEKNIKAL

Jenis Penghancur Utama: Nordberg C106 Jaw Crusher
Pembukaan suapan: 1,060 mm x 700 mm (42” x 28”)
Saiz suapan maksimum: 600 mm (24”)
Tetapan sampingan tertutup (CSS) Julat: 70 200 mm
Julat Kapasiti: Hingga 500 MTPH (bergantung kepada ketumpatan bahan & CSS)
Unit kuasa: CAT C9 / C9.3 ACERT Tier 4 Enjin diesel akhir
Jumlah Kuasa yang Dipasang: 224 kw
Feeder Type: Vibrating Grizzly Feeder VG43912V
Screen Module: Twodeck inclined screen TS303
Main Conveyor Width: 1,000 mm
Dimensi Pengangkutan (LxWxH): ~19m x ~3m x ~4m
Berat Operasi: ~45 tan
Julat Suhu Operasi: 25°C hingga +40°C

6. SENARIO APLIKASI

Pengembangan Kuari Agregat Granit | Cabaran: Existing fixed primary plant could not service new pit face location without major infrastructure cost; mobile solutions lacked necessary throughput and prescreening. Penyelesaian: Deployment of a trackmounted primary crushing and screening station fed directly by excavator at the new face. Keputusan: Eliminated need for costly ramp construction and dump truck haulage to old plant. Mencapai daya pengeluaran yang konsisten daripada 380 Mtph of minus200mm base material with improved yield of valuable railway ballast fraction due to integrated screening.

Projek Infrastruktur Berskala Besar (Pembinaan empangan) | Cabaran: Processing riverrun gravel with high sand content led to rapid crusher wear choke points in traditional setups. Solution Implementation of a modular primary station featuring an independent prescreen module ahead of the jaw crusher Results Prescreen removed over 25% of sand/fines prior to crushing reducing abrasive wear Throughput increased by18% as crusher processed only oversize Wear part replacement intervals extended by approximately40%

7 PERTIMBANGAN KOMERSIL

Pricing for a primary crushing station varies significantly based on configuration:

• Base Configuration Includes core jaw crusher basic feeder engine chassis essential conveyors PLC start/stop controls Tier pricing typically begins in range appropriate for this capital equipment class

Optional Features That Add Value:

• Dust suppression system package including water tank spray bars
• Magnet installation over discharge conveyor ferrous metal removal
• Radio remote control unit for independent feeder/crusher operation from ground level
• Extended wear part kits stock

Pakej Perkhidmatan Tersedia:

• Comprehensive Extended Warranty covering major components years unlimited hours
• Scheduled Maintenance Plan providing fixed cost annual inspections parts labor
• On Site Operator Training Program days hands instruction

Financing Options Flexible capital solutions include equipment leasing long term rental purchase leaseback structures tailored support cash flow management project timelines

8 Soalan Lazim

What type/size of excavator is recommended as a feeder?
A minimum operating weight class excavator equipped with suitable bucket capacity ensure consistent choke feeding maximize crusher efficiency productivity

How does this system handle reinforcing bar rebar in concrete demolition waste?
While jaw can process reinforced concrete integrated overband magnet discharge conveyor effectively removes liberated ferrous metals protecting downstream conveyors secondary crushers

What are typical delivery lead times after order confirmation?
Standard configurations have confirmed lead time weeks subject build slot availability engineering review Custom modular designs may require additional weeks detailed engineering fabrication

Is operator training provided with purchase?
Yes comprehensive onsite training program conducted commissioning covers daily operation routine maintenance safety procedures troubleshooting using actual plant systems

Can this station be integrated into existing fixed plant circuit as temporary primary unit?
Yes stations are designed standalone mobility can be positioned feed directly into existing secondary tertiary circuits via discharge conveyor ideal use during planned upgrades maintenance existing primary crushers