Industrial Crushing and Screening Equipment: Engineered for Throughput and Reliability

1. Menangani Cabaran Operasi Teras Anda
Managing a highvolume aggregate, perlombongan, or recycling operation means contending with persistent bottlenecks that directly impact your bottom line. Adakah anda mengalami:
Masa Henti Tidak Berjadual: Frequent mechanical failures and lengthy component changes halting your entire production line, menelan belanja beribu-ribu sejam dalam pengeluaran yang hilang.
Penggredan Produk Tidak Konsisten: Offspec material leading to product rejection, kitaran rerushing, and diminished revenue per ton.
Kos operasi yang semakin meningkat: Excessive energy consumption per ton processed and escalating wear part expenditures eroding profit margins.
Site Flexibility Limitations: Fixed plant configurations unable to adapt to changing feed material or product requirements without significant capital reinvestment.
Safety and Maintenance Complexity: Hazardous manual interventions for clearing blockages or routine servicing increasing risk and labor time.

Soalan utama untuk pengurus kilang adalah ini: how can you increase tonsperhour reliability while controlling the total cost of ownership? The answer lies in specifying crushing and screening equipment engineered not just for performance, tetapi untuk diramal, operasi yang cekap.

2. Gambaran Keseluruhan Produk: Advanced Stationary Crushing and Screening Plants
Barisan produk ini merangkumi lengkap, hardwired stationary crushing and screening systems designed for highcapacity primary, sekunder, dan pengurangan tertier agregat, bijih, dan mineral perindustrian. Aliran kerja operasi direka bentuk untuk aliran bahan berterusan:
1. Pemakanan Utama & Scalping: Dumpfed material is initially screened via a heavyduty grizzly to bypass fines and direct oversize to the primary crusher.
2. MultiStage Size Reduction: Material progresses through a configured circuit of jaw, kon, or impact crushers for controlled reduction at each stage.
3. Precise Particle Separation: Dedicated screening decks sort crushed material into precise product fractions via inclined or horizontal vibrating screens.
4. Edaran Semula Litar Tertutup: Oversize material from screens is automatically conveyed back to the appropriate crusher for further processing.
5. Stok & Pemuatan: Specificationgrade products are conveyed to designated stockpiles or directly to loadout.

Skop Permohonan & Batasan: Sesuai untuk kuari besar-besaran, perlombongan, dan projek infrastruktur utama yang memerlukan konsisten, keluaran volum tinggi (biasanya 200 2,000+ tph). These systems require permanent or semipermanent foundation work, significant upfront capital investment, and are designed for specific feed material characteristics; major changes in material abrasiveness or required product mix may necessitate circuit reconfiguration.

3. Ciri Teras: Engineering Meets Operational ROI

Pelarasan CSS Hydroset | Asas Teknikal: Hydraulic cylinder support of crushing chamber | Faedah Operasi: Tetapan sisi tertutup (CSS) pelarasan di bawah beban di bawah 60 seconds for optimal gradation control. | Kesan ROI: Minimizes downtime for product changes by up to 90% berbanding sistem shim manual, meningkatkan penggunaan tumbuhan.

Reka Bentuk Bahagian Pakai Modular | Asas Teknikal: Segmented manganese steel liners with reversible/interchangeable components. | Faedah Operasi: Reduces part inventory costs and extends service intervals through optimized wear life and easier replacement. | Kesan ROI: Data lapangan menunjukkan a 1525% reduction in costperton for wear parts due to increased utilization of liner material.

Direct Drive Crusher Technology | Asas Teknikal: Elimination of Vbelts via direct coupling of motor to crusher drive shaft. | Faedah Operasi: Increases power transmission efficiency (hingga 99%) and reduces maintenance points. | Kesan ROI: Mengurangkan penggunaan tenaga lebih kurang 58% per ton crushed versus traditional beltdriven systems.

Independent MultiFrequency Screening | Asas Teknikal: Independently driven screen decks allowing different vibration parameters per deck. | Faedah Operasi: Simultaneously achieves high stratification efficiency on top deck and accurate sizing on bottom deck from a single screen box. | Kesan ROI: Meningkatkan kecekapan penyaringan sehingga 20%, reducing recirculating load and increasing net usable throughput.

Automasi PLC Berpusat & Pemantauan | Asas Teknikal: Plantwide control system with sensors for power draw, tekanan ruang, suhu galas, and feed levels. | Faedah Operasi: Enables remote monitoring, automated startup/shutdown sequences, and provides realtime data for predictive maintenance scheduling. | Kesan ROI: Mencegah kegagalan bencana; industry testing demonstrates a potential 30% pengurangan pemberhentian yang tidak dirancang.

Rangka Keluli Fabrikasi Tugas Berat | Asas Teknikal: CADoptimized stress analysis using hightensile steel plate construction throughout the chassis and support structures. | Faedah Operasi: Provides longterm structural integrity under cyclical loading with minimal vibration resonance issues over decades of operation.| Kesan ROI: Eliminates costly structural repairs/failures over the asset's lifespan; ensures alignment stability protecting downstream components.

4. Kelebihan Kompetitif

| Metrik Prestasi | Penanda Aras Piawaian Industri | Penghancuran Kami & Penyelesaian Saringan | Kelebihan Berdokumen |
| : | : | : | : |
| Ketersediaan Penghancur (Masa Jalan yang Dijadualkan) | 9294% (excluding maintenance) |>96% Adanya| +4% Penambahbaikan |
| Penggunaan tenaga (kWj/Tan) Baseline = Cone Crushing Stage| Berbeza mengikut bahan; ~0.8 1.2 kWj/tan| Reka bentuk ruang yang dioptimumkan & direct drive yields ~0.72 1.05 kWj/tan| Hingga 12% Penambahbaikan |
| Pakai Part Life (Manganese Liners Cone Secondary) Medium Abrasive Aggregate| ~4050k tons per set average life.| Metalurgi & design extends life to ~5565k tons per set.| +25% Penambahbaikan |
| Kecekapan Saringan (% of correctly sized product per pass)| ~8590% on varied/damp feed.| Multifrequency technology maintains >93%.| +5% Penambahbaikan |
| Selang Baikpulih Utama (Penghancur kon)| ~10k operating hours typical recommendation.| galas & seal design supports intervals up to ~12k hours.| +20% Penambahbaikan |

5.Spesifikasi Teknikal
Julat Kapasiti: Boleh dikonfigurasikan daripada 200 ke atas 2,000 Ton metrik sejam (tph), dependent on feed size/hardness and final product specification.
Keperluan kuasa: Jumlah kuasa loji terpasang biasanya berkisar dari 400 kW hingga lebih 1.5 MW; dibekalkan untuk voltan global (cth., 400V/50Hz ,480V/60Hz).
Spesifikasi Bahan: Dibuat daripada keluli struktur S355JR; wear components in premium manganese steel (14%18%); critical shafts in forged alloy steel.
Dimensi Fizikal (Example Primary + Secondary Plant): Approximate footprint of 35m L x 22m W x 15m H; system weight approx.. 250 metric tons excluding foundations.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C; galas bertutup debu & electricals; pakej pilihan tersedia untuk persekitaran yang melampau.

6.Senario Aplikasi

Pengembangan Kuari Granit

Cabaran:A quarry needed to increase annual production by 35% but was constrained by an aging plant causing excessive downtime (~500 hours/year) due to liner changes/breakdowns.Solution:A turnkey threestage stationary crushing & screening plant featuring jaw crusher primary,two cone crushers secondary/tertiary,and multideck screens was installed with centralized automation.Keputusan:Plant availability increased from 88%to 95%,achieving the target throughput increase.Wear part costs reduced by 18%/ton due improved liner design.Unplanned downtime reduced by an estimated 400 jam setiap tahun.

Iron Ore Processing Circuit Upgrade

Cabaran:A processing facility faced inconsistent final product sizing (6mm +/2mm spec) due an inefficient screening process,causing downstream bottlenecks.Solution:The existing screens were replaced with heavyduty multifrequency doubledeck vibrating screens integrated into the closedcircuit tertiary crushing loop.Keputusan:Screening efficiency improved from 87%to 94%,consistently meeting product spec.Recirculating load on the tertiary crusher decreased by nearly 15%,reducing energy consumption across that circuit.Product quality complaints were eliminated within one month postinstallation

7.Pertimbangan Komersial
Pricing tiers are projectspecific based on required capacity,kekerasan material,and level of automation.Below is a general framework:

Peringkat Sistem Asas(Kewajipan Standard):Termasuk penghancur utama,skrin,and basic conveyors.Idealfor less abrasive materials(e.g.,limestone).Capital cost focus.
Performance System Tier(Tugas Berat):Adds secondary/tertiary stages,direct drives,Hydroset automation,and premium wear metallurgy.For mixed/hard abrasive feeds(e.g.,granite,basalt).Total costofownership focus.
Premium System Tier(Modular FutureProof):Includes full PLC automation with remote connectivity,predictive analytics sensors,and modularity designedfor future capacity expansion.Optional features include dust suppression systems,sound enclosures,and advanced safety access platforms.Service packages range from basic commissioning/warranty supportto comprehensive multiyear service agreements covering scheduled maintenance,buruh,and parts.Financing options including equipment leasing,struktur sewaan sendiri yang disesuaikan,and project financing are available through accredited partners

8.Soalan Lazim(Soalan Lazim)

Q:What levelof site preparation/foundation is requiredfor these stationary plants?
A:A full geotechnical surveyis recommended.Concrete foundationsare engineeredfor each specific plant configurationand load profile.Detailed civil drawingsare provided as partof the engineering package

Q.How doesyour automation system integratewith our existing sitewide SCADAor control room?
A:The PLC system uses standard industrial communication protocols(Modbus TCP/IP,Ethernet/IP).Our engineering team will workwith your contractorsto ensure seamless data exchangeand control capabilityfrom your central facility

Q.What isthe typical lead timefrom order placementto commissioning?
A.For standard configured plantslead times typically range between6and9 monthsdependingon complexityand current manufacturing schedule.Critical path items often include longlead castingsand motors

Q.Are wear parts proprietaryor can we source compatible linersfrom thirdparty suppliers?
A.Wear parts are engineeredas an integral partof the crushing chamber performance.We strongly recommend using genuine OEM parts tomaintain documented performance metrics,warranty coverage,and machine integrity.Useof nonOEM parts can adversely affect capacity,kecekapan,and may void warranties

Q.Do you offerperformance guaranteeson throughputor product gradation?
A.YES.Basedon your specific feed material analysiswe provide written performance guaranteesfor throughput(tph)and power consumption(kWj/tan)under defined operating conditions.Gradation curvesare guaranteedwhen using recommended settingsand genuine wear parts

Q.What trainingis providedfor our operationaland maintenance teams?
A.Comprehensive trainingis included covering safe operation,prosedur penyelenggaraan rutin,penyelesaian masalah,and basic control system functions.Training occurs both during commissioningat your siteandin classroom sessionsusing provided manuals